Inspection and Testing Requirements

QUALITY SPECIFICATION 40-601
Page 1 of 10
Rev 13
Date 20.01.16
Inspection and Testing Requirements for Baseplate &

Other Fabrications Requiring Qualified Welding
Procedures
Revision Number .......
Date ............................
Amendment Details ....

Date ............................
4
25-01-10
Section 3.1 added. Section 3.2 extended to prevent upgrading. Extensive revision of
section 5.0 to include dimensional and painting inspections. Hard stamping added to 6.1.
Section 6.4 added.
5
16-08-10
Title & scope changed to include other fabrications in addition to baseplates. General
revision throughout document.
6
25-11-10
Painting, machining, delivery and release sections added. Check list and release
requirements added. References to ASME IX added. Upgrading limitations clarified.
7
15-06-2012
Section 5.0 expanded. Section 6.5 added. Sections 9.4 and 9.5 clarified. Deletion of
repeated line on checklist. Requirement for weight added to release form.
8
04-04-2013
Sections 6.6 & 6.7 added. Certification requirements changed to require 3.1 certification
for all items. Section 6.5 re-worded. Section 6.6 modified to indicate that pads which are
not shown as requiring machining on the drawing are to be painted. Section 7.0 modified
to require release to be only sent to External Inspection Coordinator. Section 9.6 revised.
9
01-07-2013
Section 6.4 expanded. Section 6.7 amended. Release section moved to after Inspection.
Section 7.3 NDT operator qualification changed to EN ISO 9712. Section 7.2 d) clarified.
Date certification pack submitted added to quality release form.
10
15-08-2013
Page 7 changed from "Blast Before Prime Inspection" to "Prime Inspection and items 12
and 13 added. Section 5.3 added.
11
04/08/2014
Changes to the inspection check sheets

Date ............................
12
27/05/2015
Change of Address on page 10.

Date ............................
13
20.01.2016
Text of 6.7 moved to 6.8, new wording in 6.7 to cover Norsok painting.
Issued by:
C Thompson
Quality Approved by:
S P Jones

Date ............................
Date ............................
Date ............................
Date ............................

Date ............................

Date ............................
Sulzer Pumps (UK) Ltd

Uncontrolled valid at date of printing

Page 2 of 10
Rev 13
Date 20.01.16
1.0
Scope
This specification details the inspection, testing and certification requirements for fabrications requiring
qualified welding procedures with particular reference to baseplates.
2.0
Material
2.1
Material type, specification and grade shall be as stated in Sulzer Purchase Order/drawings.
3.0
Material Certification
3.1
Material usage within the fabrication to be clearly identified by adding the certificate number to the cutting
list or providing a material location drawing.
3.2
The Supplier shall submit to Sulzer a certified record of chemical composition, mechanical properties and
details of all heat treatments carried out, in accordance with EN 10204 Inspection Certificate 3.1 unless a
higher level is defined on the Sulzer Inspection and Test Plan.
3.3
The upgrading of steelwork (additional testing undertaken on a piece cut-off the plate, to comply with
contract requirements) is not acceptable unless agreed in advance by Sulzer in writing. Agreement will
normally be given provided 3.1 certification to EN 10204 is available for the original material.
4.0
Welding
4.1
Welding is to be carried out in accordance with BS EN 1011 or ASME IX.
4.2
Weld Procedures
Supplier to submit to Sulzer for approval details of proposed welding procedures (WPS) and welding
procedure qualifications (PQR) in accordance with the requirements of ASME IX or EN 15614.
4.3
Welder Qualification
All welders shall be qualified in accordance with requirements of ASME IX or EN 287.
5.0
Machining
5.1
Baseplates are to be machined on a machine large enough to machine all the mounting pads on the upper
surface of the baseplate and ends without having to move the baseplate on the machine. It is
preferred that baseplates are machined when mounted horizontally.
5.2
Care must be taken to ensure that the baseplate remains in its natural relaxed state when being set up for
machining and that it is not distorted by clamping. This is necessary to prevent the machined pads from
becoming distorted when released from the machine.
5.3
Holes in lifting pad-eyes must be drilled NOT flame cut.
6.0
Painting
6.1
Fabrications are to be painted as per the procedure and colour referenced in the Sulzer Inspection & Test
Plan. Particular attention to be paid to ensure that all coat thicknesses meet the specified requirements.
6.2
Prior to blasting all tapped holes are to be protected with fasteners to prevent shot ingress into holes. All
machined surfaces and flanges are to be protected with thick tape to ensure that they are not blasted.
Pipes are to be cleaned of shot after blasting.
6.3
Paint certificate to be provided in accordance with the paint procedure.
6.4
The following painting contractors are not to be used without the written consent of Sulzer Pumps UK Ltd:Forward Protective Coatings
Merseyside Coatings or their successors
6.5
If painting is sub-contracted the complete Sulzer Inspection & Test Plan must be passed to the painting
sub-contractor rather than just an extract.
6.6
Mounting pads which are not shown as machined on the baseplate drawing are to be painted.
6.7
Where painting is to be in accordance with Norsok or similarly qualified procedure, then sharp edges,
fillets, corners and welds shall be rounded or smoothened by grinding to P3 as defined in ISO 8501-3

Page 3 of 10
Rev 13
Date 20.01.16
(minimum radius 2mm), and hard surface layers resulting from flame cutting etc. shall be removed by
grinding.
6.8
If the baseplate is provided with plates for the mounting of lifting bollards the painting is to be as per the
sketch below.
7.0
Inspection
7.1
This section defines minimum inspection requirements. Note more onerous requirements may be required
by the contract specific Inspection & Test Plan.
7.2
Visual Examination
a)
Procedure - EN 970


Page 4 of 10
Rev 13
Date 20.01.16
7.3
7.4
b)
Areas to be examined - All Welds. Note that defects are best highlighted at the fabrication stage
however many defects only become apparent after priming.
c)
Defect Acceptance - Lifting attachment welds EN 25817 quality level B. All other welds quality level C
d)
All sharp edges and burrs on surface which are to be painted shall be rounded or smoothed to
ensure good paint adhesion
e)
Defects in steel sections are to be within the limits detailed in the applicable steel specification.
Magnetic Particle Examination

a)
Procedure - Sulzer Procedure TP-0002
b)
Areas to be examined -100% lifting attachments welds
c)
Defect Acceptance - EN 25817 quality level B
d)
NDT operator qualification - EN ISO 9712 level 2
Dimensional Inspection - Baseplates

Supplier is required to provide a marked up drawing for each baseplate showing the actual dimensions
obtained (both fabricated and machined) after machining. This to be undertaken using the machine used
for the machining unless a suitably large CMM is available. Any dimension found outside of drawing
tolerances must be the subject of a Sulzer approved concession request prior to delivery of the baseplate.
The baseplate is to be measured without any clamps or other such loading that will distort the fabrication
from its natural position.
This drawing is to be submitted to Sulzer for review prior to requesting release.
7.5
Dimensional Inspection All Other Fabrications

Supplier is required to provide a marked up drawing for each fabrication showing the actual dimensions
obtained after machining. Any dimension found outside of drawing tolerances must be the subject of a
Sulzer approved concession request prior to delivery of the fabrication. The marked up drawing is to
included in the certification data book
7.6
Surface Preparation & Painting Inspection

Unless otherwise specified on the ITP the Fabrication is to be inspected when primed to ensure that
surface preparation is as per the specified paint procedure and that there are no welding defects such as
pin holes, spatter, sharp edges, undercuts etc.
On completion of painting the fabrication to be inspected for painting defects and compliance with
specification with regard to dry film thickness.
7.7
Sulzer / Client Witness

Materials/components may be subject to inspection by Sulzer and/or their clients representatives. Such
inspections do not relieve the Supplier from obligations to carry out inspection and testing to verify
compliance to Sulzers Purchase Order and this specification.
Sulzer and/or their clients representatives shall be afforded access and assistance at all reasonable times
to carry out inspection and witness tests at the Suppliers premises.
Unless otherwise specified where Sulzer and/or their client inspection is required, the Supplier shall notify
Sulzer giving at least 5 working days (excluding Saturday and Sunday) advance notice and 1 full working
day to confirm that the inspection activity is on schedule or otherwise.
For baseplates the attached check list is provided as a guide to both Sulzer Inspectors and Suppliers as to
the items which are expected to be checked during inspections.
7.8
Notes for Sulzer Inspectors

On completion of any inspection a list of all defects requiring the supplier's attention must be left with the
supplier and a copy of this should be attached to the inspector's written report.


Page 5 of 10
Rev 13
Date 20.01.16
8.0
Release
Prior to delivery all baseplates are to be released by Sulzer. Fabricator to submit the attached release form
to Sulzer (Send to External Inspection Coordinator) and wait for signed return from Sulzer expediter who
will clarify the delivery point prior to delivery. Baseplates delivered without release will not be off-loaded.
9.0
Delivery
9.1
Paint must be fully cured prior to transport.
9.2
All painted fabrications are to be protected during transport by either being sheeted or transported in a
covered vehicle.
9.3
Prior to transport all machined surfaces are to be protected by preservative oil/grease.
10.0
General Notes
10.1
To enable positive identification of materials and their associated certification on receipt:a)
All certification and delivery advice documentation must include the Sulzer Purchase Order number
and Line Item number as reference in the Sulzer Purchase Order.
b)
Materials are to be individually identified by hard stamping / deep engraving / weld lettering at a
prominent location to maintain traceability to delivery documentation and associated certification.
Where there is more than one baseplate (B) per line item then letters are to be added after the
purchase order and item number such 4500123456-10/BA with the next baseplate being
4500123456-10/BB etc.
10.2
Certification shall be provided on or before delivery of the material.
10.3
Acceptance of the material shall be on receipt of acceptable certification by Sulzer.
10.4
All fabrications are to be weighed and the actual weight to be clearly shown on the advice note.
10.5
All standards referenced shall be current issues unless stated otherwise.
10.6
Failure to comply with the above requirements could result in rejection or delayed payment of invoices.

Page 6 of 10
Rev 13
Date 20.01.16
BASEPLATE INSPECTION CHECKLIST

Sulzer No
Supplier
Inspection Agency
Inspector
Inspection location
ITEM
Final Paint & Inspection
1
2
3
4
5
6
7
8
9
10
11
12
13
No
01
02
03
04
05
06
07
Sulzer P.O. No.

Supplier Ref. No.
Report No
Inspection Date
Drawing No.
Rev
RESULT
COMMENTS (Note: If Failed add items to punch list)
Material-inclusions / pitting
Welds to drawing dimensions
Weld spatter
Sharp edges and corners
Damage-general
Damage-lifting
Excessive grinding marks
Tapped hole protection
Machined surface protection
Reference nos. stamped on
Continuous Welding
Review Material Certs & NDT Reports
Digital Pics supplied
Inspection Punch List Items

Date
No
Punch List Item
08
09
10
11
12
13
14
Punch List Item
Date
Accept
Reject
On Hold
Delete as Appropriate
STAMP
Signed____________________
Dated______________________


Page 7 of 10
Rev 13
Date 20.01.16
Sulzer No
Supplier
Inspection Agency
Inspector
Inspection location
ITEM
Primer Inspection
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Sulzer P.O. No.

Supplier Ref. No.
Report No
Inspection Date
Drawing No.
Rev
RESULT
Material-inclusions / pitting
Weld spatter
Sharp edges and corners
Damage-general
Damage-lifting
Excessive grinding marks
Tapped hole protection
Machined surface protection
Reference nos. stamped on
Blast Profiles
Digital Pics. Supplied
Pin Holes in Weld
Weld Defects
Correct Paint Supplier
Correct Paint Procedure
Dry Film Thickness to Specification
DFT Meter Calibration - Readings

No
Punch List Item
Date
No
Punch List Item
01
08
02
09
03
10
04
11
05
12
06
13
07
14
Note: Punch list actions complete from previous stage inspections?
Date
YES / NO
Accept
Reject
On Hold
STAMP
Signed____________________
Dated______________________

Page 8 of 10
Rev 13
Date 20.01.16
Sulzer No
Supplier
Inspection Agency
Inspector
Inspection location
ITEM
Final Paint & Inspection
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Sulzer P.O. No.

Supplier Ref. No.
Report No
Inspection Date
Drawing No.
Rev
RESULT
Correct Colour
Correct Paint Supplier
Correct Paint Procedure
Correct Environmental Conditions
Correct Areas Painted / Unpainted
Dry Film Thickness to Specification
Paint Runs
Structural / Handling Damage
Paint Damage
Material Inclusions / Pitting
Tapped Hole Damage
Grit in Tapped Holes
Machined Surface Protection
Reference Numbers Discernable
Baseplate Covered for Transportation
DFT Meter Calibration Readings
Digital Pictures Supplied

No
Punch List Item
Date
No
Punch List Item
01
08
02
09
03
10
04
11
05
12
06
13
07
14
Note: Punch list actions complete from previous stage inspections?
Date
YES / NO
Accept
Reject
On Hold
STAMP
Signed____________________
Dated______________________

Page 9 of 10
Rev 13
Date 20.01.16
Baseplate Quality Release Form

This Quality Release does not relieve suppliers from guarantees and indemnities as to patents, materials, equipment,
workmanship and performance requirements of the Purchase Order and associated procedures. Goods not be
despatched until a signed release has been received from the Sulzer Expediter.
PART A - To be completed by the Supplier

Sulzer Purchase Order No:
Sulzer Ref No:
Project:
Supplier:
Supplier Ref No:
Description:
Item
Weight
Item No
Quantity
Use continuation sheet as necessary
We hereby certify that the items above have been manufactured in accordance with the requirements of the purchase
order and agreed concessions/deviations. We confirm that all inspections and tests have been satisfactorily carried out
and that the Manufacturing Record Dossier has been completed, unless otherwise state*
Remarks:
Date certification pack (including paint certs.)

sent to Sulzer:
Name:
Position in Company:
Signed:
Date:
* Any outstanding work/action list to be detailed here:


Page 10 of 10
Rev 13
Date 20.01.16
PART B To be completed by Sulzer

Quality
We confirm that the items listed above have been inspected/waived and may be released for despatch.
Blast:
Marked up Drawing:
Final:
Checklist Blast
- Prime
- Final
Name:
Signed:
Date:
Projects
We confirm that the items have no open client issues precluding delivery to Sulzer.
Name:
Signed:
Date:
Expediting
Delivery Point Sulzer Expediting to delete one.
Sulzer Pumps UK Limited
Manor Mill Lane
Leeds
LS11 8BR
Sulzer Pumps UK Limited

Old Bison Concrete
Intermezzo Drive
Stourton
Leeds
LS10 1DF


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QUALITY SPECIFICATION 40-601