QP –8.6B Iss.

date 1/8/2017
Release of products and services Iss.7 /Rev.0
(Inprocess inspection) Page 2 of 4

1. Purpose
To establish system for inspection and testing during production processes.

2. Scope
All products and weldments depending on contractual requirements.

3. Procedure
3.1. Inspection Test Plan form (FQP-8.6B-11) should be issued before starting
fabrication according to client specifications and contractual code.
3.2. The mainly test performed is visual inspection by using form (FQP-8.6B.8).
3.3. There are so many non destructive tests available such as:
1. Radiograhphic test (RT) Form No. (FQP-8.6B-2)
2. Ultrasonic test (UT) Form No. (FQP-8.6B-4)
3. Pentrante test (PT) Form No. (FQP-8.6B-5)
4. Magnetic test (MT). Form No. (FQP-8.6B-6)
3.3.1. All of these tests are performed according to AWS D1.1 for steel
structure (in case there is no specific client requirement as declared in
the contract agreement) and ASME manual for pressure vessels and
boilers.
3.3.2. Results are recorded in the relevant form as declared at the end of
procedure.
3.4. Prefabrication
3.4.1. prefabrication engineer / his delegate notifies QC engineeer using form
# FQP-8.6B-1.
3.4.1.1. Form # FQP-8.6B-1 is used to qualify the raw material.
3.4.1.2. For plates, QC engineer / delegate check thickness,
surfaces conditioning and lamination (lamination test is
performed according to work instruction WI-8.6A-1).
3.4.1.3. For profiles, QC engineer / his delegate check squareness,
web-off center and surface conditioning.
3.4.1.4. And also form # FQP-8.6B-1 is used to notify about the cut
out pieces from the qualified parent articles.
3.4.1.5. All dimensional inspection carried out according to the
drawing requirements by using form No. FQP-8.6B10
3.4.2. After fulfilling the tests necessary as declared in the relevant Inspection
test plan, QC engineer / his delegate fill in the second part of form #
FQP-8.6B-1 and submit a copy to prefabrication engineer.
QP –8.6B Iss.date 1/8/2017
Release of products and services Iss.7 /Rev.0
(Inprocess inspection) Page 3 of 4

3.5. Assembly
Only accepted items released by QC are transferred from prefabrication
bay to fabrication groups.
3.5.1. Fabrication group engineer / his delegate is responsible for revising the
right positioning of parts and checking dimensions according to the
relevant workshop drawings on 100% of the total quantity.
3.5.2. The above table of form # FQP-8.6B-3 declares the fabrication status.
3.5.3. Fabrication group engineer / his delegate is responsible for fill in form #
FQP-8.6B-3 concerning drawing No, item No, positioning check and
dimension check and finally sign under Ass. Column.
3.6. QC role and decisions are declared at the lower table of form #FQP-8.6B-3.
3.7. QC technican checks assembly and sign for passing to weld in case the
assembly is meeting the requirements of the relevant drawing and mark the
item according to the test status.
3.8. Fabrication group engineer / his delegate keeps the record.
3.9. Welders’ supervisor is responsible for soundness the weld, good
appearance of weld seams and be sure about actual weld size meeting the
requirement of the relevant drawing.
3.10. Signature (either from side of welders’ supervisor or fabrication group)
under the column means that the weld is completed and ready to conduct
inspection from side of QC according to what is spcified in the quality
control plan.
3.11. In case there is a defect in the weld, QC technician mark out the defected
portion of weld seams to be repaired and use form FQP-8.6B-7 for some
cases to inform welding supervisor.
3.12. In case weld seams are sound enough, QC technician signs in the
relevant subcolumn.
3.13. After the completed weld is qualified by QC, the weldment would be
subject to finishing activities.
3.14. It may be specified to subject the weldment / product to machining
process with using the same form # FQP-8.6B-3.
3.15. Final QC signature means the record is completed and the item is
released to sand blasting taken the necessary precautions to protect the
machined surfaces, if any.
3.16. The record is kept by QC engineer and a copy is submitted to fabrication
group engineer.
3.17. To inspect, the surface roughness after sand blasting and inspection wet
and dry painting is as declared in painting procedure (WI-8.6C-1).
3.18. In case heat treatment is required, the engineer in charge of furnace / the
subcontractor perform it as customer requirement / work instruction # (WI-
8.5.1A-1).
QP –8.6B Iss.date 1/8/2017
Release of products and services Iss.7 /Rev.0
(Inprocess inspection) Page 4 of 4

3.19. Any non conformity case would be treated as per Incoming inspection
procedure # (QP-8.6A).
3.20. QC Inspector issue form N.D.T request form (FQP-8.6B-14) to NDT Dept.
to carry out the percentage of N.D.T. according to Q.C. plan and the
result will be recorded in form (FQP-8.6B-3)
3.21. For B.U.S (Built Up Sections) , form # FQP-8.6B-15 is used for inspection.
3.22. During erection on site QC department can use the client forms instead of
our QC forms according to the client specification.
3.23. QC Engineer issue fabrication releas certificate for final inspection ,
painting or galvanization from No. (FQP-8.6C-2) in according to
procedure no. QP-8.6C

4. References & Forms

4.1. Prefabrication inspection report FQP-8.6B-1

4.2. Radiographic Test report FQP-8.6B-2
4.3. Fabrication inspection report FQP-8.6B-3
4.4. Ultrasonic test report FQP-8.6B-4
4.5. Liquid Penetrant report FQP-8.6B-5
4.6. Magnetic test report FQP-8.6B-6
4.7. Welding repair report FQP-8.6B-7
4.8. Visual inspection report FQP-8.6B-8
4.9. Hydropressure test report FQP-8.6B-9
4.10. Dimension inspection report (St. structure) FQP-8.6B-10A
4.11. Dimension inspection report (Tanks) FQP-8.6B-10B
4.12. Inspection and Test Plan FQP-8.6B-11
4.13. NDT request FQP-8.6B-14
4.14. B.U.S Inspection report FQP-8.6B-15
4.15. Release certificate FQP-8.6C-2
4.16. As Built material List FQP-8.6C-17
 QA/QC
Department Prefabrication Inspection Report # ( )
FQP-8.6B-1

Job No.: Date: / /

1-Filled by production: -
Drawing No/item
S.N
Rev .No Pos. Qty Dimension Heat No Remarks
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Production Eng:-
Sign:-
2-Filled and checked by QC:-

visual
S.N Dimension check Heat NO Qty Material Certificate # QC Release Remarks
check

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

QC Eng:-
Sign:-
(Iss.7/Rev.0)
 RADIOGRAPHIC TEST REPORT

Report no. Date:

PROJECT: CLIENT: Procedure:

ACCEPTANCE:
ITP No.

DRAWING No: ITEM: Qty.

AS WELD CASTED GRINDING MACHINED

SURFACE
CONDITION

Technique Description

TECHNIQUE ACTIVITY/ VOLTAGE:

FILM TYPE FOCAL SIZE/FOCAL SPOT

FILM SIZE LEAD SCREEN

SINGLE FILM/DOUBLE FILM EXPOSURE TIME

ISOTOPE / X-RAY SFD/SOD

EVALUATION
WELDER Thick No of
WELD No. IQI WELDING REANGE
STAMP mm Film
Sensitivity Density Discontinuity ACCEPT REPAIR Remarks

Abbreviations

P POROSITY IP INCOMPLETE PENETRATION LF LAKE OF FUSION S SURFACE SLAG ACC ACCEPT R REPAIR SL SLAG LINE

UC UNDER CUT IF INCOMPLETE FUSION WH WORM HOLE FM FILM MARK D DENSITY SI SLAG INCLUSION C CRACK

SKETCH :
SEE ATTACHED WELDING MAP

DSD FERROMETALCO Third Party CLIENT

Name

Signature

Date

FQP-8.6B-2 ( Iss.7/ Rev.0 )

 QA/QC
Department Fabrication Inspection Report ( )
FQP 8.6B-3
Job No.: Date.:

Bay No.: Bay Eng.: Production Control Eng.:

NDT
Group No. Drawing Rev. Item Qty. Dimension Visual QC Release
P.T M.T U.T R.t

Attached Documents: Abbrevation of results

Dimension / Drawing NDT Result A = Accept
Prefab Release Traceability R = Repair
Visual NDT Request H = Hold
RJ = Reject

Page Of ( Iss.7/REV.0 )
 ULTRASONIC TEST REPORT

Report no. Date:

PROJECT: CLIENT: Procedure:

ITP No. ACCEPTANCE:

DRAWING No: ITEM: Qty.

AS WELD CASTED GRINDING MACHINED

SURFACE
CONDITION

Technique Description

UT instrument : 0° Transducer : Freq : 4MHZ Size : 24 mmØ

Manufacture : 45° Transducer : Freq : 4MHZ Size : 8 x 9 mm

Serial No : 60° Transducer : Freq : 4MHZ Size : 8 x9 mm

Calibration DATE : 70° Transducer : Freq : 4MHZ Size : 8 x9 mm

Couplant : Basic Calibration Block : V1 & V2 for range / side driled holes Ø3 mm for gain.

Equipment and Matterials

UT Technique : SURFACE TEMPERATURE

Coverage Percentage : CABLE TYPE :

Reference Level : SCANING LEVEL:

Indications
Weld Mat. Mat. THK TOTAL WELDER
Pos 1 Pos 2 Result
No. GR 1 GR 2 mm. LENGTH STAMP
Location Amplitude Length Depth Type

Abbreviations

P POROSITY C CRACK LC Lack of fusion IP incomplete Penetration S SURFACE SLAG A ACCEPT R REPAIR

SKETCH :
SEE ATTACHED WELDING MAP

DSD FERROMETALCO Third Party CLIENT

Name

Signature

Date

FQP-8.6B-4 ( Iss.7/ Rev.0 )

 LIQUIDS PENETRANT EXAMINATION REPORT

Report no. Date:

PROJECT: CLIENT: Procedure:

ACCEPTANCE:
ITP No. MATERIAL:

DRAWING No: ITEM: Qty.

AS WELD ROUGH GRINDING MACHINED

SURFACE
CONDITION

CLEANING AGENT SURFACE TEMPERATURE

PENETRANT TYPE DRY-OUT TIME

PENETRANT CLEANING AGENT PENETRATION TIME

DEVELOPER TYPE DEVELOPING TIME

DEVELOPER CLEANING AGENT FINAL CLEANING (OK/ NO OK)

EVALUATION
WELDER STAMP TESTED LENGTH
WELD No. ACCEPT AFTER
ACCEPT. REPAIR ACCEPT AFTER REPAIR
MACHINING

Abbreviations

P POROSITY C CRACK UC UNDER CUT S SURFACE SLAG A ACCEPT R REPAIR

SKETCH :
SEE ATTACHED WELDING MAP

DSD FERROMETALCO Third Party CLIENT

Name

Signature

Date

FQP-8.6B-5 ( Iss.7/ Rev.0 )

 MAGNETIC PARTICLES EXAMINATION REPORT

Report no. Date:

PROJECT: CLIENT: Procedure:

ACCEPTANCE:
ITP No. MATERIAL:

DRAWING No: ITEM: Qty.

AS WELD ROUGH GRINDING MACHINED

SURFACE
CONDITION

TECHIQUE SURFACE TEMPERATURE Ambient

MANUFACTURER AC ELEC. YOKE

WHITE CONTRAST TEST DEVICE DC ELEC. YOKE

BLACK INK PERMANENT. YOKE

EVALUATION
TESTED
WELDER STAMP
WELD No. LENGTH ACCEPT AFTER ACCEPT AFTER
ACCEPT. REPAIR
REPAIR MACHINING

Abbreviations

P POROSITY C CRACK UC UNDER CUT S SURFACE SLAG A ACCEPT R REPAIR

SKETCH :
SEE ATTACHED WELDING MAP

DSD FERROMETALCO Third Party CLIENT

Name

Signature

Date

FQP-8.6B-6 ( Iss.7/ Rev.0 )

 (FQP-8.6B-7)
QA/QC WELDING REPAIR

Job No: Report # ( ) Rev. # ( )

DATE: / /
DRWG Item Weld Kind Of
GROUP SKETCH NDT Request No. Sign.
No. No. No. REPAIR

* P POROSITY * IP INCOMPLETE PENETRATION * WH WORM HOLE

* AP ALIGNED POROSITY * IF INCOMPLETE FUSION * UC UNDER CUT
* SI SLAG INCLUSION * C CRACK * FM FILM MARK
* SL SLAG LINE * SLF SIDE LAKE OF FUSION * D DENSITY

NDT
Operator Q.C-Eng :
Date / /

Response : NDT After Repair ( if any )

- Repair was accomplished.
Welding supervisior : NDT Operator :
Date: / / Date: / /

(Iss.7/Rev.0)
 VISUAL INSPECTION REPORT

Report no. Date:

PROJECT: CLIENT: Procedure:

ACCEPTANCE:
ITP No. MATERIAL:

DRAWING No: ITEM: Qty.

AS WELD ROUGH GRINDING MACHINED

SURFACE
CONDITION

TESTED
WELD No. WELDER STAMP FIT UP WPS No. RESULT
LENGTH

Sharp edges have been removed and rounded off with a minimum radius of 1 mm

Abbreviations

P POROSITY C CRACK UC UNDER CUT S SURFACE SLAG

A ACCEPT R REPAIR

SKETCH :

SEE ATTACHED WELDING MAP

DSD FERROMETALCO Third Party CLIENT

Name

Signature

Date

FQP-8.6B-8 ( Iss.7/ Rev.0 )

 HYDROSTATIC TEST REPORT
FQP-8.6B-9

PROJECT :
CLIENT :
JOB. NO. :
SERIAL NO. :
DWG NO. :
PROCEDURE NO. :

GAUGE SPECIFICATIONS

SERIAL NO. :
MANUFACTURER:
RANGE:
DUE DATE OF CALIBRATION :
CERTIFICATE NO.:

HYDROPRESSURE TEST

TEST MEDIUM:
TEST TEMP:
TEST PRESSURE:
HOLDING TIME:
DATE OF TEST:

TEST RESULT

Quality Control Inspector:

QC. Manager:
Authorized Inspector:

(Iss 7/Rev 0)
 DIMENSION INSPECTION REPORT

Report no. Date:

PROJECT: CLIENT:

ITP No. ACCEPTANCE:

DRAWING No: REV ITEM: Qty.

AS WELD Casted GRINDING MACHINED

SURFACE
CONDITION

Tape Micrometer Caliper Go-No Go

Measuring
Tool

Dimensions Tole. ± Deviation Result

All Dimensional Inspection Carried out According to the Drawing Requirements and accepted according to the Specefied
tolerance
SKETCH :

SEE ATTACHED DRAWING

DSD FERROMETALCO Third Party CLIENT

Name

Signature

Date

FQP-8.6B10A ( Iss.7/ Rev.0 )

CLIENT Tank Plumpness and Roundness
FQP-8.6B-10B
CONTRACT

Block: Unit Item No.:

Service: Certificate No.:
Remarks:

Tank Tank
Plumpness Roundness
Ax Accept Rx Accept
Measured 1 lt above (Y/N) Measured 1 lt above (Y/N)
bottom corner bottom corner

1
2
3
4
5
6
7
8

Reference: Tolerance
(API. 650 Par. 5)
Plumpness: Deviation Ax 1/200 H
Roundness: Tank Radius:
If 4< 20 ft
½” (12,7mm)
(6,1m)
If 20< R < 75ft
¾” (19mm)
(22,9m)
If 75<R< 125 ft
1” (25,4 mm)
(38,1 m)
If R > 125 ft 1 ¼” (31,7mm)
Local Deviations
Peaking Vertical joint ½” (12,7mm)
Banding Horizontal joint ½” (12,7mm)

Approved by: DSD Ferrometalco Third Party Client

Name:

Signature:

Date:

(Iss.7/Rev.0)
 FQP-8.6B-11
Date :
Rev. :
Inspection and Test Plan Page :
I.T.P No. :

Project: DSD Job No. :

Client :
Part Description: Applied standard :

Third party Inspection TPI Type of Test Symbol Ref.Procedure Reference record

Hold Point H

Witness Point W

Report Review Rev.

Internal Document X

Dimension report DIM

Material receiving inspection report MRIR

Material traceability report TRC

Painting report PR

Inspection release certificate IRC

Full Penetration F.P.

In Process IP

DWG. Review DWG.

Certificate cert.

Approval A

Monitor M

Prepared Checked Review Approval Remarks

Rev. Date Description

00
01
02

(Iss.07/Rev.0)
 NDT REQUEST
FQP-8-6B-14

Date: Requiest No: Project No: Client: Bay No.: NDT Type:

Item Drawing Weld Weld Length Material Material Weld Joint Welder Welding Report
Ser. Rev. Remarks
No. No. No. to be tested Thickness Type Process Type ID Position No.

RT Will not be executed unless the safety Permission request available in the safety Department (1) hour before the test

Raised By QC Engineer Received By NDT Controller

Date: Date:
Name: Signature: Name: Signature:
Time: Time:

)Iss.7/Rev.0(
 B . U . S Inspection Report
FQP 8.6B-15

A1
B
X
a1 a2 Y

H D F G

a3 a4
X

A2 C Y

Job : DWG Item : QTY: STANDARD:

Material : Flange A1 : Flange A2 : Web :

WELDER STAMP:

MEASURE
SYMBOL DWG DIM TOL. +/- OK (Y/N) DATE PC SIGNE QC SIGNE REMARKS
1 2 3
A1
A2
B
C
GEOMETRY

D
H
F
G
X
Y
B.U.S WELD

a1
a2
a3
a4
Camber
Sweep
SAW

Length
E (CUTTING ANGEL)
CNC DRILLING

Distance
between
holes

Holes Ø
diameter
VISUAL
L SIDE VIEW

TOP VIEW

R SIDE VIEW

Iss.7-Rev.0
 Release Certificate
FQP-8.6C-2

To Protective
Coating To Packing To Shipping

Status: Shipping Date:

Project:
Job No.:
Material:
S. Drawing No.:
E. Drawing No:
Code Marking:

Item: According to packing List No. # ( ) dated / / , attached pages

No. # Of

Material & Welding Processes

We hereby certify that the above-mentioned component is fabricated & inspected
in accordance with the Approved Drawing, WPS & Client Specification. & all
related NCR are closed. (If any)

Visual Inspection:
Inspection test reports are checked and released by DSD.

Non-Destructive Test:
We hereby certify that all items are tested & Accepted according to the quality
plan.
Dept. Name Date Sign
Technical Office
Production Dept.
Quality Control Fab.
Dept. Protective Coating
Shipment & Packing Dept.

Client
(Iss.7/Rev.0)
 FQP-8.6B-17

As Built Material List

Doc. No.: Job No. :

Rev.: Drawing Number :
Page : ITEM :
DESCRIPTION
POS.

CERTIFICATE
DIMENSIONS CROSS QTY. MATERIAL HEAT NO. ID PLATE REMARKS
NO.
SECTION x LENGTH (mm)

Prepared by: ** CLIENT

Quality Control Engineer
ENG. : NAME:
Sign: SIGN:
Date: / / DATE :
Iss.7- Rev.0