-
实用文档
Chiwan Sembawang
Engineering Co Ltd
Control No. :
QS-CSE-M01
QA/QC MANUAL
Rev. 4
Complied by:
Li WeiWen
Checked by:
Ge Zhi Hai
Wei ZhaoHong
Lv ZhongYi
Reviewed by:
Approved by:
Zhou XueZhong
Enforcement Date : Sept. 24, 2004
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Contents
Page: 1 of 59
Rev. No.: 4
CONTENTS
0.0
Introduction
1.0
Quality & OHS Objective for QA/QC Department
2.0
Organization of Department
3.0
Responsibilities & Functions of Department
4.0
Responsibilities & Duties of Personnel
5.0
Control of Manual
6.0
QA System
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
7.0
7.1
7.2
7.3
7.4
7.5
Internal Audit
Document Control
Quality Record Control
Control of Measuring and Monitoring Devices
Welding Control
Training
Statistical Application and Techniques
Continual Improvement
QC System
Material Control
In-process Control
NDT Control
Inspection/Test Status
Non-conforming Product Control
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7.6
7.7
7.8
7.9
7.10
8.0
Corrective Action
Preventive Action
Release Control
Inspection and Test Plan
OHS Management
List of QA/QC Produces
4
9.0
List of Quality Records
10.0
Issue Record
Attachment1: Typical Inspection Test Plan
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 0.0
Introduction
Page: 2 of 59
Rev. No.: 4
0.0
INTRODUCTION
A
principal
factor
in
the performance of an organization is
the
quality
and
safety
of
its
products
and
services.
There
is
a
world-wide trend towards more stringent customer
’
s expectations
4
with
regard
to
quality
&
OHS.
It
is
in
view
of
this
that
this
QA/QC Departmental Manual is prepared.
This
Manual
is
prepared
by
the
QA
Section
Head
as
per
the
Company
’
s
Quality
&
OHS
Manual,
checked
by
QA/QC
Manager
and
Safety Department Manager, reviewed by Management Representative
and
approved
by
GM.
The
Manual
is
a
level
2
documents
and
is
treated as a confidential and controlled document.
Quality
plan
consistent
with
all requirements of the Company
’
s
Quality & OHS System is established by reviewing design, customer
specification and job details, and the requirements of which are
communicated to departments and personnel concerned.
All
materials
are
identified
and
traceable
from
their
originality. The identification and traceability of materials are
controlled by quality records. All material received are checked
for their conformity. All non-conformance items are analyzed and
reported to QA/QC Manager for review and comments.
QC
personnel
carry
out
daily
inspection
and
monitor
the
fabrication activities. Defects in weld are monitored on a weekly
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basis.
Welders
’
performance
are
controlled
and
assessed
in
a
timely manner.
QA
personnel
conduct
day
to
day
quality
audit
and
review
established
quality
system
and
monitors
departmental
function
besides once-every-year internal quality audit organized by
QA/QC Manager and conducted by QA audit team. All quality audit
reports
shall
be
submitted
to
GM/DGMs
for
information
and
comments.
Measuring
and
test
equipments
are
calibrated
according
to
relevant
requirements
and
procedure
and
control
of
calibrated
equipment are maintained by the QA/QC Department.
All
non-destructive
testing
are
carried
out
by
qualified
personnel
in
accordance
with
approved
procedure.
Inspection
reports and procedures are maintained as quality records in QA/QC
Department.
4
These
Quality
&
OHS
System
are
prepared
in
compliance
with
ISO
9001-2000 and OHSAS 18001-1999.
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 1.0
Quality Objective
Page: 3 of 59
Rev. No.: 4
4
1.0
QUALITY OBJECTIVE FOR QA/QC DEPARTMENT
Company
’
s quality & OHS objectives have been broken down to the
relevant function departments in the documented Annual Company &
Department Quality Objectives and OHS Objectives.
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QA/QC Department shall establish and maintain its inspection and
test system, control the product quality and safety according to
customer
’
s
requirements
and
relevant
standards
to
achieve
the
related quality & OHS objectives.
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Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 2.0
Organization
Page: 4 of 59
Rev. No.: 4
2.0
ORGANIZATION OF DEPARTMENT
To
achieve
the
quality
&
OHS
objectives,
QA/QC
Department
has
established
a
quality
&
OHS
system
structure
for
the
effective
control,
evaluation
and
improvement
of
the
quality
&
OHS
of
products and service throughout all stages of the fabrication of
a product.
Table 2-1
shows the organization structure.
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Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 3.0
Department Functions
Page: 6 of 59
Rev. No.: 4
3.0
RESPONSIBILITIES & FUNCTIONS OF DEPARTMENT
3.1
Scope
This
section
defines
the
organizational
responsibilities
for functions in relation to achievement of quality & OHS.
3.2
Responsibilities of QA/QC Department
a) Responsible to ensure that Quality Management System are
adequate and complete for implementation.
b)
Responsible
to
ensure
that
code
requirements
and
customer
specifications are complied.
c)
Identify quality problems and initiate corrective actions.
d)
Ensure
that
quality
planning,
material
inspection,
in
process
inspection,
testing
and
documentation
are
carried
out during fabrications.
e)
Coordinate
with
customer
representatives
and
third
party
inspection agencies.
f)
Provide adequate training to QC/NDT personnel.
g)
Responsible for the QA/QC functions.
4
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h)
Responsible
for
the
OHS
activities
related
to
QA/QC
Department.
3.3
QA/QC Functions
The
QA/QC
Department
mainly
carries
out
various
functions
as
given below.
a)
Establishment & maintenance of Quality System and Manuals.
b)
Quality planning.
c)
Material inspection.
d)
In-process inspection.
e)
Dimensional control
f)
Surveillance for welding, thorough visual inspection prior
to corrosion protection, blasting/coating, galvanizing.
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Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 3.0
Department Functions
Page: 7 of 59
Rev. No.: 4
g)
Non- destructive testing.
h)
Material traceability.
i)
Evaluation of welder performance.
j)
Disposal of non- conformance.
k)
QA/QC documentation.
l)
Liaison
with
customer
inspectors
and
the
Third
Party
inspectors.
m)
Training for QC personnel.
n)
Quality audit.
3.4
The Various Sections of QA/QC Department
3.4.1 Quality Assurance Section
The Quality Assurance Section is headed by QA Section Head who is
responsible to the QA/QC Manager for the following functions:
a)
Quality audit and surveillance.
b)
Preparation of project Quality Plan .
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c)
Preparation and maintenance of the QA/QC Department Manual.
d)
Monitoring
of
various
quality
elements
in
related
departments
as
per
Company
’
s
Quality
&
OHS
Manual
and
Departmental Manuals and Quality System Procedures.
e)
Carrying out audit on vendors / subcontractors.
f)
Calibration of measuring / test equipment.
g)
Evaluate
the
scope
and
requirement
of
tender
document
pertaining
to
quality
control
and
NDT
and
assist
in
estimate the cost to perform such function.
h)
Control
of
welders/welding
operators
and
their
qualification .
i)
Control of welding consumables.
j)
Submission of final project documentation.
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 3.0
Department Functions
Page: 8 of 59
Rev. No.: 4
3.4.2 QC Section
QC Section is controlled by QC Section Head who is responsible to
the
QA/QC
Manager.
Following
are the QC Section functions to be
performed.
a)
Material inspection.
b)
Fit-up inspection
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c)
In-process inspection
d)
Welding surveillance / welding inspection
e)
Material traceability
f)
Dimension control
g)
Blasting and painting control
h)
Hydrostatic testing
i)
Final inspection and submission of documentation.
3.4.3 NDT Section
NDT Section is headed by NDT Section Head who is responsible to
QA/QC
Manager
for
coordinating
with
NDT
operators
in
the
performance of non-destructive testing of welds and materials as
per
code
and
customer
specifications.
Following
are
the
NDT
Section functions to be performed.
a)
Review of NDT procedure.
b)
Performing and evaluating test as per specification.
c)
Interpretation of radiographs.
d)
Weekly repair rate and welder performance.
e)
Liaison
with
customer
inspector
on
quality
problems
concerned.
f)
Reporting non-conformity items to QC coordinator.
g)
Training of NDT operators.
h)
OHS management of NDT operations.
4
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Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 4.0
Personnel Duties
Page: 9 of 59
Rev. No.: 4
4.0
RESPONSIBILITIES & DUTIES OF PERSONNEL
The responsibility, authority and interrelation of all personnel
who manage, perform and verify work affecting quality & OHS shall
be
defined,
particularly
for
personnel
who
need
the
organizational freedom and authority.
QA/QC Department has explicitly defined the general and specific
responsibility
and
duty
for
its
personnel
whose
activities
influence fabrication and/or service quality & OHS as follows:
4.1
QA/QC Department Manager
The
QA/QC
Department
Manager
is
responsible
to
the
General
Manager
for
the
overall
quality
assurance
of
the
Company
Management
System
and
the
quality
control
of
the
production
operation by initiating the following actions:
a)
Planning
and
maintaining
an
acceptable
quality
assurance
program.
b)
Preparing,
maintenance
and
implementation
of
QA/QC
4
procedures
to
ensure
that
all
quality
&
OHS
requirements
are
achieved
in
accordance
with
Client
’
s
Specifications,
Standards,
Codes
and
Company
’
s
Quality
&
OHS
management
system.
c)
Conforming
to
the
specified
contractual
quality
requirements for the project.
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d)
Planning
and
organizing
quality
audits
on
a
timely
basis
and reacting the findings in a positive manner.
e)
Ensuring
the
achievement
of
department
quality
&
OHS
objective.
f)
Responsible
for
the
OHS
affairs
of
QA/QC
Department,
ensuring the safety of NDT activities and operations.
4
4.2
QA Section Head
The QA Section Head is responsible for the QA function, including
quality audits and monitoring of QA activities. He reports to the
QA/QC Department Manager. The following will be his main tasks:
a)
Monitoring execution status of Quality & OHS System of the
Company.
b)
Review
of
QA/QC
procedures,
such
as
quality
plan,
inspection
and
test
plan,
material
control
procedure,
NDT
procedures, NDT extent etc.
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 4.0
Personnel Duties
Page: 10 of 59
Rev. No.: 4
c)
Planning
and
performing
of
quality
audits
including
major
vendors and subcontractors.
d)
Liaison with customer
’
s representatives.
e)
Monitoring performance of non-conformity items.
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4.3
QC Section Head
The
QC
Section
Head
is
responsibility
for
the
implementation
of
QC
activities,
he
reports
to
the
QA/QC
Department
Manager,
the
following will be his main tasks:
a)
Controlling
and
evaluation
of
project
QC
coordinators,
inspectors of all disciplines and surveyors.
b)
Liaison
with
the
project
manager
and
customer
QA/QC
representatives.
c)
Arrangement
of
quality
meeting
to
avoid
resulting
in
problems
between
disciplines
and
department
regarding
quality matters and inspection progress checks.
4
4.4 NDT Section Head
The NDT Section Head reports to the QA/QC Department Manager, and
is responsible for the following tasks:
a)
Preparation,
maintenance
of
NDT
procedures
and
RT
safety
procedure.
b)
Performing and evaluating test as specified.
c)
Interpretation of radiographic films.
d)
Documentation of the test status.
e)
Liaison
with
customer
inspector
on
quality
problems
concerned.
f)
Reporting
of
non-conformance
items
to
project
QC
coordinator.
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g)
Implementation of NDT procedures and ensuring the safety of
NDT activities and operations.
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 4.0
Personnel Duties
Page: 11 of 59
Rev. No.: 4
4.5 QA Engineer
The QA Engineer is directly responsible for the QA activities and
reports
to
the
QA
Section
Head.
The
following
will
be
his
main
tasks:
a)
Performance
of
quality
audit
including
major
vendors
and
subcontractors.
b)
Preparation of inspection and test procedures, Quality Plan
and NDT extent etc.
c)
Liaison with project QC coordinator.
d)
Responsible
for
the
calibration
of
measuring
and
testing
equipment.
e)
Control
of
internal,
external
NCRs,
and
complaints
from
customer.
f)
Evaluation of work load for tenders.
g)
Review of NDT drawing.
h)
Document Filling systems and submission.
4.6
Welding Engineer
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The
Welding
Engineer
is
directly
responsible
for
the
control
of
welder
qualifications
and
welding
consumables.
He
reports
to
QA
Section Head. The following will be his main tasks:
a)
Receive
inspection
of
welding
consumables
together
with
procurement personnel and preparing inspection report.
b)
Supervising
and
instructing
the
storage,
baking
and
issuance of welding consumables.
c)
Organizing
training
and
certifying
of
welder
and
welding
operator.
d)
Evaluation the performance of welder and welding operator.
4.7
Assistant QA Engineer
The
assistant
QA
engineer
reports
to
the
QA
Section
Head
and
shall be responsible for following tasks :
a
)
Prepa
ration
of
summary
sheet
for
material
traceability
and
QC/NDT inspection reports.
b
)
Typin
g
Quality
System
Manuals,
procedures,
inspection
formats
and project documents.
c )
Preparation of as-built documentation for project and bidding.
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 4.0
Personnel Duties
Page: 12 of 59
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Rev. No.: 4
4.8
Project QC Coordinator
The
project
QC
coordinator
is
directly
responsible
for
the
quality control activities of the assigned project. He reports to
the QC Section Head and has the responsibility of controlling and
evaluating
the
QC
inspectors
engaged
in
his
project.
The
following will be his main tasks:
a)
Implementation
of
QC
procedures
and
assessment
of
QC
inspectors.
b)
Liaison
with
personnel
concerned
including
engineering
,
purchasing and PMT.
c)
Coordination
with
QA/QC
Personnel
including
QA
Engineer,
NDT Personnel and inspectors of various disciplines.
d)
Preparation of non-conformance reports (NCR)
e)
Consult with Project Manager to discuss quality matters
f)
Control of inspection status.
g)
Release control
4.9
QC Inspector
The
QC
inspectors
of
various
disciplines
report
to
project
QC
coordinator and shall be responsible for the following tasks:
a)
Performing
and
evaluating/witnessing
required
inspection
and test .
b)
Preparation of inspection and test reports.
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c)
Control of non-conformance items.
d)
Monitoring of the workmanship and inspection activities.
e)
Liaison
with
customer
inspectors
on
quality
matter
concerned.
f)
Reporting
of
non-conformance
items
to
project
QC
coordinator.
g)
Issue conformance release notice to products .
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Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 4.0
Personnel Duties
Page: 13 of 59
Rev. No.: 4
4.10
NDT Operator
The NDT operator is responsible for the following tasks:
a)
Performance of NDT works as per codes and specifications.
b)
Preparation
of
weekly
welding
repair
rate
and
welder
performance.
c)
Preparation of NDT reports and summary sheets.
d)
Interpretation of radiographs and liaison with customer
’
s
representative.
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 5.0
Control of Manual
Page: 14 of 59
Rev. No.: 4
5.0
CONTROL OF MANUAL
This
QA/QC
Department
Manual
has
been
prepared
in
order
that
a
set
of
systems,
procedures
and
QA/QC
functions
are
available
in
the
QA/QC
Department.
The
Manual
serves
as
a
guide
to
ensure
continuous
adherence
to
code,
customer
’
s
specification
and
standardization.
5.1
The QA/QC Manual prepared by QA/QC department is treated as
level
2
document
and
issued
with
the
approval
of
the
General Manager through QA/QC Department.
5.2
All
proposals
for
revision
in
the
QA/QC
Manual
shall
be
filled
in
attached
form
“
Application
for
Quality
System
Document Revision
”
for the approval of General Manager has
been obtained.
5.3
All revisions/amendments shall be issued after the approval
from the General Manager.
5.4
Holders
of
controlled
copies
of
the
QA/QC
Manual
are
assigned
a
specific
reference
number.
They
shall
receive
all amendments / revisions.
5.5
Uncontrolled
Manual
will
not
be
amended
or
revised
and
shall not be used by CSE personnel.
5.6
This
QA/QC
Manual
is
treated
as
a
CONFIDENTIAL
document,
unless
authorized
by
the
General
Manager,
this
document
实用文档
shall
not
be
issued
to
public,
only
CSE
personnel
shall
have access to this document.
5.7
All
latest
revision
are
indicated
with
a
|
?
mark
at
the
right margin of the revised paragraph or sentence.
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Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 15 of 59
Rev. No.: 4
6.0
QA SYSTEM
6.1
Internal Audit
6.1.1 Internal
Quality
audits
shall
be
performed
at
least
once
every year by company
’
s QA audit team to determine whether
the quality management system:
a)
conforms
to
the
planned
arrangements
and
quality
management
system
requirements
set
up
by
the
organization
and
to
the
requirements
of
this
International Standard.
b)
Is effectively implemented and maintained.
The
annual
internal
audit
plan
shall
be
prepared
by
the
QA/QC
Department
and
approved
by
Quality
Management
Representative.
The
audit
program
shall
be
planned
taken
into
consideration
the
status
and
importance
of
the
processes and areas to be audited as well as the results of
previous audits.
6.1.2 Day to day internal quality audits shall be conducted by QA
Engineer
with
the
aim
of
checking
effectiveness
of
QA
activities,
indicating
improvements
and
pointing
out
inadequacies and negligent activities.
6.1.3 QA
audit
team
organized
by
QA/QC
Department
Manager
shall
consist
of
the
competent
personnel
who
are
independent
of
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the
specific
activities
or
area
being
audited,
auditors
shall not audit their won work.
6.1.4 QA
Engineer
shall
be
given
sufficient
free
access
to
all
areas where activities related to quality are implemented,
to
all
drawings,
specifications
procedures,
records,
certificates
and
any
other
related
documents
as
necessary
for him to perform his duties.
6.1.5 Quality
audit
shall
cover
areas
such
as
Operations
Department,
Yard
Department,
Technical
Department,
Business/Marketing
Department,
Personnel
Department,
Equipment
and
Facilities
Department,
QA/QC
Department
and
Purchasing Department. And the audit shall be scheduled and
conducted on all elements of quality system annually.
6.1.6 All areas to be audited shall cover quality elements as per
ISO
9001,
pre- designed
formats
such
as
Reviewed
Items
of
Quality
System
Audit
(see
attached
form
QS/CSE
25.04.18)
and
Non-conformance
Report
of
Internal
Audit
(See
attachment
form
QS/CSE
25.04.19)
shall
be
used
for
audit
purpose.
If
required,
the
checklist
for
internal
audit
shall be established.
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 16 of 59
Rev. No.: 4
6.1.7 The QA audit team shall discuss all quality aspect with the
department Managers on the spot and request for corrective
action.
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6.1.8 The
QA
Engineer
shall
demand
Department
Managers
responsible
for
the
activity
being
audited
to
carry
out
their quality activities as per Quality System established
by Company.
6.1.9 Department
Managers
being
audited
should
ensure
that
necessary
and
appropriate
corrective
actions
are
taken
to
eliminate detected non-conformities and their causes within
specified time.
6.1.10
T
he QA/QC Department shall be responsible for the follow-up
activities
to
the
corrective
actions,
include
the
verification
of
the
actions
taken
and
the
reporting
of
verification results.
6.1.11
A
ll audit findings should be documented and/or submitted to
GM/DGMs for information and / or comments.
6.1.12
A
ll
quality
audit
reports
are
treated
as
Company
’
s
CONFIDENTIAL documents.
6.1.13
T
he
internal
audit
results
shall
be
submitted
to
quality
management review meeting for review.
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Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 17 of 59
Rev. No.: 4
6.2
Document Control
6.2.1 Responsibility
6.2.1.1
QA/QC
Department and Safety Department have the responsibility of
organizing departments concerned to prepare their quality &
OHS system documents.
6.2.1.2
The
quality & OHS system documents prepared by each department
shall
be
practical
and
integral
conforming
to
the
requirements of ISO 9001-2000 and OHSAS 18001-1999.
6.2.1.3
QA/QC
Department
and
Safety
Department
are
responsible
for
monitoring
the
implementation
of
the
documents
and
recommending revision where necessary.
6.2.2 Document Structure
6.2.2.1
Quali
ty
&
OHS
system
documents
are
including:
quality
&
OHS
policy
and
objectives,
quality
&
OHS
manual,
departmental
manuals,
project
procedures,
general
working
instruction
and quality & OHS records.
实用文档
6.2.2.2
All
the requirements and provisions adopted by the company for
its quality & OHS management system should be documented in
the form of procedures or manuals.
6.2.2.3
Recor
ds
are
a
special type of document and shall be maintained
to
demonstrate
achievement
of
the
required
quality
&
OHS
and
effective
operation
of
the
quality
&
OHS
system
and
controlled according to the requirements in clause 6.3.
6.2.3 Initiation, approval and issuance of Document
6.2.3.1
Quali
ty
&
OHS
Manual
should
provide
an
adequate
description
of
the
quality
&
OHS
management
system
while
serving
as
a
permanent
reference
in
the
implementation
and
maintenance
of the system.
6.2.3.2
Compa
ny manual and department manuals shall be checked by QA/QC
Manager
and
Safety
Department
Manager,
reviewed
by
Deputy
General Manager and approved by GM prior to issue.
6.2.3.3
The
general
working
instructions
and
project
procedures
shall
be approved by respective Department Manager. If required,
it shall be submitted to customer for approval.
6.2.3.4
The
pertinent issue of appropriate documents shall be available
at
appropriate
locations
where
operation
essential
to
the
effective
functioning
of
the
quality
&
OHS
system
are
performed.
The
issue
records
shall
be
maintained
by
the
relevant departments.
Chiwan Sembawang Engineering Co. Ltd.
实用文档
QA/QC MANUAL
Section: 6.0
QA System
Page: 18 of 59
Rev. No.: 4
6.2.4 Review and Revision of Document
6.2.4.1
All
quality
&
OHS
documents
shall
be
reviewed
and
updated
as
necessary,
changes
to
documents
shall
be
reviewed
and
re-
approved
as
required
by
6.2.3
unless
specifically
stated
otherwise.
6.2.4.2
The
changes to documents shall be indicated with a
“
|
?
”
mark
at the right margin of the revised paragraph or sentence.
6.2.4.3
Docum
ents
shall
be
reissued
after
practical
change
have
been
made.
6.2.4.4
A
master
list
shall
be
established
to
identify
the
current
revision status of documentation.
6.2.5 Filing, Storage and maintenance of Document
6.2.5.1
All
quality
documents
shall
be
legible
and
identifiable
and
stored
and
maintained
in such a way that they are readily
retrievable
in
facilities
that
provide
a
suitable
environment to minimize deterioration or damage and prevent
loss.
实用文档
6.2.5.2
A
master
list
shall
be
established
to
identify
the
current
revision
of
documents
in order to prelude the use of non-
applicable documents.
6.2.6 Obsolete Document
Obsolete
documents
shall
be
promptly
removed
from
appropriate points of issue or user or properly identified
for a reference.
6.2.7 Numbering system of Documen
6.2.7.1
r of Quality & OHS Manual
QS/CSE/M 00
Company
manual number
Manual initial
Company
abbreviation
Quality
OHS system symbol
Numbe
and
4
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 19 of 59
Rev. No.: 4
6.2.7.2
Numbe
r of Departmental Manual
QS-CSE MXX
Department
designation
Manual
initial
Company
abbreviation
Quality
and
OHS system symbol
Department designation:
01 --- QA/QC Department
02
---
Business/Marketing
Department
03 --- Operation Department
04 --- Technical Department
05 --- Purchase Department
06
---
Equipment/Facility
4
Department
07 --- Safety Department
08
---
HR/Administrative
Dept.
09 --- Yard Department
实用文档
6.2.7.3
Numbe
r of Project Document or General Working Instruction
a. Special Procedures for Project:
XXXX / XX / XX
Procedure Serial No.
Designated Functional Department No.
Designated Project No.
b. General Working Instruction:
QS / CSE / WI XX / XX
Procedure Serial No.
Designated Functional Department No.
Working Instruction
实用文档
Company Abbreviation
Quality and OHS System Symbol
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 20 of 59
Rev. No.: 4
Department designation:
01 --- Technical Department
02 --- Purchase Department
03 --- Operations Department
04 --- QA/QC Department
05 --- Equipment/Facility Department
06 --
4
- HR/Administrative Department
07 --- Business/Marketing Department
08 --
- Safety Department
09 --- Yard Department
6.2.8 Submission of Project Final Document
6.2.8.1
Preparation and collection of project final documents
QA/QC
Department
prepares
and
collects
the
following
documents (or as per the requirements of contract):
a)
Copies of mill/test certificates for primary structures,
piping, etc.
b)
Shop drawing
c)
NDT drawing
d)
Scheme
e)
Lofting & cutting drawing
f)
Modification Notices
实用文档
g)
Member drawing
h)
WPS
i)
Quality plan
j)
Inspection procedures
k)
NDT procedures
l)
NDT extent
m)
QA/QC Memo.
n)
PMT Memo.
o)
Customer
’
s Memo.
p)
All kinds of inspection reports
q)
Subcontracting drawing and others
6.2.8.2
Submi
ssion of final document
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 21 of 59
Rev. No.: 4
1)
Upon
completion
of
the
project,
the
QA/QC
Department
shall
compile
the
final
project
documents
which
are
designated
to
retain
by
the
contract.
These
documents
shall
be
bound
up
with
content
and
project
identification.
2)
The
final
document
shall
be
submitted
to
customer
for
review and approval.
实用文档
3)
The
PMT
shall
photocopy
the
approved
final
documents
according
to
the
requirements
of
contract,
and
return
the original document to QA/QC Department.
4)
Upon
completion
of
the
project,
the
QA/QC
Department
shall
hand
over
the
original
of
final
documents
to
the
Archives of Technical Department.
6.2.9 Disposal of documents
6.2.9.1
Prior
to
disposal
of
documents,
the
QA/QC
Manager
shall
verify
that the retention period is expired.
6.2.9.2
Documents
exceeding
retention
period
are
disposed
off
by
shredding,
incinerating
or
tearing
manually. If any obsolete documents are retained for legal
and/or
knowledge-preservation
purpose,
they
shall
be
suitably identified by stamp marking.
6.2.10 External document control
The
documents
from
customers
or
suppliers
such
as
standards,
specifications,
drawings,
site
instructions
or
site
queries
shall
be
registered in a master list with an
appropriate
review
approval
and
identification
and
the
issuance
shall
be
controlled
by
relevant
functional
departments.
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 22 of 59
Rev. No.: 4
4
6.3
Records Control
6.3.1 The
QA/QC
Department
shall
be
responsible
for
the
management
and
control
of
quality
records.
The
Safety
Department
shall
be
responsible
for
the
management
and
control of OHS records.
6.3.2 The
function
departments
has
the
responsibility
to
design
the record forms, prepare and collect the records adopted.
6.3.3 A
master
list
shall
be
established
by
QA/QC
Department
to
list
the
records
adopted
by
each
function
departments
and
specify the retention period.
6.3.4 All kinds of inspection reports are prepared and signed
by QC inspector or NDT operator, then submitted to customer
representative/the third party for approval and signature.
After
that,
all
inspection
reports
shall
be
passed
to
documentation
clerk
to
check
and
input
to
computer,
a
summary list containing report No. will be tabulated.
6.3.5 All of records shall be legible, identifiable and complete,
the change of the content shall be signed by initiator.
6.3.6 The
function
departments
shall
be
responsible
for
collecting, compiling, indexing related records, and submit
them
to
Archives
of
Technical
Department
with
a
index
for
storage and maintenance.
实用文档
6.3.7 The records shall be stored and maintained to prevent from
damage, loss and deterioration.
6.3.8 The
project
records
shall
be
compiled
into
the
final
documents and controlled as per clause 6.2.8.
6.3.9 Retention
times
of
records
shall
be
established
depending
on the requirements of contract, management and statutory.
The records required by applicable industry standards shall
be
retain
for
not
less
than
the
time
period
specified
by
the
industry
standards
or
5
years
whichever
is
longer.
Records
required
to
provide
evidence
of
conformity
to
requirements and of the effective operation of the quality
& OHS management system shall be retained for a minimum of
5 years. Records exceeding retention period may be disposed
off
by
shredding,
incinerating
or
tearing
manually,
prior
to
disposal,
the
QA/QC
Manager
and
Safety
Manager
shall
verify that the retention period is expired.
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 23 of 59
Rev. No.: 4
6.3.10
Number of records
QS / CSE XX . XX . XX
Serial number
Controlled
department number
Company
number
Company
abbreviation
Quality
and
OHS system symbol
Distribution of Controlled Department Number:
01 --- Technical Department
02 --- Purchase Department
03 --- Operations Department
04 --- QA/QC Department
05 --- Equipment/Facility Department
06 --
4
- HR/Administrative Department
07 --- Business/Marketing Department
08 --
- Safety Department
09 --- Yard Department
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 24 of 59
Rev. No.: 4
6.4
Control of Monitoring and Measuring Equipment
6.4.1 This
procedure
covers
the
control
activities
for
maintaining
and
calibrating
the
precision
monitoring
and
measuring equipment used by the company .
6.4.2 QA
Engineer
shall
be
responsible
for
making
sure
that
all
the precision measuring and test equipment being used have
been calibrated .
6.4.3 QA Engineer shall keep a master list to control the status
of monitoring and measuring equipment.
6.4.4 All
monitoring
and
measuring
equipment
used
in
quality
&
OHS
control
activities
to
assure
conformance
to
the
requirements
of
standards
concerned
shall
be
identified
with
controlled
number
indicated
on
such
equipment
or
on
tag attached to the equipment.
6.4.5 A
sticker
shall
be
placed
on
the
equipment
such
as
UT
detector,
MT
detector,
Laser
Range
Finder,
Leveling
Instrument,
Theodolite,
pressure
gauges
and
recorder
indicating
date
of
calibration
and/or
due
date
for
calibration.
6.4.6 All
monitoring
and
measuring
equipment
used
by
the
operators
shall
be
returned
to
the
QA
Engineer
in
advance
of the due date for calibration.
实用文档
6.4.7 The users of all such items shall make sure that they are
using
only
the
calibrated
equipment,
and
ensure
they
are
protected
from
damage
and
deterioration
during
handling,
maintenance
and
storage
and
mis-adjustment
during
operation,
and
ensure
the
environmental
conditions
are
suitable for inspections and measurements performed.
6.4.8 All
unserviceable
equipment
shall
be
rejected
and
segregated and an entry shall be made in the register.
6.4.9 QA/QC
Department,
QA
Engineer
in
particular,
shall
check
that only calibrated equipment are used during the process
of fabrication.
6.4.10
C
alibration
of
instruments
such
as
UT
detector,
MT
detectors, Laser Range Finder, Leveling instrument shall be
done by qualified personnel designated by QA/QC Manager in
accordance
with
relevant
calibration
procedure
or
standards.
6.4.11
C
alibration
of
instruments
such
as
steel
tape
measure,
pressure
gauges
and
recorders
shall
be
done
by
Shen
Zhen
Academy of Metrology & Quality Inspection (SZAMQI) or other
authority party.
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 25 of 59
Rev. No.: 4
6.4.12
T
he
customer
representative
and/or
third
party
inspector
shall
have
access
to
check
the
items
and
records
whenever
the need arises.
6.4.13
C
alibration
period
for
measuring
and
test
equipment
is
as
follows:
Type of Equipment
Period
Calibrated by
Measuring
. Laser Range Finder
6 months
CSE/SZAMQI
Instrument/T
. Leveling Instrument
6 months
CSE/SZAMQI
ool
. Theodolite
6 months
CSE/SZAMQI
. Steel Tape Measure
12
SZAMQI
. Vernier Caliper
months
SZAMQI
12
months
Pressure
. Pressure Gauge
6 months
SZAMQI
test
. Pressure Recorder
6 months
SZAMQI
Equipment
NDT
. UT Detector
3 months
CSE
Equipment
. MT Detector
6 months
CSE
.
γ
-Ray Gauge
12
SZAMQI
. UT Standard Block
months
SZAMQI
. MT Standard Block
59
SZAMQI
months
59
months
Coating
. Adhesive Tester
6 months
HongKong
Inspection
. Surface Profile Gauge
12
Materialab
Device
.
Dry
Film
Thickness
months
SCNCM
Gauge
12
SCNCM
实用文档
Others
months
. Holding Oven
12
. Baking Oven
months
.
Digital
Pincerlike
12
Mutimeter
months
. Digital Thermometer
12
.
Temperature
months
Controlling and
12
Recording Instrument
months
. Welding Machine
12
months
12
months
SZAMQI
SZAMQI
SZAMQI
SZAMQI
SZAMQI
CSE
Note:
SZAMQI:
Shenzhen
Academy
of
Metrology
&
Quality
Inspection.
SCNCM: South China National Center Metrology
6.4.14 When
the
equipment
is
found
to
be
outside
of
its
requirements, QA/QC Department shall assess and record the
validity of the previous measuring results, a NCR shall be
raised
and
the
equipment
shall
be
repaired
and
re-
calibrated.
If
the
conformance
of
products
is
affected,
the
affected
products
shall
be
re-measured
and/or
repaired.
6.4.15 If
the
computer
software
is
used
in
the
monitoring
and
measuring
of
specified
requirements,
QA/QC
Department
shall confirm it have the ability to satisfy the intended
application
prior
to
initial
used
and
reconfirm
as
necessary.
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 26 of 59
Rev. No.: 4
4
6.5
Welding Control
6.5.1 Weld identification
6.5.1.1
Techn
ical
Department
shall
responsible
for
ensuring
that
each
weld
is
uniquely
identified
structural
NDT
drawings
or
piping
isometric
drawings.
For
the
structure,
the
weld
number will be a sequential number 001 through 999 prefixed
by the NDT drawing number. For the piping, the weld number
will be sequentially numbered per isometric drawing number.
6.5.1.2
Yard
Department shall have the responsibilities to mark the weld
number on the components for weld traceability.
6.5.1.3
All
of
fabrication
and
inspection
activities
and
records
of
welds shall be based on the unique weld number.
6.5.2 WPS & PQR
6.5.2.1
WPS &
PQR
shall
be
prepared
by
welding
engineer
of
Technical
Department
as
per
requirements
of
specifications
and
relevant
standards,
and
approved
by
customer
or
the
third
party.
实用文档
6.5.2.2
Welde
rs
and
welding
operators
shall
perform
welding
in
accordance with the approved WPS.
6.5.2.3
Appro
ved
WPS
shall
be
displayed
on
site
as
close
as
to
the
welding location for reference by inspectors and welders.
6.5.3 Welding consumables control
6.5.3.1
Weldi
ng consumables receiving inspection
a) When
welding
material
arrive,
they
shall
be
examined
by
welding
engineer
for
compliance
with
the
purchase
order,
mill
certificate
and
specifications
regarding
quality,
batch number, quantity, type and size.
b) Welding electrodes, filler wires and fluxes that show signs
of
damage
or
deterioration
such
as
cracked
or
flaked
coatings, rusty or dirty wires etc. shall not be used.
c) Any
consumables
which
deviate
from
the
specification
or
manufacturer
’
s
recommendations
shall
be
rejected
and
placed
in
a
separate area in the warehouse and be clearly
tagged as a non-conforming consumable.
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 27 of 59
Rev. No.: 4
实用文档
6.5.3.2
Weldi
ng consumable storage
a) Welding
materials
shall
be
stored
in
such
a
manner
as
to
prevent
intermingling
with
materials
of
different
specifications, brands and lots.
b) Welding electrodes, wire and flux shall be put up above the
ground
0.1
-
0.3
meter
to
facilitate
the
air
circulation
all round.
6.5.3.3
Weldi
ng consumable issuance
a) Welding
consumable
room
storeman
shall
dry
flux
coated
welding
electrodes
and
flux
to
minimize
moisture
contents
and
keep
them
in
the
heated
storage
oven
under
the
conditions
specified
by
the
welding
Engineer
and/or
manufacturer
’
s recommendations before being issued.
b) The records for drying or baking shall be maintained by the
electrodes-room storeman.
c) The welding consumable shall be issued according to project
based
on
the
type
of
welding
consumable
specified
by
welding engineer.
6.5.3.4
Weldi
ng consumable use
a) Welding
consumable
shall
be
used
strictly
in
compliance
with WPS and the manufacturer
’
s recommendations.
b) Welding
electrodes,
low- hydrogen
electrodes
in
particular,
shall
be
stored
in
quivers
during
use.
Welding
flux
and
flux core welding wire shall be kept away from moisture.
实用文档
6.5.4 Welder and welding operator
6.5.4.1
All of welders and welding operations shall be
qualified to relevant welding codes before allow them to
work on actual products.
6.5.4.2
A
badge
will
be
issued
by
QA/QC
Department
to
qualified
welders
and
welding
operators
for
identifying
their
qualifications.
A
master
list
with
certificates
of
qualified
welders
engaged
in
the
project
shall
be
submitted
to
customer
for
approval
prior
to
commencement
of welding.
6.5.5
Welding operations
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 28 of 59
Rev. No.: 4
6.5.5.1
A
ll
welding
shall
be
performed
as
per
approved
WPS
by
qualified
welders
and
welding
operators
under
the
monitoring of welding supervisor and QC inspector, and be
visually inspected by QC inspectors prior to NDT.
6.5.5.2
A
ll
welding
equipment
shall
be
in
good
condition
and
the
voltage,
amperage,
and/or
wire
feed
speed
gauges
on
the
welding
machine
shall
be
fully
operable
and
properly
calibrated
by
Equipment/Facility
Department
as
per
the
requirements
of
customer
’
s
specification
and/or
clause
6.4 of this manual.
实用文档
6.5.5.3
W
here
a
tack
weld is incorporated in a welded joint, the
shape
of
the
tack
shall
be
suitable
for
incorporation
in
the
finished
weld,
and
it
shall
be
free
from
cracks
and
other
deposition
faults,
tack
welds
which
crack
shall
be
removed.
6.5.5.4
W
elding quality and welder performance shall be controlled
as per the requirement of clause 6.7 of this manual.
实用文档
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 29 of 59
Rev. No.: 4
6.6
Training
6.6.1 Training and qualification of welder and welding operator
6.6.1.1
Train
ing schemes for welders and welding operators are to
be
made
by
Welding
Engineer
from
time
to
time
to
guide
and
transform
unskilled
labors
to
skilled
welders
and
welding
operators
to
meet
the
needs
of
production.
All
skilled
welders
and
operators
shall
be
qualified
to
relevant
welding
code
before
allowing
them
to
work
on
actual products.
6.6.1.2
Train
ing
schemes
are
mainly
embodied
in
qualification
test
required by customer.
6.6.1.3
Quali
fication
test
shall
be
carried
out
using
production
equipment in a fabrication area or the Training School.
6.6.1.4
PMT
shall
notify
the
QA/QC
Department
when
there
is
a
requirement
for
welders/
welding
operator
qualification.
Notification
will
include,
but
not
be
limited
to,
the
following:
实用文档
a)
b)
c)
d)
Welding process/method
Welding position
Applicable products
Customer
6.6.1.5
Weldi
ng
Engineer
shall
submit
the
proposed
welding
procedure
specification
(PWPS)
to
customer
for
approval,
when
required.
6.6.1.6
The
Welding Engineer will raise a test schedule which shows the
type
of
test,
coupon
numbers,
stamp
number,
name/badge
number and date of test. The schedule shall be distributed
to
PMT
who
will
ensure
that
welders/welding
operators
and
material are made available.
6.6.1.7
The
Welding
Engineer
shall
also
notify
the
following
persons
before the test is due to start:
a)
Customer (If applicable)
b)
c)
Certifying Authority (If applicable)
QA/QC Manager
Chiwan Sembawang Engineering Co. Ltd.
QA/QC MANUAL
Section: 6.0
QA System
Page: 30 of 59
Rev. No.: 4
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