The engineering booklet is one of the documents that the manufacturer or supplier must prepare and deliver to the employer at the end of the contract, and the general list of documents is as follows.
- Final drawings (As built) single line – control – terminal diagram – location
- List of main equipment and related catalogs
- List of additional items and equipment required at startup
- Reports and calculation tables if necessary
- Instructions for loading, transporting, installing, testing, commissioning and maintenance
- Data sheet and technical specifications
- Report routine tests performed in the factory or type test
- Certificate or minutes of the employer inspector test and certificate of shipment
The documents are usually in hard copy and electronically delivered to the employer in the number of copies agreed in the contract.
ITP
ITP is a procedure that uses agreements between site executives, quality control, monitoring and the employer to determine the inspection work routine. The preparation of this document will generally be particularly sensitive in the implementation of the project process, because on the one hand, if the number of inspection points is high and the type is inappropriate during the work, the work speed is greatly reduced and in some cases due to the need to rework The executive group increases sharply. On the other hand, if suitable stations are not defined and these inspections are reduced, in addition to the fact that in many cases, after one stage of work, the possibility of inspection and troubleshooting in the next stage will disappear, executive contractors will also pay attention to They will lose the quality of work. Also, the type of ITP defined defines to some extent the number of people needed for the quality control group.
The items that should be mentioned in an ITP can be categorized as follows:
1- Raw formats. In general, all reports required by the end of an inspection, including invitation inspection format, correspondence format, welder test, dimensional inspection, etc., should be accompanied by an appropriate numbering process and a reference number assigned to each report in An ITP is placed and the raw formats are sealed as a reference for all devices related to inspection on the site.
2- The type of executive activity that is performed on the site. In this section, it is necessary to define sections as control stations by categorizing the type of activities that are performed before attending the site or on the site. For example, we can refer to the cutting activity, which in critical cases, even at the marking stage for cutting, should be defined as a station for inspection and control.
3- Activities that control groups such as quality control group, supervision group and employer should do at this stage. For example, in the case of cutting, the control groups must perform a visual inspection of the dimensions of the cut piece.
4- Specifying the admission reference and relevant tolerances. In this part of the document, a reference should be introduced to determine how to perform the inspection and the limits of acceptance of the observed defects. For example, in the case of cutting, you must provide a standard drawing or number for the dimensional tolerances of the Fabrication Procedure that lists the permissible tolerances.
5- Expressing the type of document issued at this stage of the inspection. In this column, the name and number of the report that should be issued according to the table of raw reports should be mentioned in this step. For example, in the case of cutting operations, the type of document “visual and dimensional inspection report” and its number should be mentioned as example 012.
6- In the last step, the type of inspection station will be introduced for each working group present on the site. The types of checkpoints should be abbreviated, which are described in the first part of the document. The common types of checkpoints are as follows:
Review: This station is for reviewing documents and the executive team can continue their executive work and finally have to provide the relevant documents for review.
Approve: This station is the same as the previous station for reviewing documents, with the difference that until the approval of the submitted documents, the executive team is not allowed to continue what they have to do based on these documents.
Witness: At this stage, the representatives of the inspection teams must be introduced. According to the agreement, the executive group must inform the control, supervision and employer groups in writing for inspection, for example, 2 days before the executive work reaches this stage, for example, 2 days. The executive work will not be stopped at this stage and the inspector will be present at this stage of the inspection or will refuse to attend, but whenever the inspector wants to review the relevant documents, these documents must be provided to him and he is obliged to To approve these documents.
Spot Witness: The inspection and inspection process in this section is the responsibility of the inspector and depending on the contract of the project, the issuance of a written invitation for inspection may or may not be necessary.
Hold Point: All conditions in this inspection station are the same as Witness station, with the difference that the inspector must be present at this stage and the executive team is not allowed to continue working without approval.
The first thing that I think is important in developing an ITP is the preparation of raw formats for the inspection process to the final stages.
Be sure to mention the reference standard used at that stage and the format number approved by the employer for preparation at that stage when defining the inspection station. Failure to prepare raw formats at the beginning of the work will cause the personal tastes to change the shape of the formats several times by changing people, both in the quality control department and in the employer department.
The second item in the preparation of ITP is to mention all work procedures such as construction method, painting method, review of executive drawings and… as a Hold Point station. It is of particular importance that the start of executive work without the approval of these documents by the employer, can cause severe financial losses to the contractor to correct the previous stages of work.
A very important and sensitive issue that is not paid attention to in most cases is the PIM (Pre-Inspection Meeting) session. I strongly recommend that you do not start the inspection without holding this meeting and preparing the minutes that have the approval of all the groups involved.
In my opinion, the issues that are important to be discussed in this meeting and mentioned in the minutes are as follows:
1- How to number inspection formats
2- How and when to announce the inspection request
3- How and when the employer’s approval if he is not present at the inspection stations
4- Determining the maximum time required by the employer to review the submitted documents and announce the opinion
5- Determining how to approve the contractor quality control personnel
6- Determining how to perform non-destructive tests and presenting radiographic films
7- Determining the storage location of radiographic films (at the disposal of the contractor or employer)
In fact, ITP or inspection plan and document is a document that describes the inspection process of the project and the position of the executive teams of the site, quality control, supervision and the employer. Undoubtedly, the preparation of such a document is particularly sensitive because determining a large number of checkpoints or improper selection of the type of checkpoint, will reduce the speed of work and consequently increase the costs imposed on the executive team.
Specification
This document is called a spec. This document talks specifically about the technical specifications of a device, for example the specification for control valve, talks about control valves. For example, types of actuators or actuators, whether pneumatic or hydraulic, type of valve, whether it is a rose or butterfly, type of body material, technical specifications of the positioner, seat, plug, etc. It is mentioned in this document. Therefore, the specification summary is given in the design criteria document.
What is WPS Welding?
WPS stands for Welding Procedure Specification, a written instruction that outlines the various details of a part welding process and the information needed to produce a weld.
WPS certificate Information required for the welder to use, for example, type of welding process (manual electrode arc, argon welding, CO 2 weldingEtc.), plan for connecting parts to each other (edge to edge connection, corner, shield, etc.), type of welding in that connection (groove or corner welding), welding position (flat, horizontal, vertical and ceiling), edge making or ready Groove making, base metal material and its characteristics, welding cross-section thickness, pipe diameter, type of filler metal and its size, preheating temperature, interpass temperature and post-welding heat treatment (PWHT), to advance welding, gas used in Provides related processes, electrical specifications of welding (type and intensity of current, polarity and voltage) and information related to the technique and method of work. The welder is obliged to weld according to this instruction and the welding inspector controls the compliance of the process with it. Welding instructions are prepared according to a standard / code and the requirements for manufacturing a part or structure according to that standard / code must be observed in WPS.
What is PQR welding?
The purpose of preparing WPS, in addition to announcing the necessary specifications and information of the welding process, is to ensure and guarantee the quality of the weld. After preparing the WPS, it should be evaluated whether the weld created according to this instruction will be in accordance with the designed weld specifications. That is, can it meet the design goals? For this purpose, the written instructions must be tested and approved. In other words, before performing welding according to the WPS provided on the main part / structure, it must be ensured that the weld obtained with this instruction can meet the designer’s expectations or not. To ensure this, the most common method is to weld the test sample (Coupon) according to the specifications in the code / standard, according to the same WPS. From these samples, smaller samples called specimens are prepared in a qualified laboratory. The number of tests for each test is determined according to the relevant code / standard. The tests are subjected to quality and weld health tests according to the requirements of the code / standard. If these tests can meet the acceptance criteria of the same code / standard, WPS is considered approved and can be used as an approved instruction for a specific range according to the code / standard. The document that reports the relevant WPS approval along with the test results on the welded test specimen, the material specifications and dimensions of the test specimen, and a summary of the information required for welding is called the PQR. PQR stands for Procedure Qualification Record. The document that reports the relevant WPS approval along with the test results on the welded test specimen, the material specifications and dimensions of the test specimen, and a summary of the information required for welding is called the PQR. PQR stands for Procedure Qualification Record. The document that reports the relevant WPS approval along with the test results on the welded test specimen, the material specifications and dimensions of the test specimen, and a summary of the information required for welding is called the PQR. PQR stands for Procedure Qualification Record.
What is WPQ or WQR welding?
Once the welding instruction (WPS) has been prepared, approved (PQR) and determined that the instruction can achieve the designer’s goals, the welder must also be assured of the welding skills that meet the design objectives. To be obtained. Given that the purpose of the Welding Instruction Approval or PQR test is to validate and guarantee the Welding Instruction and the Welder Approval is not the goal, it is also necessary to certify the qualifications of the welders for welding according to the relevant WPS. In other words, WPS is certified by the most skilled welder by performing welding, but after WPS approval, the skills and competence of the welders according to whom WPS is to perform and produce the desired WPS weld must also be measured. For this purpose, the welder to be certified shall weld the test coupon sample according to the specifications in the code / standard, in accordance with the same WPS. Samples are subjected to quality and weld health tests according to code / standard requirements. If these tests meet the acceptance criteria of the same code / standard, the welder will be considered a WPS certified welder and will be employed as a WPS certified welder in accordance with the desired code / standard.
WPQ, WQR or WQT is the document in which the certification of the welder is reported along with the test results performed on the sample and a summary of the necessary WPS information and specifications of the test sample and its welding.
WPQ stands for Welder Performance Qualification, WQR stands for Welder Qualification Record, and WQT stands for Welder Qualification Test Record.