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Project: NINGBO 6RTGs

Rev No. 0
No.

Description

QUALITY CONTROL PLAN


Quality Control Activity

QA Document

Acceptance
Standard

Verifying Documents

Job No. 1201


Inspection Activity
NCSC

Client/Third
Party

Note

This Quality Control Plan (QCP) describes the most important process steps for fabrication and erection of the main steel structure and
mechanical parts of RTG cranes. Associated with the processes are the QA/QC - activities based on ISO 9001, the corresponding acceptance
criteria according to NCSC requirements, e.g. product standards or other regulations and the verifying documents necessary for documentation of
the test and inspection results.
At least the specified process steps (their sequence is just informal) are to be executed and documented by the charged sub-contractor (SC) for
fabrication. Additional and more stringent own requirements of the sub-contractor are not terminated by these NCSC regulations. If necessary, the
listed and attached NCSC- standard documents like weld sketch and test instructions are to be completed by more detailed documents of the subcontractor.
Sub contractors without certified quality system have to prove by adequate means before being charged with the contract, that their processes are
ruled by QA and only those structures are delivered which comply with the specified requirements with no limitation.
The European and American standards, mentioned for qualification and execution of welding and inspection work are considered to be equal.
To this Quality Assurance Plan (QAP) additional Quality Inspection Plans (QIP) with specific regulations for the particular structure will be added if
needed.

(QCP) RTG ISO 9001


NCSC .
() NCSC
NCSC

,
(QCP)

Page 1 of 10

Project: NINGBO 6RTGs

Rev No. 0
No.

Description

QUALITY CONTROL PLAN


Quality Control Activity

QA Document

Acceptance
Standard

Job No. 1201

Verifying Documents

Inspection Activity
NCSC

Client/Third
Party
/

1.0 PRE-FABRICATION
Review specification, finalize
deviations, amendments

Confirm compliance with


specification
Confirm compliance with
specification and validity,
qualify tackers and welders
if necessary

1.1

Fabrication specification and


drawing

1.2

Welding Procedure Qualification

1.3

Welding personnel qualification

1.4

QC personnel Qualification

Confirm compliance with


specification and validity

1.5

Calibration (if necessary)

Confirm the calibration


status and validity of main
equipment

QP-PD-02

WI-PD-02

AWS D1.1

WPS and PQR

WI-PD-02

AWS D1.1

Certificates

WI-QA-13

QC personnel List
and NDT certificate
NDT

QP-QA-06

Calibration record

2.0 RECEIVING INSPECTION

2.1

Approved supplier/Subcontractor

Confirm the material supplier


/sub-contractor approved,
otherwise QA Audit
/

QP-PU-01
QP-PU-02

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Approved Supplier
List or QA Audit

Note

Project: NINGBO 6RTGs

Rev No. 0
No.

Description

2.2

Material receiving inspection

2.3

Non-conforming material

2.4

Identification of material in
stockyard

2.5

Material Issuing

2.6

Material tracing

2.7

Testing & Inspection

QUALITY CONTROL PLAN


Quality Control Activity

Confirm material received


meets the requirements of
the specification, purchase
order, project specification
and delivery note. Check mill
certificate with material
received. Visual inspection
or NDT

Non-conforming Material to
be limited or forbidden

Confirm Job number, type


and batch No. identified on
Material and Mill Cer.

Confirm material issuing in


accordance with the shop
application and drawing.

Confirm material used in


main structure can be traced

Authenticate materials and


components quality

QA Document

Acceptance
Standard

Verifying Documents

Job No. 1201


Inspection Activity
NCSC

Client/Third
Party
/

QP-QA-05

Specification

Mill certificates

RI

QP-QA-12
QP-QA-13

NCR

QP-LD-05
WI-LD-05

SAP system

RI

RI

QP-PD-03

Material issuing
record

RI

QP-PD-04

Material tracing list

RI

RI

SP23

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Test report

Note

Project: NINGBO 6RTGs

Rev No. 0
No.

Description

QUALITY CONTROL PLAN


Quality Control Activity

2.8

Matl. NoN-Destructive test

UT of tubes and plates

2.9

Gearbox,Drum,coupling,Brake,S
heave,Rope, spreader, wheel,
wheel rim, twistlock etc.
,,,,,,
,,,,

Visual inspection, confirm


type, size, test
report/inspection report
,,,
/

2.10

Electrical components( Gensets,


Motors, Registors, transformer
cabin,E-house etc)
( ,,
, ,,).

Visual inspection, confirm


type, test report
,

2.11

Hydraulic Equipment(Hydraulic
power units, cylinders etc)
(, )

Visual inspection,
cleanliness report, pressure
report
,

2.12

Non conformity reports

QA Document

Acceptance
Standard

Verifying Documents

Job No. 1201


Inspection Activity
NCSC

Client/Third
Party
/

QP-QA-05

Specificati
on,

NDT Report
NDT

RI

QP-QA-05

Specificati
on and
purchasing
Drawing

Cretificate of
conformity

RI

QP-QA-05

Specificati
on and
Application

certificate of
conformity

QP-QA-05

Specificati
on and
Application

certificate of
conformity

RI

Source of imperfection
rectified

QP-QA-05

Standard
requireme
nts

Non conformity
report

Measure profiledry film


thickness and visual grade

WI-PD-05

Specificatio
n

RI

RI

3.0 FABRICATION
3.1

Material pre-treatment

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Paint Inspection
Record

Note

Project: NINGBO 6RTGs

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No.

3.2

3.3

3.4

3.5

3.6

Description

NC cutting and material


preparation inspection

UT-lamination test acc.


to indications in fabrication
drawings

Fitting inspection

Welding Control

Welding inspection

QUALITY CONTROL PLAN


Quality Control Activity

Inspect the dimension,


grade of material prepared
and NDT according to part
list and drawing.
,
Joints area with tensile load
in thickness direction

Visual and dimension


inspection of fit-up and tack
welds according to drawing
and relevant requirement

Control consumable storage


and delivery, check welding
process according to WPS,
check welders qualification

Visual inspection according


to drawing and standard

QA Document

Acceptance
Standard

Job No. 1201

Verifying Documents

Part list and NC


cutting Record

Inspection Activity
NCSC

Client/Third
Party

RI

RI

QP-PD-03

ISO9013

QP-PD-03

Contract
or GB
standards
/AWSD1.1

/AWS
D1.1

QP-QA-11
WI-PD-07
QP-PD-04

Drawing
and WPS

RI/I

QP-QA-11
WI-LD-01
WI-PD-03

WPS

Consumable
Certificate and
Consumable Baking
and Issue Record

RI

RI

WI-QA-02
QP-PD-04

Drawing
and AWS
D1.1:2000
ISO5817

Visual Inspection
Report

RI/I

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NDT record
NDT

Note

Project: NINGBO 6RTGs

Rev No. 0
No.

3.7

3.8

Description

QUALITY CONTROL PLAN


Quality Control Activity

QA Document

Acceptance
Standard

Job No. 1201

Verifying Documents

Inspection Activity
NCSC

Client/Third
Party
/

Structure dimension Inspection

Check the dimension and


distortion of welding
structure according to
drawing, standard and
relevant requirement

WI-QA-06
QP-PD-04

Drawing
ISO 13920

Dimension
Inspection Report

RI/I

NDT

Applied UT/RT/MT/PT to
weld seam /
//

WI-QA01/03/04/05

AWS
D1.1:2000
& As Per
Drawing

NDT Report

WI-QA-08

Leak Test Report

RI

RI

WI-QA-14

RI

WI-QA-06

Drawing
ISO2768

Dimension
Inspection Report
(machining)

RI

QP-QA-03
WI-QA-07

Release Report

3.9

Leak Test

3.10

Cleanness of fuel tank

3.11

Machining Inspection

3.12

Release

Applied leak test to the


sealed structure

Check the cleanness of fuel


tank and sealing before
release

Check alignment before


machining and check final
dimension after machining

Review all inspection reports


and quality documents,
release structure to painting
shop

4.0 Painting

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Note

Project: NINGBO 6RTGs

Rev No. 0
No.

4.1

Description

All the welds, damaged areas,


burns and rust etc. should be reblasted to Sa2.5, and other
undamaged areas will be
cleaned and sweep blasted
,,
SA2.5 ,

4.2

Painting Inspection

4.3

Cleanness of fuel tank and


corrosion protection

QUALITY CONTROL PLAN


Quality Control Activity

QA Document

Acceptance
Standard

Inspect sweep blast cleaning


quality and blast profile.
/.

Verifying Documents

Inspection Activity
NCSC

Client/Third
Party
/

ISO 85011:1988

Blasting Inspection
Report

RI/I

WI-PD-05
SP01

Specification

Painting Inspection
Report

RI/I

WI-QA-14

Inspection Report

RI

QP-QA-11
WI-PD-07

Drawing
WPS
FEM

RI/I

QP-QA-11
WI-QA-02
WI-QA-04

Drawing
and AWS
D1.1:2000
ISO5817

Visual Inspection
Report and NDT
Report

RI

WI-QA-05
SP01

Check Primer, intermediate


and top coat according to
painting procedure, contract
and relevant standard

Check the cleanness of fuel


tank and corrosion
protection before release

Job No. 1201

5.0 Erection

5.1

5.2

Fitting Inspection

Welding Inspection

Visual and dimension


inspection of fit-up and tack
welds according to drawing
and relevant requirement

Control welding procedure


and applied inspection of
visual and NDT to the weld
seam

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Note

Project: NINGBO 6RTGs

Rev No. 0
No.

Description

5.3

Assembly Dimension Inspection

5.4

Painting Inspection

5.5

Mechanism Installation
Inspection

5.6

Gantry Travel System

5.7

High Strength Bolt Installation

QUALITY CONTROL PLAN


Quality Control Activity

Inspect structure dimension


according to relevant
requirement, assure each
erection step under control

Check touch up and top coat


according to painting
procedure, contract and
relevant standard

Check equipment type,


quality certificate, installation
procedure, relevant
dimension and data
according to drawing and
requirement

After gantry wheel installed,


check the span and the
straightness of wheel

Check the type, dimension


of bolt, torque and screw
sequence ,
,

QA Document

Acceptance
Standard

Verifying Documents

Job No. 1201


Inspection Activity
NCSC

Client/Third
Party
/

WI-QA-06

Drawing
ISO 13920
FEM

Dimension
Inspection Report

RI/I

WI-PD-05

Contract
SIS

Painting Inspection
Report

RI/I

QP-PD-07

FEM

Inspection Report

R/I

Drawing

Inspection Report

Inspection Report

RI/I

QP-QA-11

QP-QA-11

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Note

Project: NINGBO 6RTGs

Rev No. 0
No.

Description

5.8

Cleanness of Fuel Tank

5.9

Cleanness of Hydraulic System

5.10

Electrical System Inspection

5.11

Commissioning Test

5.12

Punch list

QUALITY CONTROL PLAN


Quality Control Activity

Before fuel filling, check


cleanness to keep tank from
dirty, rust and all things may
cause jam

Flush the system and check


on line
Check equipment type,
quality certificate, cabling,
installation procedure, and
insulation resistance etc.
relevant data according to
drawing and requirement

Test crane according to


commissioning report

QA Document

Acceptance
Standard

Job No. 1201

Verifying Documents

Inspection Activity
NCSC

Client/Third
Party
/

WI-QA-14

Inspection Report

QP-QA-11
WI-QA-19

WI-PD-08

IEC

Inspection Report

RI

RI

Commissi
oning
report

Commissioning/Acc
eptance report

standard
and
contract

Check opened item

QM-2000

Point out all defects of crane


list in the punch list table
and confirmed before
shipping

QM-2000

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Note

Project: NINGBO 6RTGs

Rev No. 0
No.

Description

6.DOCUMENTATION
Final Dossier

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

Note
H - hold point

QUALITY CONTROL PLAN


Quality Control Activity

QA Document

Acceptance
Standard

Job No. 1201

Verifying Documents

Inspection Activity
NCSC

Client/Third
Party

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

R/W

Compilation of dossier to include


:
Quality Plan

QC and NDT personnel


qualificatons

Welders Certificates List

Mill Certificates

Paint Certificates

Welding consumables Certificates

Technical Query Reports

Visual Inspection records

NDT reports

Pressure Test Report

Dimensional Inspection Reports

Blasting and Paint Inspection


Reports

Gantry inspection reports

Final acceptance testing record

Punch list

R - review

RI - RandomInsepction
W - witness
Page 10 of 10

- inform

Note