QAP-09 Equipment Calibration

q~Doc Ref : QAP-09

QUALITY ASSURANCE Date: t " January 2009

Kencana InfrastructurePROCEDURE Revision No : 0

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Cover Page

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EQUIPMENT CALIBRATION AND MAINTENANCE

PROCEDURE

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KENCANA INFRASTRUCTURE SDN BHD

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NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE

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Date : 1st January 2009

Revision No : 0

EQUIPMENT CALIBRATION

AND MAINTENANCE PROCEDURE

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TABLE OF CONTENTS SECTION DESCRIPTION PAGE

1.0 PURPOSE 2 2.0 SCOPE 2 3.0 REFERENCES 2 4.0 DEFINITIONS 2 5.0 PROCEDURE 2 5.1 CALIBRATION CONTROL 2 – 3 5.2 IDENTIFICATION 3 5.3 CALIBRATION 3 5.4 CALIBRATION PERSONNEL AND FREQUENCY 3 - 4

5.5 CALIBRATION OF PRESSURE GAUGES AND RECORDERS

4

5.6 CALIBRATION OF TEMPERATURE GAUGES AND RECORDERS

5

5.7 CALIBRATION OF ELECTRODE OVENS 5 – 6 5.8 CALIBRATION OF WELDING MACHINES 6 – 7 5.9 CALIBRATION OF STEEL TAPES 7 – 8 5.10 CALIBRATION OF BLASTING/PAINTING EQUIPMENT 8 – 9

5.11 CALIBRATION OF MACHINE YOKE FOR MAGNETIC PARTICLE INSPECTION

9

5.12 CALIBRATION OF OTHER EQUIPMENT 9 6.0 SPECIAL REQUIREMENTS 10 7.0 RECORDS 10

APPENDICES

APPENDIX I QUARANTINE HOLD TAG APPENDIX II INSPECTION AND TESTING EQUIPMENT REGISTER APPENDIX III EQUIPMENT/ INSTRUMENT CALIBRATION REPORT APPENDIX IV CALIBRATION OF BAKING/ HOLDING OVEN REPORT APPENDIX V WELDING EQUIPMENT CALIBRATION REPORT APPENDIX VI MEASURING TAPE CALIBRATION REPORT APPENDIX VII PAINTING EQUIPMENT CALIBRATION REQUIREMENTS APPENDIX VIII MPI PERFORMANCE CALIBRATION CHECK REPORT OF YOKES

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1.0 PURPOSE This procedure is to provide the guideline of the correct control for the inspection,

calibration and maintenance of equipment. 2.0 SCOPE This procedure covers the inspection, measuring, testing and frequency of the

maintenance of equipment utilized for the projects on any quality related activities undertaken.

3.0 REFERENCES

• ISO 9001 : 2008 - Clause 7.6 • Quality Manual (QM)

4.0 DEFINITIONS

CALIBRATION : To ascertain the error (if any) of a device by comparing the device output against a known standard; to adjust the output of a device to a desired value, within a specified tolerance

NDT : Non Destructive Testing Externally : Third Party e.g. DNV or SIRIM Internally : Kencana Infrastructure T&C : Testing and Commissioning

5.0 PROCEDURE

5.1 Calibration Control

5.1.1 The QA/QC Coordinator shall be responsible to ensure that all equipment are maintained in good working condition and calibrated. All equipment which is out of calibration shall be attached with Quarantine Tag “Do Not Use” (See Appendix I).

5.1.2 Each measuring and testing equipment which has been calibrated

shall be identified by marking with a unique serial number, complete with a sticker indicating the date of calibration, validity date and next calibration date.

Equipment that is without a valid calibration tag or is due for

recalibration shall be locked up and attached with a Quarantine Tag and shall not be used until it is recalibrated and found acceptable.

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5.1.3 The QA/QC Coordinator shall maintain a register of all measuring and testing equipment currently used for the project, see Appendix II inspection and testing equipment register.

5.1.4 Depending on the type of equipment being used calibration may be

either by Kencana Infrastructure qualified personnel or calibrated by an approved third party agency such as DNV, SIRIM, etc. (refer to section 5.4 calibration personnel and frequency)

5.1.5 Recalibration of equipment shall be carried out when the calibration

is due or when ever there is a reason to suspect inaccuracy of the equipment.

5.2 Identification

The QA/QC Department shall create a register to monitor the status of all equipment which required calibration. This register shall list the equipment description, serial no. and any relevant documents, i.e. certificates, etc. for details refer to Appendix II.

5.3 Calibration

5.3.1 Calibration of equipment shall be carried out under the condition relevant to the accuracy of the equipment concerned.

5.3.2 All measuring and testing equipment or instruments used in

connection with a quality inspection activity shall have a label to be attached to it by the person who performing the calibration with the following information;

Serial no. : Date of Calibration : Due For Calibration : Witnessed By : 5.3.3 Only clean dry air/ nitrogen shall be used for calibration of

pneumatic instruments. 5.3.4 Calibration method and accuracy acceptable allowance shall be as

per Manufacturers’ Standard. 5.4 Calibration Personnel and Frequency

5.4.1 Equipment which required calibration externally by an approved

authority, against certified equipment which has a valid relationship, traceable to nationally recognized standard, such as DNV, SIRIM, etc.

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5.4.2 Equipment required calibration Internally by Kencana Infrastructure

personnel (In house) to the company’s calibration procedure against certified equipment which has a valid relationship, traceable to a nationally recognized standard.

Where the calibration is conducted by Kencana Infrastructure

personnel under control conditions e.g. temperature and humidity, the calibration shall be witnessed and approved by Kencana Infrastructure QA/QC Coordinator or his assignee.

5.4.3 The frequency of calibration shall be determined by manufacturers’

recommendation, or annually if the frequency is not determined by the manufacturer.

The detailed calibration schedule is shown in Appendix II for each item of measuring and testing equipment.

5.5 Calibration of Pressure Gauge and Recorders

5.5.1 Calibration of pressure gauges and recorders shall be by means of

a Dead-Weight-Tester or Standard Test Gauge, which has been certified by SIRIM and within the validity period.

5.5.2 Check minimum of 5 readings when the pressure reading is

increasing and another 5 readings when the pressure reading is decreasing. The gauge shall be lightly tapped before each reading is taken. Five (5) readings indicate when the dial of pressure gauge/ recorder is at 0%, 25%, 50%, 75% and 100% of the total indicated pressure.

5.5.3 The maximum error permissible is +/- 1% of full scale maximum

value. 5.5.4 All reading shall be recorded and signed by the calibration

personnel, using the Kencana Infrastructure Equipment/ Instrument Calibration Report (Refer Appendix III)

5.5.5 The gauge/ recorder shall be subjected to adjustment, repair or

replacement if the error is beyond the limit mentioned in 5.5.3 5.5.6 Calibration of pressure gauges/ recorders shall be conducted by

T&C Department and witnessed by Kencana Infrastructure QC Inspector.

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5.6 Calibration of Temperature Gauge and Recorders

5.6.1 Calibration of Temperature gauges and recorders shall be by means of a Thermocouple probe, Platinum resistant thermometer, Temperature calibrator and Dry block calibrator, or other equivalent equipment which has been certified by third party and within the validity period.

5.6.2 Set the dry block calibrator to desired temperature and allow it to

stabilize for a minimum 10minutes. 5.6.3 Check minimum of 5 readings when the temperature gauge/

recorder is at 0%, 25%, 50%, 75% and 100% of the total indicated temperature (check the minimum 3 readings if the full range of the gauge/ recorder is less than 100°C)

5.6.4 The maximum error permissible is +/- 5% of full scale maximum

value. 5.6.5 All reading shall be recorded and signed by the calibration

personnel, using the Equipment/ Instrument Calibration Report. (Refer Appendix III)

5.6.6 The gauge/ recorder shall be subjected to adjustment, repair or

replacement if the error is beyond the limit 5.6.7 Calibration of temperature gauges/ recorders shall be done by

Kencana Infrastructure T&C Department and witnessed by Kencana Infrastructure QC Inspector.

5.7 Calibration Of Electrode Ovens

5.7.1 All ovens shall be fitted with a calibrated Temperature Gauge to display operational temperature.

5.7.2 The temperature of oven shall be verified every six months by using

a calibrated Digital Thermometer or Contact Thermometer or whenever there is a reason to suspect a fault of equipment. Where the gauge is out of tolerance, the oven shall not be used for baking or holding of electrodes and marked as in 5.1.2.

5.7.3 Prior to servicing the oven, the remaining electrode shall be

transferred to another oven and the oven shut-off for the duration of 24 hours.

5.7.4 Blow away dust and dirt from the interior of the oven using

compressed air. Compressed air shall be clean and dry.

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5.7.5 Check and rectify the door and external of the oven for air tightness and also all terminals, connections and tighten, this is necessary to ensure that the optimum temperature shall be maintained at all time.

5.7.6 Place the power switch in “on” position to energize the oven and set

the temperature to the required degree (example 150ºC for holding and 300ºC baking) by turning the dial on the temperature display unit or by push button selector according to the type of oven used.

5.7.7 Place an industrial mercury thermometer inside the oven for

checking the temperature or by other suitable method.

5.7.8 Check the temperature 300ºC min with an allowable tolerance of up to +5% of the required temperature.

5.7.9 The verification of oven temperature shall be done by Kencana

Infrastructure QA/QC Department, and the oven calibration report (refer Appendix IV) shall be maintained in a record file by the QA/QC Department. Faulty ovens shall be removed from serviced and repaired. Rectified ovens shall be acceptable after the compliance is verified by Kencana Infrastructure qualified personnel.

Note: When either of the temperature setting or display unit deviates more

than 10% of the required temperature, it shall be re-calibrated to within the permitted tolerance.

5.8 Calibration Of Welding Machines 5.8.1 Welding machines shall be maintained in good working condition,

calibration shall be performed every six months. The voltage and current output shall be accurate to within ± 5V/10 Amps.

5.8.2 Blow away dust and dirt from the interior of the transformer using

clean and dry compressed air. Check all terminals, connections and tightened them where necessary.

5.8.3 Place the power switch in the “on” position to energize the welding

sets power sets sources fan and control circuiting. Adjust/ select the amperage control to the desired ampere. The welding set is now in a ready-to-weld status.

5.8.4 Check the amperage and voltage output of the welding set with a

calibrated AC/DC clamp ammeter during welding. If the readings on the ammeter do not correspond to the amperage and voltage setting on the welding set within a tolerance of ±10% A and ±5 v respectively, adjust as necessary.

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In the case of regulators the services of manufacturer’s technician may be called upon to calibrate these sets where necessary.

5.8.5 The type of ammeter tester shall be capable of recording both

alternating and direct current for the range of current and voltage, refer to Appendix V. Kencana Infrastructure Maintenance Section shall conduct and witnessed by client representative (if required) of the calibration. The QA/QC Department shall maintain the equipment calibration record as in Appendix V.

5.9 Calibration Of Steel Tapes

5.9.1 The master tape shall be calibrated and certified by approved third party.

5.9.2 A calibrated master tape shall be used as a reference to calibrate

other steel tapes, the result of the comparison reading shall be recorded, refer to Appendix VI.

5.9.3 Calibration of steel tapes will be conducted by Kencana

Infrastructure QC Inspector. A tensioner shall be used when calibrating the steel tapes.

5.9.4 The procedure for calibration shall be as follows:

i) Pull the master tape on a flat surface and tension it with a

10kgs force. ii) Mark out the datum and every equally spaced predetermined

distance such as 5m, 10m, 15m, etc. iii) Note down the temperature reading.

iv) Pull the tape to be calibrated on the same surface and align

it so that the tape’s reading coincides with the datum marker in step (ii).

v) Tension the tape to 10kgs or as per manufacturer’s

recommended tension. vi) Check the differences between the tape and the master tape

at the equally spaced marking and record the results. (The differences shall not exceed 5mm or 0.2% of the calibration length whichever is smaller).

vii) Prepare the calibration report which contain the following

information :

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- Particulars of the Master Tape - Date of calibration - Temperature during calibration - Tape’s identification no. - Differences/discrepancies of the calibrated tape.

5.10 Calibration of Blasting/ Painting Equipment

5.10.1 The blasting/ painting equipment list addressed in Appendix VII shows the blasting/ painting equipment used by Kencana Infrastructure. The calibration method where applicable are indicated in Appendix VII.

5.10.2 Surface Profile gauge

The surface profile gauge is dial gauge mounted on a large base foot in the centre of which is a precision ground tungsten carbide tip. The amplitude of a blasted will be measured by using a surface profile gauge.

Prior to use, the gauge must be calibrated

a) Surface profile gauge shall be calibrated before use by

painting Inspector. b) The instrument is held perpendicular to the sample surface

and the tip enters the valleys and its penetration is registered on the scale. Before taking any reading the gauge must be calibrated to zero point.

c) Place the surface profile gauge on a flat glass. Press the

gauge until fully sit on the flat glass and adjust the indicator needle to zero.

d) The final adjustment is made by rotating the outlet scale

using the knurled ring. The surface profile gauge is now in a ready to use.

5.10.3 Electronic Dry Film Thickness Gauge

The electronic dry film thickness gauge used for measuring thickness of a coating over ferromagnetic substrate. Prior to use the gauge must be calibrated.

a) The electronic Dry Film thickness gauge shall be calibrated

by Painting Inspector.

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b) The instrument is first calibrated by zeroing on bare mild steel and to be adjusted for calibration using foils provided. The tolerance accuracy is within +/-5.

c) Select a magnetically insulated shim of known thickness that

close to the thickness of the paint to be measured and place to shim on the blasted surface.

d) Place the probe onto the shim and press firmly. The

thickness of the shim will be displayed on the LCD gauge screen. If the thickness does not correspond to the shim thickness, press the display adjustment up down until the reading attain.

5.11 Calibration of Machine Yokes for Magnetic Particle Inspection

5.11.1 The magnetizing force of yokes shall be verified by Kencana Infrastructure NDT Coordinator before utilizing on the project, at least once a year, or whenever a yoke has been damaged and repaired. If a yoke has not been in used for a year or more, a check shall be done prior to first use.

5.11.2 Each alternating current electromagnetic yoke shall have lifting

power of at least 10 lb at maximum pole spacing that will be used.

5.11.3 Each permanent magnetic yoke shall have a lifting power of at least 40 lb at maximum pole spacing that will be used, refer to Appendix VIII

5.11.4 To determine the “Magnetizing Field Adequacy”. Spray the

surface with Ardox contrast aid paint, magnetize the surface and place the Burma Castrol Type 1 Flux indicator transversely to the magnetic field. Spray the surface again with Ardox Black Magnetic Ink. When three (3) indicators are clearly visible, adequate magnetic field has been achieved.

5.12 Calibration Of Other Equipment

5.12.1 Calibration of other equipment not detailed above shall be carried out externally as per the manufacturer’s instruction (Calibration Schedule) which is detailed in the respective manuals. The specific instrument shall be sent to a recognized institution for calibration as detailed in 5.4.1

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6.0 SPECIAL REQUIREMENTS

6.1 The environmental condition where the instruments are calibrated where possible shall be maintained at constant temperature and humidity.

6.2 The equipment shall be maintained by regular inspection to establish the

specific equipments “Master Gauge” status. This shall be conducted where required by approved personnel as indicated in section 5.4-Calibration Personnel and Frequency.

7.0 RECORDS

Title Responsibilities Retention Period

7.1 Inspection & Testing QA/QC Manager At least 1 year after Equipment List completion of project 7.2 Calibration reports QA/QC Manager Until due for calibration or certificates

APPENDICES

QAP–09 Rev-0

Appendix I

NON-CONFORMANCE TAG

(QUARANTINE TAG)

HOLD DO NOT USE

PROJECT : _______________________

ITEM DESCRIPTION : __________________

_____________________________________

REMARKS : __________________________

_____________________________________

ISSUED BY : ________________________

SIGNATURE : ________________________

DATE : ________________________

QAP-09 Rev-0Appendix II

DATE NEXT DEPT.CAL CAL HOLDING SIGN DATE SIGN DATE

REMARKSERIAL NOMODELDESCRIPTION BORROW RETURN RECEIVEDCERT NO

INSPECTION AND TESTING EQUIPMENT REGISTER

RANGENO

Tag Number : Model no. :Type : Order No. :Manufacturer : Dial/ Change Range :Signal Range : Serial No. :Service : Req. No. :

Actual % Span % Error Actual % Span % Error

Control Mode Proportional Integral Derivative

ON - OFF Diff Gap Auto/ Manual

Control Action Direct Reverse

Controller Alignment Correct

Trip Set 1 : Reset :

Trip Set 2 : Reset :

Auto Temperature Correction RangeSP Gravity/ Density Correction SettingZero Elevation/ Suppression Setting

Description : Checked By :Serial No. :Date of Calibration : Name :Certificate No. : Date :

Comments :

Checked/ Witnessed By :Signature : Signature :Name : Name :Date : Date :

EQUIPMENT/ INSTRUMENT CALIBRATION REPORT

Equipment/ Instrument :

EQUIPMENT DATA

QAP-09 Rev-0Appendix III

CALIBRATION CHECK

% Span Master Reading

Reading OutputRising ( ) Falling ( )

CONTROLLER CHECK

ALARM/ SHUTDOWN

UNIT

CORRECTIONS

MASTER DATA

DATE OVEN NUMBER

TEMPERATURE GAUGE NUMBER

OVENTEMPERATURE

READINGON GAUGE

( ˚C)

MASTERTEMPERATURE

ACTUALREADING

( ˚C)

CALIBRATED BY VERIFIED BY VERIFIED BY (Client)

SIGN : SIGN : SIGN :NAME : NAME : NAME :DATE : DATE : DATE :

QAP-09 Rev-0Appendix IV

CALIBRATION OF BAKING / HOLDING OVEN REPORT

(CALIBRATE EVERY SIX MONTH)

REMARK

QAP-09 Rev-0Appendix V

MASTER ACTUAL MASTER ACTUAL

`

Calibrated By : QAQC Verified By :

Signed By : Signed By :Name : Name :Date : Date :

CERT. NO.

WELDING EQUIPMENT EVERY SIX MONTH CALIBRATION REPORT

REMARKSVOLTAGE MASTER

METERSERIAL

NUMBERDATE EQUIPMENT NUMBER EQUIPMENT TYPE

AMPERAGE

Description : Department Own :

Length : Temperature :

Tape No : Tension :

REMARKS

DATE OF INSPECTION :

MASTER TAPE PARTICULARSDESCRIPTION :

LENGTH :

TAPE NO :

CALIBRATION DATE :

NEXT DUE DATE :

The above mentioned particulars have been inspected and accepted by :

Name : Name :

Date : Date :

Appendix VIQAP-09 Rev-0

MEASURING TAPE CALIBRATION REPORT

MASTER LENGTH (mm)

REAL LENGTH (mm)

ERROR LENGTH (mm) ERROR %

QA/ QC Coordinator Client Rep.

QAP-09 Rev-0Appendix VII

Note 1 : Coating inspection instruments test cannot be calibrated successfully and deemed beyond limit shall not be used and stored in a box marked "Defective Units".

PAINTING EQUIPMENT CALIBRATION REQUIREMENTS

2) Surface Profile Gauge Elcometer / Model 123 Calibrate daily using flat glass

TYPE OF EQUIPMENT BRAND NAME / MODEL TYPE OF CALIBRATION

1) DFT Gauge Calibrate daily using zero plate and measured calibration foils.Elcometer / Model 345F

3) Surface ThermometerElcometer

(magnetic Type)

Once a year or as recommendeds by manufacture [See Note 1]

4) Keane-Tator Surface Profile Elcometer N/A

Comparator

7) High-Voltage Holiday Detector Elcometer Calibrate annually by externally approved authority

5) Whirling Hygrometer Elcometer N/A

6) Low-Voltage Holiday DetectorElcometer Calibrate prior to use

(Wet Sponge)

8) Adhesion Pull-Off Tester Elcometer DITTO

9) WFT Gauge Elcometer N/A

SERIAL NO :

EQUIPMENT MODEL : DATE TESTED :

MAGNETIC PARTICLE INSPECTION METHOD : DRY WET FLUORESENT

MAGNETIC PROCESS : CONTINUOUS TRU-CONTINUOUS RESIDUAL

MAGNETIZING CURRENT : AC

DIRECTION OF MAGNETIC FIELD :

LIFTING POWER OF YOKE

AC (4.5 KG) 10 LBS. AT THE MAXIMUM POLE SPACING YES NO

DC (18.1 KG) 40 LBS. AT THE MAXIMUM POLE SPACING YES NO

REMARKS :

TESTED BY : VERIFIED BY :

SIGN : SIGN :

NAME : NAME :

DATE : DATE :

CABLE WRAP SEQUENCE

PERMANENT MAGNET

DC

PROD. PLACEMENT

JOB LOCATION :

MPI PERFORMANCE CALIBRATION CHECK REPORT OF YOKES

QAP-09 Rev-0Appendix VIII

Documents

QAP-09 Equipment Calibration