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PROCESS & DOCUMENTATION

Manufacturing quality, at its most fundamental, is compliance to specifications. The fundamental basis for managing operations to produce quality products is the quality of design and compliance to standards.

Poor manufacturing quality comes at a significant cost. Through inefficiencies, delays, direct expenses, and customer dissatisfaction, rework, scrap, product failures, and recalls may significantly harm a manufacturing.

Quality assurance in manufacturing contains three major functions: quality design and engineering, quality control, and quality management.

Today, INOVATERM manufactures goods on time, the first time, and every time in order to attain and maintain a competitive position in worldwide markets by sticking to its core principles.

In each project, INOVATERM provide the quality control documentation indicated below in accordance with customer specifications.

Documentation

Pressure Vessels
(1.Before Manufacturing)
ITEM No. DESCRIPTION ACCORDING TO
1,1 DWG, Design, Calculation Document ASME Sec. VIII or EN 13445
1,2 Welding Map with WPS ASME
1,3 WPS & PQR ASME IX,EN 15608, EN 15614-1-1
1,4 Welder Qualification Certificates ASME IX, EN ISO 14732
1,5 NDE Personnel Certificates ASME V, EN 473, EN 9712
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1,6 Hydro Static Test Procedure ASME Sec. VIII or EN 13445
1,7 Painting Procedure EMP Spec.
(2.Materials)
ITEM No. DESCRIPTION ACCORDING TO
2,1 Material Certificates EN 10204 3.1.
2,2 Welding Filler Materials ASME IX
(3. During Manufacturing)
ITEM No. DESCRIPTION ACCORDING TO
3,1 Head Forming and Dimension Check DWG, ASME Sec. VIII or EN 13445
3,2 Check of Rolling of Shell DWG, ASME Sec. VIII or EN 13445
3,3 Marking,Opening Nozzles and Nozzle Orientation DWG
3,4 Fit‐Up, Welding of pipe to flange WPS/DWG
3,5 PT,MT,RT and UT ASME/NDT Map/NDT Procedure
3,6 Visual & Dimensional Check DWG
3,7 Hydrostatic Test ASME VIII, EN 13445
3,8 Surface Fınısh and Painting Check EMP Spec.
(4. Final Inspection)
ITEM No. DESCRIPTION ACCORDING TO
4,1 Final Check of Documentation P.O. and Specifications
4,2 Ex-Works Release EMP Spec.
(5.Shipping)
ITEM No. DESCRIPTION ACCORDING TO
5,1 Marking Control & Release Note EMP Spec.
5,2 Loading Inspection EMP Spec.
5,3 Shipping Release EMP Spec.

Heat Exchangers
(1. Before Manufacturing)
ITEM No. DESCRIPTION ACCORDING TO
1,1 Approval By Customer Drawing, Calculations, Inspection Plan, Fabrication and Test Procedures Customer Specification
1,2 Approval By 3rd Party Drawing, Calculations, Inspection Plan, Welding Specification ASME VIII Div.1, Customer Spec.
1,3 Receiving Examination Receiving Examination of Purchased Parts (Especially Tubes, Tube Sheets etc.) UG 11 Drawing
1,4 Welding Map with WPS ASME Section IX
1,5 WPS & PQR ASME Section IX
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1,6 Welder Qualification Certificates ASME Section IX
1,7 NDE Personnel Certificates ASME Section V
1,8 Material Traceability transfer stamping of loose part to fill out the list of material certificates ASME VIII Div.1 UG-93, UG-77
1,9 Check of Transfer Stamping and Material Certificates check of the ready loose and store parts acc. to the material list and certificates UG-93, UG-10
1,10 Material Certificates EN 10204 3.1.
1,11 Pre Inspection Meeting Before Start of Manufacturing –
(2. During Manufacturing)
ITEM No. DESCRIPTION ACCORDING TO
2,1 Welding Supervision Check of the Tacked Welds Seams Preparation, Welding Workmanship, Filler Metals and Qualified Thickness, Welder Stamps, Welding Material Specification During Fabrication and Welds Surface Quality ASME VIII Div.1, UG-97, UW-31, UW-32, Welding Spec.
2,2 Shell Assembling and Welding Check of the Gap and Alignment Offset of Longitidunal and Circumferential Welded Butt Joints Before Weld, Check the Roundness and Height of Welding Seam ASME VIII Div.1, UW-33, UW-35 Drawing
2,3 Testing of Shell The Welds on Shell Side Shall Be 100% MT or PT Tested and all the Butt Welds Shall Be 100% RT Tested. ASME VIII Div.1, UW-11, ASME VIII Div.1, UG-97, UW-33,35 UW-50 Drawing NDE Procedure
2,4 Shell Side Heat Treatment after Welds Visual Check the Situation of the Shell DRAWING
2,5 Main Dimensional Check of Shell Main Dimensional Check of the Vessel.To Marking the Vessel Axis on Top Left and Right Side As Soon as Nozzle Axis. Check Nozzle Situation. Welds Ditribution and Apperance, Base Material Surface Quality. DRAWING
2,6 Chamber Assembling and Welding Open the Chamber Shell, Welding the Nozzles and Flanges, Welding the Floating Head Customer Specification Drawing
2,7 Testing of Channel Check weld surface quality of channel and floating head. Making NDT Examination to welding joint according codes ASME VIII Div.1, UG-103, ASME V Art. 6 DRAWING NDE Procedure
2,8 Dimensional Inspection Before Assembling Tube Bundle Before start of assembling the tube bundle, dimensioanl inspection of tube-sheet holes, tubes DRAWING TEMA
2,9 Assembling Tube Bundle DRAWING
2,10 Welding Tube to Tubesheet DRAWING Welding Doc.
2,11 Expanding Tube to Tubesheet DRAWING
2,12 Tube to Tubesheet Joint Examination 100%NDE Examination ASME VIII Div.1, UG-103, ASME V Art. 6 DRAWING NDE Procedure
2,13 Joint Heat Treatment after Weld –
2,14 Reinforcement Pad Leak Test Visual Check of all Welds of Leaks and Possible Deformations DRAWING
2,15 Hydrostatic Test of Vessel Visual Check of surface quality and dimension. Pressure test according to the drawing. Request according to the drawing. ASME VIII Div.1, UG-99, DRAWING
2,16 Hydrostatic Test of Tube Side Visual Check of surface quality and dimension. Pressure test according to the drawing. Request according to the drawing. ASME VIII Div.1, UG-99, DRAWING
2,17 Surface Treatment Vessel Application of Paint Works outside of the vessel. Check of the surface treatment and measurement of the piant dry layer thickness. DRAWING PAINTING SPEC.
(3. Final Inspection)
ITEM No. DESCRIPTION ACCORDING TO
3,1 Final Inspection Conforming with Drawing Main Dimension Nameplate Final Documentation (PED/2014/68/EU) Finish Workmanship ASME VIII Div.1, UG-119, UG-120, Purchase Order Drawing
3,2 Ex-Works Release EMP Spec.
(4.Shipping)
ITEM No. DESCRIPTION ACCORDING TO
4,1 Marking Control & Release Note Check of Closed Flange Opening and Transport Lockings. Filling with 0.03 MPa Nitrogen. Make sure spare part conform with the packing list. DRAWING CUSTOMER SPEC.
4,2 Loading Inspection EMP Spec.
4,3 Shipping Release EMP Spec.

Prefabricated Piping Spools
(1.General)
ITEM No. DESCRIPTION ACCORDING TO
1,1 Drawing Review and Approval Construction Drawings
1,2 ITP Approval This Specification
1,3 Welding Plan ASME B31.3 Para 328 + ASME IX, equiv. EN
1,4 WPS & WPQR Review ASME B31.3 Para 328 + ASME IX, equiv. EN
1,5 Welder Qualification Certificates (WQR, WOQR) ASME B31.3 Para 328 + ASME IX, equiv. EN
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1,6 NDE Procedures (VT, RT, MT or PT) (Review of all radiographs films) Review ASME B31.3 Para 343 + ASME BPVC Sec V Art 1, equiv. EN
1,7 NDE Personnel Qualification Review ASNT SNT-TC-1A, level II Alternative: ISO 9712
1,8 Surface Finishing & Painting Procedure EMP Spec.
1,9 Base & Welding Material Mill Test Reports (incl.heat treatment records,etc.) EN 10204 3.1.
1,10 Check Incoming Material and Mill Marks Record Manuf. Procedure
(2.Construction)
ITEM No. DESCRIPTION ACCORDING TO
2,1 Visual and dimensional checks before assembling Construction Drawings
2,2 Cutting, Markings Transfer and Traceability Construction Drawings
2,3 Preparation of Weld Edges ASME B31.3 para. 328.4 – According to the approved WPS.
2,4 Matching of Weld Edges ASME B31.3 para. 328.4 – According to the approved WPS.
2,5 Preheating ASME B31.3 para. 330 – According to the approved WPS.
2,6 Welding ASME B31.3 para. 328 – According to the approved WPS.
2,7 Removal of Tack Welds Approved WPS
2,8 Drawing code and job number marking on each line Construction Drawings
2,9 PT on 100% Removed Tack Welds ASME V article 6 or EN equiv.
2,10 Welding map, Welder identification and weld number marking on each weld Construction Drawings and Welding Map
2,11 VT on 100% on complete welding ASME B31.3 para. 344.2 + ASME V Article 9 or EN equiv.
2,12 UT on 100% branch ASME V Article 4 or EN equiv.
2,13 PT on 100% fillet and socket welds ASME B31.3 para. 344.5 + ASME V Article 2 or EN equiv
2,14 RT on 100% circumferential butt welds ASME B31.3 Para 328 + ASME IX or EN equiv.
(3.Final Testing)
ITEM No. DESCRIPTION ACCORDING TO
3,1 Piping Internal Check Construction Drawings
3,2 Final Visual & Dimensional & Quantity Check of Prefabricated Spools Construction Drawings
3,3 Final Marking Check ASME B31.3 para. 328.4 – According to the approved WPS.
3,4 Hydraulic Test Not Applicable
3,5 Protective Coating & Painting Check EMP Spec.
3,6 Packaging Inspection Before the Delivery Manuf. Procedure
3,7 Manufacturer Data Book Release EMP Spec.
3,8 Check for Piping Readiness for Shipment / Ship Release EMP Spec.
3,9 Pre-shipment Inspection EMP Spec.

Steel Structures

(1.General)
ITEM No.DESCRIPTIONACCORDING TO
1,1Design and engineering reviewEN 1090-2: EXC2;
EN 3834 -3
1,2Materials certificatesEN 10204 3.1
1,3WPS, PQR and welder qualificationsStd. Manufacturer
EN 15614; EN 287
1,4NTD operator qualificationsStd. Manufacturer
EN 9712
1,5Visual Test (VT) on weldsStd. Manufacturer
EN 17637; EN 5817 liv. C

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1,6Magnetic Test (MT) on weldsEN 17638;
EN 23278
1,7UT for welds with full penetrationEN 17640;
EN 11666, EN 16810
1,8UT for lamination of platesEN 10160 E1S1
1,9Check of zinc protectionEN 1090-2: EXC2
EN 1461
(2.Final Testing)
ITEM No.DESCRIPTIONACCORDING TO
2,1Check of markingDWG
2,2Visual and dimensional testP.O. and specifications
EN 1090-2: EXC2
2,3Packing and marking checkPO and specifications
2,4Final check of documentationP.O. and specifications
Reg 305/2011/EC
2,5ShipmentSuitable packing for track
according to Employer packing spec.

CERTIFICATES