This article is to provide a brief description of quality plan and inspection & testing plan (ITP) for equipment and materials to be procured by CONTRACTOR for Oil & Gas EPCI Project.
What is Quality Plan?
Quality plan is document (3.7.2) specifying which procedures (3.4.5) and associated resources shall be applied whom and when to a specific project (3.4.3), product (3.4.2), process (3.4.1) or contract. (ISO 9000:2005 3.7.5)
A document specifying the processes of the quality management system (including the product realization processes) and the resources to be applied to a specific product, project or contract can be referred to as a quality plan. (ISO 9001:2008 Clause 7.1 Planning of product realization, NOTE 1)
Content of the quality plan
The examples and lists provided in ISO 10005-2005 standard clause 5 should not be considered comprehensive or limiting in any way.
The quality plan for a specific case should cover the topics examined below as appropriate. Some topics in the following list may not applicable, for example where design and development are not involved.
· Quality plan input
· Quality objectives
· Management responsibilities
· Control of documents and data
· Control of records
· Customer communication
· Design and development
· Production and service provision
· Identification and traceability
· Customer property
· Preservation of product
· Monitoring and measurement
A preliminary Project Quality Plan (PQP)
During Project Tender/Bidding Stage, TENDERER shall submit a preliminary Project Quality Plan describing, in outline, the Quality Management system TENDERER intends to implement for each phase of the WORK.
What is Inspection and Test Plan (ITP)?
An Inspection and Test Plan (ITP) or test plan is a document detailing a systematic approach to testing a system or product (e.g. material, component, machine, package, software, etc.) such as a visual inspection, dimension inspection, welding inspection, function test, factory acceptance test, etc. and participation of all parties.
Why do we need to make a test plan?
Guarantee the product quality and ensure the product function achieved the requirement of design.
ISO 9001:2008 Clause 7.4.3 Verification of purchased product requires that the organization shall establish and implement the inspection or other activities necessary for ensuring that purchased product meets specified purchase requirements.
Where the organization or its customer intends to perform verification at the supplier’s premises, the organization shall state the intended verification arrangements and method of product release in the purchasing information.
Typical Inspection and Test Plan
For EPCI Project, each Vendor shall complete the Contractor/Company approved format of Inspection and Test plan and shall provide with his bid proposal as an indication of type of test performed by him to access the quality system. On placement of order, VENDOR shall formally submit the Inspection and Test Plan as part of Vendor Document Submission for CONTRACTOR ‘s approval.
Project Quality Control Plan or Inspection & Test Plan (ITPs) of major Vendors and Sub-contractors will be submitted by Contractor to COMPANY for approval in order to include their level of involvement during the implementation of the Inspection Plans.
How to make a test plan?
Firstly, we consider what function need to test and what function we can ignore, we should optimize the process and method to make the process more efficient and simple.
The test plan for manufacture is different from debugging test because the production test must be appropriate for mass production, we need this process is efficient and automatic testing method.
The hardware test is to verify the feasibility of the design, but production test is to verify the product performance and quality whether influenced by material and processing technology.
Depending on the product and the responsibility of the organization to which the test plan applies, a test plan may include one or more of the following:
· Design Verification or Compliance test – to be performed during the development or approval stages of the product, typically on a small sample of units.
· Manufacturing or Production test – to be performed during preparation or assembly of the product in an ongoing manner for purposes of performance verification and quality control.
· Acceptance or Commissioning test – to be performed at the time of delivery or installation of the product.
· Service and Repair test – to be performed as required over the service life of the product.
· Regression test – to be performed on an existing operational product, to verify that existing functionality didn’t get broken when other aspects of the environment are changed (e.g., upgrading the platform on which an existing application runs).
A complex system may have a high-level test plan to address the overall requirements and supporting test plans to address the design details of subsystems and components.
Test plan document formats can be as varied as the products and organizations to which they apply.
There are three major elements that should be described in the test plan:
· Test Coverage,
· Test Methods, and
· Test Responsibilities.
Test coverage in the test plan states what requirements will be verified during what stages of the product life. Test Coverage is derived from design specifications and other requirements, such as safety standards or regulatory codes, where each requirement or specification of the design ideally will have one or more corresponding means of verification.
Test methods in the test plan state how test coverage will be implemented. Test methods may be determined by standards, regulatory agencies, or contractual agreement, or may have to be created new. Test methods also specify test equipment to be used in the performance of the tests and establish pass/fail criteria. Test methods used to verify hardware design requirements can range from very simple steps, such as visual inspection, to elaborate test procedures that are documented separately.
Test responsibilities include what organizations will perform the test methods and at each stage of the product life. This allows test organizations to plan, acquire or develop test equipment and other resources necessary to implement the test methods for which they are responsible. Test responsibilities also includes, what data will be collected, and how that data will be stored and reported (often referred to as “deliverables”). One outcome of a successful test plan should be a record or report of the verification of all design specifications and requirements as agreed upon by all parties.