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Doc Ref : QAP-09

QUALITY ASSURANCE PROCEDURE

Date:

t " January 2009

Revision No : 0 Cover Page

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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

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KENCANA INFRASTRUCTURE SDN BHD

REV NO

DATE
NAME

PREPARED BY
SIGN DATE NAME
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REVIEW ED BY
SIGN DATE

I
NAME TKH

APPROVED BY
SIGN DATE

27.12 08

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15.12.08

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22. 12.08

27.12.08

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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

TABLE OF CONTENTS

Date : 1st January 2009 Revision No : 0 Page 1 of 10

SECTION 1.0 2.0 3.0 4.0 5.0

DESCRIPTION PURPOSE SCOPE REFERENCES DEFINITIONS PROCEDURE 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 CALIBRATION CONTROL IDENTIFICATION CALIBRATION CALIBRATION PERSONNEL AND FREQUENCY CALIBRATION OF PRESSURE GAUGES AND RECORDERS CALIBRATION OF TEMPERATURE GAUGES AND RECORDERS CALIBRATION OF ELECTRODE OVENS CALIBRATION OF WELDING MACHINES CALIBRATION OF STEEL TAPES CALIBRATION OF BLASTING/PAINTING EQUIPMENT CALIBRATION OF MACHINE YOKE FOR MAGNETIC PARTICLE INSPECTION CALIBRATION OF OTHER EQUIPMENT

PAGE 2 2 2 2 2 23 3 3 3-4 4 5 56 67 78 89 9 9 10 10

6.0 7.0

SPECIAL REQUIREMENTS RECORDS

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

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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

Date : 1st January 2009 Revision No : 0 Page 2 of 10

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

4.0

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

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 : Non Destructive Testing : Third Party e.g. DNV or SIRIM : Kencana Infrastructure : Testing and Commissioning

NDT Externally Internally T&C

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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

Date : 1st January 2009 Revision No : 0 Page 3 of 10

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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

Date : 1st January 2009 Revision No : 0 Page 4 of 10

5.4.2 Equipment required calibration Internally by Kencana Infrastructure personnel (In house) to the companys 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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

5.6

Date : 1st January 2009 Revision No : 0 Page 5 of 10

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 100C) 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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

Date : 1st January 2009 Revision No : 0 Page 6 of 10

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 150C for holding and 300C 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 300C 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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

Date : 1st January 2009 Revision No : 0 Page 7 of 10

In the case of regulators the services of manufacturers 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 tapes reading coincides with the datum marker in step (ii). v) Tension the tape to 10kgs or as per manufacturers 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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

-

Date : 1st January 2009 Revision No : 0 Page 8 of 10

Particulars of the Master Tape Date of calibration Temperature during calibration Tapes 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. 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. 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. 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.

b)

c)

d)

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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

b)

Date : 1st January 2009 Revision No : 0 Page 9 of 10

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. 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. 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.

c)

d)

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 manufacturers 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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EQUIPMENT CALIBRATION AND MAINTENANCE PROCEDURE

Date : 1st January 2009 Revision No : 0 Page 10 of 10

6.0

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

6.2

7.0

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

7.2

QA/QC Manager

APPENDICES

QAP09 Rev-0 Appendix I

NON-CONFORMANCE TAG (QUARANTINE TAG)

HOLD
DO NOT USE

PROJECT

: _______________________

ITEM DESCRIPTION : __________________ _____________________________________

REMARKS : __________________________ _____________________________________

ISSUED BY : ________________________ SIGNATURE : ________________________ DATE : ________________________

INSPECTION AND TESTING EQUIPMENT REGISTER

DATE CAL NEXT CAL DEPT. BORROW RETURN RECEIVED HOLDING SIGN DATE SIGN DATE

QAP-09 Rev-0 Appendix II

NO

DESCRIPTION

MODEL

SERIAL NO

RANGE

CERT NO

REMARK

QAP-09 Rev-0

EQUIPMENT/ INSTRUMENT CALIBRATION REPORT

Appendix III

Equipment/ Instrument : Tag Number EQUIPMENT DATA Type Manufacturer Signal Range Service % Span CALIBRATION CHECK Master Reading Actual : : : : : Rising ( % Span ) % Error Actual Model no. Order No. Dial/ Change Range Serial No. Req. No. Reading Output Falling ( % Span ) % Error : : : : :

Control Mode

Proportional ON - OFF

Integral Diff Gap Reverse

Derivative Auto/ Manual

CONTROLLER CHECK Control Action Controller Alignment Correct ALARM/ SHUTDOWN UNIT

Direct

Trip Set 1 : Trip Set 2 :

Reset : Reset :

Auto Temperature Correction Range CORRECTIONS SP Gravity/ Density Correction Setting Zero Elevation/ Suppression Setting Description MASTER DATA Serial No. Date of Calibration Certificate No. Comments : : : : : Name Date : : Checked By :

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

QAP-09 Rev-0 Appendix IV

CALIBRATION OF BAKING / HOLDING OVEN REPORT

(CALIBRATE EVERY SIX MONTH)

OVEN TEMPERATURE READING ON GAUGE ( C) MASTER TEMPERATURE ACTUAL READING ( C)

DATE

OVEN NUMBER

TEMPERATURE GAUGE NUMBER

REMARK

CALIBRATED BY SIGN NAME DATE : : :

VERIFIED BY SIGN NAME DATE : : :

VERIFIED BY (Client) SIGN : NAME : DATE :

WELDING EQUIPMENT EVERY SIX MONTH CALIBRATION REPORT

AMPERAGE EQUIPMENT TYPE MASTER ACTUAL MASTER ACTUAL VOLTAGE

QAP-09 Rev-0 Appendix V

DATE

EQUIPMENT NUMBER

MASTER METER

SERIAL NUMBER

CERT. NO.

REMARKS

Calibrated By : QAQC Signed By : Name Date : :

Verified By : Signed By Name Date : : :

QAP-09 Rev-0

MEASURING TAPE CALIBRATION REPORT

Appendix VI

Description Length Tape No

: : :
REAL LENGTH (mm)

Department Own Temperature Tension

ERROR LENGTH (mm)

: : :
ERROR % REMARKS

MASTER LENGTH (mm)

DATE OF INSPECTION : MASTER TAPE PARTICULARS DESCRIPTION LENGTH TAPE NO CALIBRATION DATE NEXT DUE DATE : : : : :

The above mentioned particulars have been inspected and accepted by : QA/ QC Coordinator Client Rep.

Name : Date :

Name : Date :

QAP-09 Rev-0

PAINTING EQUIPMENT CALIBRATION REQUIREMENTS

Appendix VII

TYPE OF EQUIPMENT

BRAND NAME / MODEL

TYPE OF CALIBRATION

1) DFT Gauge

Elcometer / Model 345F

Calibrate daily using zero plate and measured calibration foils.

2) Surface Profile Gauge 3) Surface Thermometer

Elcometer / Model 123

Calibrate daily using flat glass

Elcometer (magnetic Type) 4) Keane-Tator Surface Profile Elcometer Comparator 5) Whirling Hygrometer 6) Low-Voltage Holiday Detector Elcometer (Wet Sponge) 7) High-Voltage Holiday Detector Elcometer Elcometer

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

N/A

N/A

Calibrate prior to use

Calibrate annually by externally approved authority

8) Adhesion Pull-Off Tester

Elcometer

DITTO

9) WFT Gauge

Elcometer

N/A

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".

QAP-09 Rev-0

MPI PERFORMANCE CALIBRATION CHECK REPORT OF YOKES

Appendix VIII

JOB LOCATION

SERIAL NO

EQUIPMENT MODEL :

DATE TESTED :

MAGNETIC PARTICLE INSPECTION METHOD :

DRY

WET

FLUORESENT

MAGNETIC PROCESS

CONTINUOUS

TRU-CONTINUOUS

RESIDUAL

MAGNETIZING CURRENT

AC

PERMANENT MAGNET

DC

DIRECTION OF MAGNETIC FIELD

PROD. PLACEMENT

CABLE WRAP SEQUENCE

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 : SIGN NAME DATE : : :

VERIFIED BY : SIGN :

NAME : DATE :