ABOUT OUR INDUSTRIAL SERVICES

Our habit of always taking the competition one step further in the sectors we serve is also valid in inspection and surveillance activities. As an organization that develops competition in our fields of activity, both technically and within the framework of service approach; We produce solutions for you in your projects by observing the requirements of the technical specifications with our expert staff under 3rd party surveillance.

This service, which is sought especially in large projects with high budgets, is becoming a necessity in all kinds of projects day by day. This type of inspection services, which both add efficiency to the process and contribute positively to the result, can be applied in all processes from the production stage to the completion of the project.

3. Why is 3rd party surveillance services needed?

There are many reasons why institutions need inspection and surveillance services. In a project; This type of surveillance activities are needed in order to be a decision maker in order to resolve technical disputes between the supplier and the customer in the whole process from the production of the products to the assembly of the equipment in the field. 3rd party inspection bodies, which take responsibility for technical decisions with an impartial approach outside the customer or supplier, take responsibility in this aspect and reduce the burden of both parties.

All kinds of products and equipment need to be designed, manufactured and assembled in accordance with certain standards and checked for compliance. 3rd party inspection organizations are also involved in the preparation of the ITP (Inspection & Test Plan) document, which is the part of determining the specifications and related standards in the projects, determining the inspection frequencies and expected results.

In the developing world, there are now standards that determine the production, design and assembly requirements for all kinds of products. As Szutest, with the power of our technical infrastructure, we closely follow these standards, regulations and their updates, creating a chance for the project owner to take precautions before the project starts.

Thanks to the services we have been providing in the field of product certification for many years, we have managed to transfer the experience we have gained to the inspection activities we carry out in field applications. In this way, by questioning the product-specific conditions in national and international standards, such inspections are needed both to proceed smoothly during the project and to provide the product in the promised quality and to end the project.

What types of inspections are available in this context?

The 3 most critical factors in a project are cost, quality and time. Therefore, we can say that inspection and surveillance activities contribute to these 3 key factors.

To ensure the quality of the product, there are processes in place that require the project to be approved by the relevant 3rd party organization at the design stage. The best examples of this are pressure equipment assessed under the 2014/68/EU Pressure Equipment Directive or steel constructions assessed under the 305/2011/EU Construction Products Directive, which require design approval before the start of production. In such a case, the 3rd party organization performs a design review. The design of the product affects the project and therefore the quality.

The production of non-conforming products and sending them to the assembly site without inspection or approval causes both project delays and unnecessary costs. Companies that do not want to face such problems demand that inspections are carried out and reported during the manufacturing phase of the product by inspection organizations. Since the most critical stage before final assembly is manufacturing, the most frequently requested 3rd party inspection activities are production inspections.

For a product whose design has been approved and production has been carried out in accordance with the specifications, the next stage is related to the transportation of the product to the site without damage and on time. Pre-load surveillance or on-site input control activities are also important, especially when the project deadline is crucial or specific conditions are required during transportation.

Inspections carried out during the assembly or construction phase are also critical to prevent irreversible errors in the final structure. These inspections are also very common. Here, inspection specialists are permanently on site to ensure that the planned progress of the project is not disrupted and that the stipulated technical requirements are checked and regularly reported.

As Szutest; We provide solutions for on-site assembly inspections, including design approval, manufacturing inspection, pre-loading inspection and input control.

Written by İlker Erdinç ELİNÇ

Personal Protective Equipment

Personel Protective Equipments are evaluated under 2016/425/EU Personel Protective Equipment Directive issued by the European Commission. The 2016/425 /EU Personal Protective Equipment Directive has determined three categories: category I, II and III. Products are evaluated and certified according to these categories for conformity. At the end of the successful certification process, the manufacturer has the right to affix CE labels to its products.

Eye Protection Equipment – Goggles and Face Shields

Goggles and face shields that provide eye protection, including droplets and splashes, are evaluated under the EN 166 standard. The EN 166 standard is a harmonized standard under the 2016/425 / EU Personal Protective Equipment Directive and covers products that are mandatory to use the CE mark. The standard has determined both the design features and the material features to be used in the product.

Safety goggles and face shields within the scope of EN 166 standard are considered as Category II products described in the regulation. The certification process for the products in this category is as follows;

EC Type Examination Certification

Module B Certificate

For this, the manufacturer should create a technical document containing all the details of the products’ features. In addition, product samples must be tested in the accredited laboratory of the notified body. ‘EC Type Examination Certificate’ is published after the technical file is approved and the tests are completed successfully. After the process the manufacturer can affix their products CE label. The validity of the certificate is 5 years. If the face shield manufacturer choose the option COVID-19, which the new procedure published by EC for his period, the validity of the certificate is 1 year. There is no COVID-19 option for goggles

The tests to be applied to the face shields within the scope of the COVID-19 option are as follows:

For more detailed information, you can review the regulation or contact Szutest Uygunluk Değerlendirme A.Ş. experts and get information.

Personal Protective Equipment

Personel Protective Equipments are evaluated under 2016/425/EU Personel Protective Equipment Directive issued by the European Commission. The 2016/425 /EU Personal Protective Equipment Directive has determined three categories: category I, II and III. Products are evaluated and certified according to these categories for conformity. At the end of the successful certification process, the manufacturer has the right to affix CE labels to its products.

Protective Clothing Against Infective Agents

EN 14126 standard covers overalls that protect against infective agents and microorganisms. The standard has determined 6 different classes. Depending on how long it protects the person wearing the protective clothing against infective microorganisms, it has determined 6 different classes as follows.

Additional standards are required in the conformity assessment and certification processes for manufacturers that produce according to the EN 14126 standard and have to affix the CE label to their products. EN 14126 standard cannot be used alone. EN 13034 (Clothing That Protects Against Liquid Chemicals) and EN ISO 13982-1 (chemical protective clothing that protects the body against chemical particles emitted by air) are complementary standards of EN 14126 standard and protective clothing must meet the requirements of these standards in the certification process.

Protective clothing within the scope of EN 14126 standard is classified as Category III in the regulation. The certification process for the products in this category is as follows;

1. Step :EC Type Examination Certification

Module B Certificate

For this, the manufacturer should create a technical file containing all the details of the products’ features. In addition, product samples must be tested in the accredited laboratory of the notified body. ‘EC Type Examination Certificate’ is published after the technical file is approved and the tests are completed successfully. The validity of the certificate is 5 years.

2. Step : Module C2 or Module D Certificate

The EC Type Examination Certificate alone does not offer the right to affix CE labels to products. In addition to the Type Examination Certificate, manufacturers who want to attach a CE label to their products must have a certificate according to one of the following options. Manufacturers determine which complementary modules to implement.

1. Option Module C2 Certificate (Conformity to based on internal control of production)

The Notified Body performs the production control stages carried out by the manufacturer regarding the mass production of the products and the inspection and tests carried out at the factory. In addition, in order to ensure the validity of the certificate, the notified body conducts audits at the production facility at least once a year at random intervals.  The validity of the module C2 certificate continues depending on the realization of surveillance audits.

2. Option Modul D Certificate (Conformity to based on the quality assurance of the production)

Manufacturers who prefer to receive certificates according to this module must operate a quality management system. The notified body carries out the inspection of the quality management system applied at the production facility and publishes the certificate after the positive inspection.

In summary, protective clothing manufacturers who want to affix CE labels to their products must have obtained Module B + Module C2 or Module B + Module D certificates. For more detailed information, you can review the regulation or contact Szutest Uygunluk Değerlendirme A.Ş. experts and get information.

Personal Protective Equipment

Personel Protective Equipments are evaluated under 2016/425/EU Personel Protective Equipment Directive issued by the European Commission. 2016/425 /EU Personal Protective Equipment Directive has determined three categories as category I, II and III. Products are evaluated and certified according to these categories. At the end of the successful certification process, the manufacturer has the right to affix CE labels to its products.

Dust Masks

There are two types of masks, which are with and without valves and which protect against dust particles are subject to conformity assessment and certification according to the EN 149 standard, a harmonized standard under this regulation. There is a classification as FFP1, FFP2 and FFP3 in the standard, and the tests in the conformity assessment process are designed and carried out according to which manufacturers choose these classes.

The FFP classification described in the EN 149 standard is as following;

The European Commission has developed a procedure for half filter masks that will be newly documented due to the COVID 19 pandemic. This procedure is a new certification process for half masks with filters during this special emergency period we live in. Masks will only be evaluated to provide protection for the COVID 19 virus. The assessment saves time and money, by considering the EN 149 standard, ignoring all the details that are not required for virus protection. The table below compares the tests to which only masks providing protection for the COVID 19 virus and are subjected to the tests to which all protection types of the EN 149 standard are subjected to.

The World Health Organization has published an informative guide on the use of FFP2 and FFP3 class masks defined in this regulation and the standard, as required by the Covid-19 pandemic precautions. You can find the link of the relevant guide document in the resources section of this article.

Masks covered by the EN 149 standard are considered as Category III products described in the regulation. The certification process for the products in this category is as follows:

1. Step :EC Type Examination Certification

Module B Certificate

For this, the manufacturer should create a technical file containing all the details of the products’ features. In addition, product samples must be tested in the accredited laboratory of the notified body. ‘EC Type Examination Certificate’ is published after the technical file is approved and the tests are completed successfully. The validity of the certificate is 5 years.

2. Step : Module C2 or Module D Certificate

The EC Type Examination Certificate alone does not offer the right to affix CE labels to products. In addition to the Type Examination Certificate, manufacturers who want to affix a CE label to their products must have a certificate according to one of the following options. Manufacturers determine which complementary modules to implement.

1. Option Module C2 Certificate (Conformity to based on internal control of production)

The Notified Body performs the production control stages carried out by the manufacturer regarding the mass production of the products and the inspection and tests carried out at the factory. In addition, in order to ensure the validity of the certificate, the notified body conducts audits at the production facility at least once a year at random intervals.  The validity of the module C2 certificate continues depending on the realization of surveillance audits.

2. Option Modul D Certificate (Conformity to based on the quality assurance of the production)

Manufacturers who prefer to receive certificates according to this module must operate a quality management system. The notified body carries out the inspection of the quality management system applied at the production facility and publishes the certificate after the positive inspection.

In summary, mask manufacturers who want to affix CE labels to their products must have obtained Module B + Module C2 or Module B + Module D certificates. For more detailed information, you can review the regulation or contact Szutest Uygunluk Değerlendirme A.Ş. experts and get information.

Resurces:

2016/425/EU Personal Protective Equipment Regulation

EN 149+A1 Respiratory protective devices – Filtering half masks to protect against particles – Requirements, testing, marking

Link to the guide document published by the World Health Organization https://www.who.int/docs/default-source/documents/advice-on-the-use-of-masks-2019-ncov.pdf

PPE-R/02.075 Usage Suggestion Guide

Third Party Surveillance

Third party surveillance starts from the initial phase of product or project and involves all the process from procurement of materials, production to final examination. As SZUTEST, we report all the procedures of the project via inspection of our technically efficient experts within the frequencies (daily, weekly and monthly) that are specified according to our customers’ needs in accordance with ITP (Inspection Test Plan).

Below are the control procedures in general terms that we execute according to the internationally and/or nationally valid standards throughout our third party examinations which is an accredited service having a wide range of variety.

Document controls;

Examination the projects and contracts: It is one of the most important factors for the success of the project to detect any situation that might cause conflicts on the documents and the parties are needed to be informed on necessary actions.

Examination the procedure and instructions of the supplier: To ensure the corrective actions via informing the parties about the contrasts between company application standards and their own procedures/instructions before the project starts.

Examination the documents on special processes: If there are special processes as welding equipment, soldering iron…etc we test whether the necessities of the standards are met. We control the competence of the crew as well and fix the nonconformities or complete the insufficient tests.

The special processes in general terms are as below:

• PQR, BPQR (The approval of welding and brazing methods.)
• WPC, WOC (The certificate of welders and welding operator)
• Flame straightening
• Flame and cold cutting procedure
• Tighten and torque procedures

The quality and competence documents of the firm: Since the competence of manufacturing and quality systems of the supplier firms have to be proven, we control the documents of the firm and review their competence on manufacturing.

The Control Of Producing;

The control of raw and consumption materials; We control the certificates (EN 10204 standard, specification 2.2, 3.1, 3.2) of the raw and consumption materials that will be used and as SZUTEST we also examine whether those are in accordance with the mechanic-chemical product specification standards that is mentioned on the certificate.

The products are rated according to production standards via visual and dimensional controls. Besides, we examine the stocking and storage areas to make sure if the products are affected from each other or the negative environment conditions.

The calibration control of the measurement tools and equipment: The capacity and operating frequencies of the equipment that are used during the process of production and quality control should be in accordance with the frequency and tolerance signified by the equipment supplier. Besides the measurement equipment must be calibrated by an independent institution and the deviations have to be known beforehand. All the examinations and evaluations must be done considering these deviations.

The controls during production-installation: We control the credibility of the staff, check if the raw and consumption materials are chosen right and whether in accordance with the production methods that are mentioned in the supplier’s own procedures and general standards. In addition, when we detect an inappropriate situation during the production-installation we take the necessary actions for protection and regulations.

Connection processes and connection element controls: Generally, the materials as steel construction, pipelines, pressure vessels and storage tanks are two separate pieces connected by welder, solder or bolt. Welder and solder are permanent connections. There are many parameters of this special process (type of machine, working conditions and staff…etc.) that are needed to be controlled.

Firstly, to make sure if the main and filling materials are suitable for each other and the calculated mechanical value is right, we need to have Procedure Qualification Record (PQR). The transfer of the parameters into production is done via Welding Procedure Specification (WPS) and the competent staff. After the execution, we perform non-destructive tests following the methods and rates mentioned in ITP by using welding or soldering iron. These tests are generally, visual test (VT), magnetics test (MT), penetrant test (PT), ultrasonic test (UT) and radiographic test (RT). The critical steps are; suitability of execution and assessment, the competency of the staff performing the tests and the compliancy of the equipment. Bolted-joint connections are generally done in installation workshop. The mechanics and plating properties of the loaves and the other elements, extrusion method and extrusion value should be controlled.

The last dimensional controls; Dimensional control is a vital step since even a small measurement mistake can cause work loss in the installation workshop which means additional costs. That’s why, we make dimensional controls on the final product and utilize for relevant tolerances, send directly to installation workshop.

The controls of corrosion protection process; The protection of corrosion is an important process because it determines the life or structure of a product. An inapt corrosion protection can cause huge costs afterwards. Generally, corrosion protection methods are; paint, galvanic and coating. (polyethylene, polymer…etc.)

As SZUTEST here are our services for corrosion protection;

Execution Setting Controls; We control the setting which the painting will be done to check whether it has the appropriate temperature and humidity. We also check if it is at the dew point or not.

Visual inspection; The control of the surface on which the application will be done, to see if the surface is purged of residuals of rust, oil, dirt and dust.

Surface roughness tests; The control of the surface by measuring the surface roughness. The aim is checking the suitability of paint’s grain structure and surface roughness.

Salt test; Checking of the salt ratio of the surface to understand if it is in the legal limits.

Dust test; The test for the dust ratio that is attached on the surface which is invisible.

Dry and wet film thickness measurements (WFT, DFT); During the application measuring WFT to see if it reached the right DFT thickness and to prevent work losses. DFT thickness application is done after the paint dries then we test its thickness.

Pull off test; Testing the performance of the cured, dry paint by the pulling test to see at which depth and pressure value it breaks off.

Cross cut test; We check the cured, dry paint surface by cutting the paint cross and using a tape (with the standard specifications) to test the sticking ratio.

Holiday test; It’s a non-destructive inspection method to find out the small holes and spaces that are difficult to see with naked eye.

The control of quality file; It is a filing system which includes all control forms, certificates and test reports…etc. from the beginning to the end. It is important to keep retrospective records in order to inspect the reasons of the possible mistakes or non-compliances by an independent institution.

As Szutest; the standards that we make observations and investigations are as follows:

• EN 1090-2,-3 The production and installation controls of steel and aluminum buildings.
• AWS D.1.1, AWS D.1.2, AWS D.1.5, AWS D.1.6 The production and installation controls of steel and aluminum buildings.
• Pipe production observations suitable for API 5L, EN 10219, EN 10217, EN 10216, EN10222 etc. standards.
• API 650 production of atmospheric storage tanks, installation, controls.
• ASME B31.1, ASME B31.3, ASME B31.4 , ASME B31.5, ASME 31.8 and API 1104 The installation and production controls of the pipe lines.
• The control of valves’ standard suitability controls, impermeability and to supervise the performance tests as in the norms of API6D, API600, AD2000 and EN standards.
• The examination of the equipment and control of the pressure vessels in the standard of EN 13445, EN 12952, EN 12953 EN 13458
• Power Plants (Wind Tribunes, Natural Gas Cycle Power Plants, Thermic and Hydroelectric Power Plants)
• Petrochemistry Plants and Refineries

EN 10204  3.2 Material Certification

Why Is It Necessary To Get EN 10204  3.2 Certification?

It is vital to choose and provide raw materials from reputable suppliers for projects like steel constructions, pressure vessels, storage tanks, pipelines…etc. It is necessary to verify the technical properties, product certificates and test reports before purchasing profiles, pipes, plaques, brackets…etc. Especially when it comes to long distance commerce the certificates that are provided by the producers only could be unreliable. SZUTEST is an independent organization which carries out inspections impartial from the producer and the customer and prepares the EN 10204 3.2 certificate and document of compliance when the results meet the standards. Via our accredited certificate a bridge of trust is built between the producer, buyer and client.

How Does Certification Work?

Firstly, our inspectors control the production process then they take samples, monitor the testings and report the results. We evaluate the results, prepare and publish EN 10204 3.2 certificate of conformity for the ones that in conformance with the necessary product standards. Here are some product standards given in the below which are certified by EN 10204:

• API 5L
• BS 534
• BS 3601
• EN 10217
• EN 10219
• DIN 1626
• EN 10216
• EN 1759
• EN 1092
• EN ISO 3183
• ASTM A 106
• EN 10025
• EN 10028
• ASTM A 36
• ASTM A 53
• EN 10216
• EN 10224
• EN 10255
• EN 10305
• EN 10312