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.
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