1.0  GENERAL

Total Quality is the “Watch Word” of the work and SMART AUTOMATION (SMART means specific; Measurable; Attainable; Realistic; Time-bound) shall strive to achieve the highest quality standards for Instrumentation Erection contract works.

• SA provides services of a Quality Assurance Engineer.
• SA ensures that all their staffs comprise of highly experienced and should be exposed to a carry-out high Quality Instrumentation Erection Contract Works.
• SA ensures that the quality is maintained in all the works connected with the contract at all stages.
• SA ensures that all Inspection, Measuring and Testing Equipment that are used are calibrated by some authorized agency and the valid calibration certificate remains available for verification by the Customer.
• SA arranges inspection of the works at various stages as required by the Customer; also an immediate corrective action is taken by SA for the non-conformances if observed.

2.0  INSPECTION / QUALITY ASSURANCE / QUALITY CONTROL / STATUTORY INSPECTION

Various Inspection/Quality Control/Quality Assurance Procedures/Methods at various states of Erection and Commissioning shall be as per the Guidelines for QUALITY, SAFETY and PRODUCTIVITY.

• SA prepares Quality Assurance Log Sheets and Protocols, Welding Logs and other Quality Control and Quality Assurance Documentation.
• The Protocols between SA and the Customer shall be made prior to installation for correctness of foundations, materials, procedures, at each stage of installation, generally as per the requirement of the Customer.
• A daily log book is maintained by every Supervisor/Engineer of SA on the job in duplicate (one for the Customer and one for SA).
• High Pressure welding details like serial number of weld joints, welders name, date of welding, details of repair, heat treatment, etc. are documented in welding log.
• Record of radiography containing details like serial number of weld joints, date of radiography, repairs, etc. are also maintained.
• Heat treatment details of HP welds indicating minimum temperature recorded, heating rate, cooling rate, soaking time, etc. are also recorded and documented.
• SA ensures speedy alignment and welding of all equipment erected and completes all tests required for inspection as per Quality Assurance procedures.
• Any minor rectification or repair of defective work found during inspection is rectified free of cost by SA.

3.0  IMPULSE LINES

• All impulse lines burrs and air lines shall be thoroughly cleaned before installation.
• Routing of pipelines shall include sufficient flexibility for thermal expansion.
• Pipes shall be cold bent using hydraulic bending machines only.
• Horizontal impulse lines shall be laid with proper slopes.
• Supports for piping shall be adequate and shall not exceed limits:
  1. 1/4" OD / 3/8" OD SS/Copper Tube – Continuous
  2. 1/2" NB Pipe/Tube – 5'
  3. 1/4" NB Pipe/Tube – 5'
  4. 1" NB Pipe/Tube – 8'
• All CS impulse line welding shall be done using welding generator/rectifier.
• Impulse lines of alloy steel / SS shall be TIG welded.
• Minimum number of fittings shall be used wherever possible.

4.0  ELECTRICAL CABLING / WIRING

• All cables will be laid in cable trays, dressed and clamped properly and terminated with suitable lugs and ferrules.
• All electrical connections shall be tested for polarity.
• Insulation test of circuits shall be done.
• Checking of operation of individual equipment shall be carried out.
• GI cable trays shall be of bolted construction.
• Sharp bends of cable trays shall not be provided.
• Installation of cable racks and support structures shall be done in all areas:
  1. Ladder perforated trays for trenches and risers.
  2. Perforated trays for higher elevations.
• Cable racks shall be shared with other contractors wherever required and SA shall cooperate fully.

5.0 INSTRUMENTS AND EQUIPMENTS

• Field instruments positioned for easy access and maintenance.
• Racks and supports fixed on PCC or steel structures.
• Power cylinders aligned and connected properly.
• Transmitters mounted as per service requirement.

6.0 GUIDELINES FOR HANDLING SOLID STATE MODULES

• Handled only by qualified persons.
• Static discharge ensured before handling.
• Use of anti-static bags mandatory.
• Soldering tools properly grounded.

7.0 GUIDELINES

• Commissioning assistance provided till contract completion.
• Qualified personnel provided round the clock.
• Testing, calibration and troubleshooting included.

8.0 INSTRUMENTATION CONTROL / PANELS / CUBICLES / DESKS

• Unloading and storage in covered areas.
• No jerks or impacts during handling.
• Inspection after unloading.

9.0 STORAGE

• Stored in original packing until installation.
• Protection against moisture, fumes and termites.
• Periodic inspection records maintained.

10.0 OUR SAFETY PROCEDURES ARE AS FOLLOWS

• No smoking or lighters allowed inside refinery.
• Work permits mandatory in hazardous areas.
• Proper housekeeping maintained.
• Accidents reported immediately.