Ⅰ. OBJECTIVE
The requirements established herein are complementary to the General Requirement for the Quality of Goods. In case of conflict, this Inspection Requirement prevails.
Ⅱ. Inspection Planning And Execution
2.1 General Conditions for Manufacturing Inspection
The steps listed below must be defined as minimum waiting points by the person responsible for the manufacturing Inspection, and must be detailed in the PIT:
a) Pre-manufacturing inspection.
b) Post-manufacturing inspection.
c) Factory acceptance tests.
d) Final inspection.
e) Verification of all manufacturing records provided for in the PIT, including non-conformity reports issued throughout the manufacturing, assembly, and testing process.
For this manufacturing inspection, the modality of action for the certified professional, according to NBR 16278 is IF-PP. Alternatively, IF-CT can be adopted for nipples and IFAT for flanges.
2.2 Inspection And Testing Plan
The SUPPLIER must prepare an Inspection and Testing Plan (ITP) and issue it for approval by the Person Responsible for Manufacturing Inspection.
The ITP must follow the standards established by ISO 9001, ET-0000.00-0000-972-1AL-001, and this Inspection Requirement.
The ITP must ensure the compatibility of the equipment to be supplied with the project, procedures, and contractual documentation.
En SUPPLIER must identify in the ITP the extent of its monitoring in inspection events at SUB-SUPPLIERS.
This Inspection Requirement addresses the minimum items that must be verified during the manufacturing inspection of the hoses.
2.3 Documentation
The SUPPLIER must provide all documentation, procedures, certificates, and applicable standards necessary for monitoring by the Person Responsible for Manufacturing Inspection.
The procedures must contain the respective acceptance criteria referencing the respective standard or guide. These must be submitted for analysis and approval by the person responsible for manufacturing inspection. The procedures must follow what is established in the OCIMF/GMPHOM 2009 guide and other referenced standards.
2.4 Inspection prior to manufacturing
2.4.1 Analysis Of Documents – Drawings, Certificates, Procedures, And Qualifications.
The following documents must be analyzed by the person responsible for manufacturing inspection, when applicable to the project:
a) Certification of NDT inspectorsb) Certification of painting inspectors.
c) Certification of dimensional inspection inspectors.
d) Qualification and adaptation of the inspection procedure by non-destructive testing by a level 3 inspector in the respective technique.
e) Qualification and adaptation of the painting procedure to the project by a painting inspector.
f) Dimensional examination procedure qualified by a dimensional examination inspector
g) Procedure for identification, transfer, and control of traceability of materials.
h) Procedure for controlling non-conformity reports (RNC). The RNCs must be presented to the person responsible for manufacturing inspection, containing the manufacturer’s opinion on the corrective actions to be taken, before their execution and, subsequently, their closing.
i) Drawings released for manufacturing.
j) Non-destructive testing procedures.
k) PMI procedure.
l) Reaming procedure.
m) Testing procedures.
n) Delta ferrite content examination procedure.
o) Procedure for applying internal and/or external coating.
p) Report template for dimensional examination, indicating dimensions and respective tolerances.
q) Procedure for performing stress relief heat treatment.
r) Procedure for draining, cleaning, and drying the equipment after testing.
s) Procedure for pickling, passivation, and inerting.
t) Calibration certificates for instruments to be used in inspection and factory tests using standards traced to the Brazilian calibration network or similar when the vessel is manufactured abroad.
u) Plate straightening procedure.
v) Conditioning, shipping, transportation, and storage procedures.
w) Indication of devices/equipment, including the required accuracies, to obtain quality, in the verification of critical dimensions, operation, and performance tests.
2.4.2 Prototype
Verify that appropriate prototype tests are valid during the manufacturing period.
2.4.3 Materials
Review the documentation associated with the material tests, verifying adherence to the established procedure, the frequency of testing, and whether the results were satisfactory.
2.4.4 Flanges
Check that the flanges are of the specified type.
Check the pressure class of the flange, that the manufacturer’s identification is clearly visible, together with the batch number, which must be fully traceable to the manufacturer’s test certificate.
Check that the anti-corrosion coating complies with the purchase order requirements and that the flange faces are not damaged.
2.4.5 Nipples
Check that the tube or sheet metal forming the nipple, as well as all other materials used for its manufacture, are fully traceable in relation to their respective material certificates.
Check that the dimensions and surface condition of the nipples are in accordance with the specifications, as well as the wall thickness measurement. Confirm that the results are in the nipple manufacturer’s test certificate.
Check that all procedures, specifications, and qualifications related to welding are in accordance with the applicable standards.
Check that all radiographs of the longitudinal welds in nipples made from sheet metal are correct.
And all circumferential welds of the flange/nipple joint are in accordance with the procedures.
2.4.6 Nipple Preparation
Special attention should be given to surface preparation to ensure the absence of any grease or other substances that could compromise the chemical bond between the elastomer and the steel.
Check that the various bonding agents used to prepare the nipples are within their specified shelf life and are applied in accordance with the Manufacturer’s instructions, and that the subsequent application of elastomer-based compounds is carried out within the permissible times.
Check that the permissible times between the preparation of the nipple and its subsequent incorporation into a hose are not exceeded.
2.4.7 Mandrel Preparation
Check that the mandrel is clean and free from any imperfections, dents, scratches, or other significant surface defects that could result in damage to the hose coating during removal from the mandrel.
Any elastomer found adhered to the mandrel after its extraction should be investigated to ensure and confirm that the coating has not been torn or damaged during removal from the mandrel.
Check that the release agent is applied uniformly to that part of the mandrel on which the hose will be manufactured. If, while the releasing agent is being applied, adequate precautions are taken to ensure that the prepared nipples are not contaminated by the agent.
2.5 Inspection After Manufacture
The person responsible for manufacturing inspection shall check the manufacturing documentation of the hose, confirming that it was manufactured in accordance with the relevant specification and procedures.
Full traceability of the materials used in the manufacture of the hose shall be verified.
2.5.1 Acceptance Tests
Before the start of the acceptance tests, the person responsible for manufacturing inspection shall check:
a) If the configuration of the ends of the bundle is in accordance with the specifications.
b) If the dimensions of the hose are in accordance with the specifications requested in the purchase order and are within the specified tolerances.
c) If the weight of the hose is in accordance with the specifications.
d) If the calculated buoyancy reserve, when applicable, is in accordance with the specifications in the purchase order.
Acceptance tests must be performed according to the OCIMF/GMPHOM 2009 guide. The person responsible for manufacturing inspection must monitor the factory acceptance tests, as follows:
2.5.1.1 Minimum Bend Radius Test
During the test cycles and also with the hose straight, there must be no evidence of breakage, kinking, ovalization, separation of the outer layer, or separation of the material from the buoyancy layer.
2.5.1.2 Flexural Stiffness Test
The average value of the flexural stiffness of the hose must be calculated.
2.5.1.3 Hydrostatic Test
During the test of each hose, the presence of leaks must be checked. The values of temporary or permanent elongations must be measured and verified to determine if they are within the tolerance.
2.5.1.4 Vacuum Test
During the vacuum test of each hose, the person responsible for the Manufacturing Inspection must check for evidence of bubble formation, layer detachment, adhesion failure, or other defects in the hose.
2.5.1.5 Electrical Test
Each hose must be tested to measure its electrical properties. The electrical resistance must be in accordance with the specifications in relation to the request in the purchase order.
2.5.1.6 Test Of Lifting Eyes
It must be verified that all lifting eyes were manufactured from the specified materials and tested under satisfactory conditions of use. After testing, verify that all welds have been 100% inspected by the Magnetic Particle method in accordance with applicable standards.
2.5.1.7 Hydrostatic Testing of Floats
When floats are supplied together with hoses, the Manufacturing Inspector must review the certification related to the hydrostatic testing of the floats.
2.6 Quality Records
The SUPPLIER must keep the following quality records available for review by the Manufacturing Inspector:
a) Certificates of raw materials or components.
b) Report on receipt of materials and equipment, which must comply with a system of traceability of parts with their certificates.
c) Reports of non-destructive tests provided for in the PIT and IEIS.
d) Reports of non-conformities containing the respective manufacturer’s opinion, corrections, corrective and preventive actions.
e) Technical consultations.
f) Reports of dimensional examinations.
g) Reports of destructive tests.
h) Certificates of welding consumables.
i) Records of execution of stress relief heat treatment.
j) Test report.
k) Reports of inspections of the application of the coating, detailing the preparation of the surface, each layer applied, as well as results regarding thickness, adhesion, and mapping of the retouched regions.
2.7 Data Book
The SUPPLIER must issue a Data Book for each hose containing at least the following information:
a) Description of the hose and procedures.
b) Prototype certificate.
c) Certificate of hose testing by the SUPPLIER.
d) Material certificate.
e) NDT and Welding and Qualification procedures.
f) SUPPLIER material test reports.
g) Adhesion test report.
h) Vulcanization procedure.
i) Hydrostatic tests.
j) Galvanization reports.
k) Accessories certificate (if necessary).
l) Lifting eye test certificate (if necessary).
m) Certificate of acceptance by the person responsible for manufacturing inspection.
The Data Book must be approved by the person responsible for manufacturing inspection.
Ⅲ. Handling, Preservation, Storage, And Shipment
The handling, preservation, storage, and shipping of hoses must be carried out in accordance with OCIMF2009 Standard N-2169 – Maritime Hoses – Handling, Packaging, Transportation and Storage (N-2169 translated will be supplied later)