Chapter 16: Documentation, Calibration & QA Records

 

Chapter 16: Documentation, Calibration & QA Records

This chapter focuses on the importance of documentation, calibration of instruments, and maintaining QA records to ensure traceability, reliability, and compliance in mechanical projects, especially fabrication, machining, and EPC environments.

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🔍 1. Importance of QA/QC Documentation

Ensures traceability of materials, processes, and inspections.

Aids in third-party audits, client inspections, and certifications.
Protects both company and client in case of defect claims or legal disputes.
Enables continuous improvement through data analysis and review.

📄 Common Documents:

Material Test Certificates (MTCs)

Welding Procedure Specification (WPS)
Procedure Qualification Records (PQR)
Inspection and Test Plans (ITP)
Non-Conformance Reports (NCR)
Final Dossier (QA/QC file submitted at project handover)

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⚙️ 2. Instrument Calibration

Calibration ensures that measuring tools give accurate and reliable readings.

Instruments must be calibrated as per manufacturer guidelines or international standards (e.g., ISO 17025).

🔧 Calibration Examples:

Instrument	Calibrated For	Frequency
Vernier Caliper	Length accuracy (±0.02 mm)	Every 6 months
Pressure Gauge	Pressure range accuracy	Annually
Welding Machine	Voltage & Amperage Output	Every 3–6 months

🔍 Calibration Certificates Must Include:

Instrument ID & serial number

Standard used for calibration
Date of calibration & due date
Technician’s signature

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📋 3. Inspection and Test Records (ITR)

• Part of the QA file, showing compliance at each stage of production or construction.

• Includes details of:

  • Incoming raw material checks

  • In-process and final inspections

  • NDT results

  • Witnessed tests by third-party inspectors

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🧾 4. Final Dossier Compilation

A comprehensive project QA document handed over to the client, containing:

Approved drawings

MTCs, WPS, PQR
Inspection records, NDT reports
NCR and corrective action reports
Calibration records

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🏭 Field Example:

At a power plant project, a flange leak caused delays because the torque wrench used had not been calibrated in 18 months. Investigation found over-tightening due to a misreading. If the calibration certificate had been checked, the failure and cost overrun could have been avoided.

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✅ Key Standards Referenced:

• ISO 9001:2015 – Quality Management System

• ISO 17025 – Calibration and testing laboratories

• API Q1/Q2, ASME Section V & IX (for welding/NDT records)

Chapter 16: MCQs – Documentation, Calibration & QA

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Q1. What is the primary purpose of QA/QC documentation?
A) To increase the size of the final report
B) To ensure traceability and demonstrate compliance
C) To confuse auditors
D) To save paper
🟩 Correct Answer: B

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Q2. Which of the following is not typically part of a QA/QC dossier?
A) Approved Drawings
B) Welding Procedure Specification (WPS)
C) Calibration records
D) Purchase orders
🟩 Correct Answer: D

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Q3. Calibration ensures:
A) Speed of welding
B) Tools are accurate and reliable
C) Reports are long
D) Tools remain new
🟩 Correct Answer: B

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Q4. Which international standard governs calibration laboratories?
A) ISO 9001
B) ISO 45001
C) ISO 17025
D) ISO 14001
🟩 Correct Answer: C

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Q5. The tool used to measure torque should be calibrated:
A) Every day
B) Only when it breaks
C) At regular intervals (e.g., 3-6 months)
D) After painting
🟩 Correct Answer: C

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Q6. Which document shows the outcome of quality inspections at each stage?
A) NCR
B) ITP
C) ITR (Inspection & Test Record)
D) MSDS
🟩 Correct Answer: C

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Q7. Which of the following is an example of a non-conformance report (NCR)?
A) Welder ID list
B) Pressure test certificate
C) Report identifying wrong material used in fabrication
D) Inspection checklist
🟩 Correct Answer: C

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Q8. What key detail should a calibration certificate include?
A) Inspector's age
B) Date of calibration and next due date
C) Welding speed
D) Project budget
🟩 Correct Answer: B

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Q9. Final QA Dossiers are usually submitted:
A) At the start of the project
B) When the contract is signed
C) At project handover to client
D) When procurement starts
🟩 Correct Answer: C

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Q10. If an uncalibrated pressure gauge is used, the likely risk is:
A) Perfect pressure readings
B) Legal compliance
C) Inaccurate readings and potential failure
D) Fast completion
🟩 Correct Answer: C