title: sbs quality of materials general requirements … · 2019-08-15 · api source inspector –...

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QUALITY OF MATERIALS GENERAL REQUIREMENTS

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INDEX OF REVISIONS

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Original Issue General Revision

Altered items 4.26, 8.1.1; 8.2.1.1 d); 8.2.2; 8.3.1 a) b) d); 8.3.3; 8.3.6; 9.1.3; 9.4.2; 9.6; 9.6.1; 9.6.4 d); 10.1 a); 11.2.4; 12.1.1; 12.2; 14.5.2.1

Removed items 6.2; 6.2.1, 8.2.1.1 e); 8.3.1 e); 11.2.4.2; 11.2.4.2 Included items 11.2.5; 11.3.2; ANNEX II II.6

REV. 0 REV. A REV. B REV. C REV. D REV. E REV. F

DATE 12/12/2018 29/03/2019 05/08/2019 PROJECT QB QB QB

EXECUTION CSM5 EM1E RNIU CTNR CTMV CSM5 EM1E RNIU CTNR CTMVA50O RNIU CTNR

MF84 UT6E

VERIFICATION UTE9 UTJ6 TW9O SMS8 CTM5 UTE9 UTJ6 TW9O SMS8 CTM5 TW9O UTE9 UTJ6 APPROVAL CXX6 CXX6 CXX6 INFORMATION IN THIS DOCUMENT IS PROPERTY OF PETROBRAS, IT IS PROHIBITED TO USE OUT OF THIS PURPOSE.

THIS FORMULARY BELONGS TO PETROBRAS N-381 REV. L.

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INDEX

1. PURPOSE 3

2. SCOPE 3

3. REFERENCES 3

4. DEFINITIONS, TERMINOLOGIES AND ACRONYMS 4

5. HIERARCHY OF DOCUMENTS 7

6. PERSONNEL QUALIFICATION AND CERTIFICATION 8

7. METROLOGY 8

8. MANUFACTURING INSPECTION 9

9. MANUFACTURING INSPECTION PLANNING 12

10. MINIMUM MANUFACTURING INSPECTION ACTIVITIES 15

11. MANUFACTURING INSPECTION EXECUTION 15

12. RECORDS OF MANUFACTURING INSPECTION 17

13. CERTIFICATE OF CONFORMITY 18

14. QUALITY AUDIT 19

ANNEX I – Guideline for ITP Preparation 22

ANNEX II – Guideline for Issuance of Manufacturing Inspection Records 23

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1. PURPOSE This Technical Specification aims to establish the minimum quality requirements to be met in the supply of materials to PETROBRAS.

2. SCOPE 2.1. This document applies to the corporate materials of the Critical and Strategic segments purchased directly by PETROBRAS. 2.2. This document may be supplemented by Complementary Quality Requirement for a family or group of families of materials. NOTE 1: The list of corporate materials is available for consultation on the Petronect portal (www.petronect.com.br). NOTE 2: The Complementary Quality Requirement applicable to each family of material shall be consulted on the Petronect portal. NOTE 3: The communication with PETROBRAS Quality of Materials Department shall be via e-mail [email protected].

3. REFERENCES 3.1. ISO 9001 - Quality Management Systems - Requirements 3.2. ISO 9712 - Non-Destructive Testing - Qualification and Certification of NDT

Personnel 3.3. ABNT NBR 14842 - Criteria for the Qualification and Certification of Welding

Inspectors 3.4. ABNT NBR 15218 - Criteria for Qualification and Certification of Industrial Paint

Inspectors 3.5. ABNT NBR 15523 - Qualification and Certification of Inspector of Dimensional

Control 3.6. ABNT NBR 16278 - Manufacturing Inspection - Personnel Qualification and

Certification for the Oil and Gas Sector 3.7. ISO/IEC 17020 - Conformity Assessment - Requirements for the Operation of

Various Types of Bodies Performing Inspection 3.8. ISO/IEC 17025 - General Requirements for the Competence of Testing and

Calibration Laboratories 3.9. BSI EN 10204 - Metallic products - Types of inspection documents 3.10. I-ET-0000.00-0000-970-PSQ-001 – Procedure and Personnel Qualification

and Certification NOTE 1: The edition/revision of the documents applicable to the PROJECT will be that defined in the contractual documentation, if not specified, the current

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edition/revision on the date of signature of the contract applies. NOTE 2: PETROBRAS standards referenced above are available on PETROBRAS website (www.petrobras.com.br / Business Channels / Supplier Channel / Technical Standards). NOTE 3: PETROBRAS technical specifications referenced above are available on PETROBRAS website (www.petrobras.com.br / Business Channels / Supplier Channel / Technical Specifications).

4. DEFINITIONS, TERMINOLOGIES AND ACRONYMS The definitions adopted in this document are presented in ABNT NBR 16278. In addition, the following terms are used in this document: 4.1. Document Approval – AD (Aprovação Documental) Event in the manufacturing cycle where document approval (procedure) is required by the Responsible for Manufacturing Inspection before the Execution of the respective activity. 4.2. API American Petroleum Institute. 4.3. API Source Inspector – API SI Manufacturing Inspector certified by API. 4.4. Corporate Material The materials used in PETROBRAS industrial process, whose failure or lack may endanger the safety of people, facilities and/or the environment, influence the operational performance and/or compromise the quality of PETROBRAS final product. Corporate materials shall have Manufacturing Inspection. 4.5. Certificate of conformity Document issued by the Supplier of the material attesting the product's conformity with the contractual requirements. 4.6. Occurrence of Divergence Notice – COD (Comunicado de Ocorrência de

Divergência) Record of technical or commercial divergences between the Supplier and PETROBRAS, with the consequent notification of technical problems or poor performance to the Supplier, based on the quality tools and the International Standard of Quality ISO 9001. The main objectives of COD are eliminate such divergences and prevent their recurrence. However, if the Supplier does not take the necessary actions, it may result in the application of Administrative Sanction or Technical Disqualification.

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4.7. Purchasing Company Company that buys the material. 4.8. ET (Especificação Técnica) Technical Specification 4.9. Family of Materials A set of similar materials, which by their size, manufacturing process and technology involved in their production, are manufactured and/or marketed by a certain set of Suppliers. 4.10. Supplier It is the company that will provide the material directly to PETROBRAS, according to the Contractual Instrument. 4.11. Contract Manager Employee of PETROBRAS, responsible for all contractual subjects. 4.12. Supplier Quality Indicator – IQF (Índice de Qualidade do Fornecedor) Value, between 0 and 100%, resulting from the Supplier's performance after PETROBRAS quality audit. This indicator is related to the family of material and the audited plant. 4.13. Critical Item A component, part of the scope of supply, which failure may cause interruption of operation, damage to the environment or impairment to the safety of persons and facilities, as defined by the Supplier Quality System or Design Standard. 4.14. Lot Set of identical materials, obtained from the same run of raw material and manufactured in a uniform process. 4.15. Monitoring Point (MP) Follow-up of a continuous manufacturing or inspection process in the Supplier's manufacturing cycle where there is no need to notify the Responsible of Inspector of Manufacturing, who may witness it as often as it deems necessary in order to verify its Execution in compliance with contractual procedures and requirements. 4.16. Accredited Inspection Body - AIB Third party company accredited according to ISO 17020 Type A to provide Manufacturing Inspection service.

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4.17. Organization Corporation involved in the supply chain of the material or service scope of the contract and subject to contractual requirements, either as Supplier or Subsupplier. 4.18. Audit Body PETROBRAS Quality of Material Department formally designated to perform the quality audit of materials and the inspection service. 4.19. Purchase Order (PC – Pedido de Compras) Document issued to supply materials and services associated with values, terms and conditions. 4.20. Corrective Action Plan A Plan elaborated by the Supplier, reporting the corrective actions related to identification of the root cause of a nonconformity, to be implemented in its Quality Management System. 4.21. Special Process Process in which the conformity of the final product cannot be readily or economically verified, e.g. welding, forging, casting etc. 4.22. Technical Qualification Documental and/or presential technical evaluation process of a Supplier of materials or services based on a set of requirements and indicators, aiming to demonstrate its manufacturing and technical capacity, tradition of supply and eventual approvals and certifications specific to a particular service or object evaluation. 4.23. Nonconformity Report – NCR (RNC - Relatório de Não Conformidade) Inspection record issued by the Quality System of the Organization according to the precepts of ISO 9001. 4.24. Informative Report - Registration of Nonconformity – IR-NCR (RI-RNC -

Relatório de Inspeção – Relatório de Não Conformidade) Inspection record issued by the Responsible for Manufacturing Inspection to report any deviation from the contractual requirements observed during the manufacturing process not identified by the Supplier Quality Control. Shall be issued for rejection of intermediate inspection events. NOTE: This inspection record does not follow the provisions of ISO 9001. The treatment of nonconformity shall be provided by the Organization to respond to the contractor according to the Quality System implemented.

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4.25. Complementary Quality Requirement Document issued by PETROBRAS that complements and overlaps this General Quality Requirement for the families of materials specified therein. NOTE: Families of Materials of and their Complementary Requirements are available on the Petronect Portal. 4.26. Responsible for Manufacturing Inspection – RIF (Responsável pela

Inspeção de Fabricação) Individual or legal entity designated to coordinate, plan and execute the Manufacturing Inspection. For Suppliers required to hire an Inspection Body, RIF is the actual contracted Inspection Body. 4.27. Material Requisition – RM (Requisição de Material) PETROBRAS document describing the scope of supply. 4.28. Manufacturing Inspection Service Service provided by Accredited Inspection Body in the Execution of Manufacturing Inspection activities. 4.29. Subsupplier It is the company chosen and qualified by the Supplier to provide the material or components of the materials and/or services. 4.30. Shall As used in this document, "shall" denotes a mandatory requirement. 4.31. Should As used in this document, "should" denotes a recommendation or that which is advised but not mandatory.

5. HIERARCHY OF DOCUMENTS When not specified in contract, the documents follow the hierarchy below in decrescent order: 1. Material Requisition (RM), Technical Specifications (ET), Data Sheet (FD),

Drawings (DE), Circular Letters, Technical Norms and other documents of the bidding process;

2. Complementary Quality Requirements; 3. Materials Quality General Requirement. In case of conflict among requirements of contractual documents, the Supplier shall issue a request for clarification to PETROBRAS Contract Manager.

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6. PERSONNEL QUALIFICATION AND CERTIFICATION

6.1. Certification of Inspectors 6.1.1. Except in cases required by Standard or contractual document, the activities of Welding, Dimensional Control, Non-Destructive Testing and Painting should be inspected by certified personnel by the National System of Qualification and Certification of Personnel (SNQC), in compliance with the Qualification and Certification Regulations listed below:

a) Welding Inspection: ABNT NBR 14842; b) Inspection of Dimensional Control: ABNT NBR 15523; c) Inspection by Non-Destructive Testing: ABNT NBR NM ISO 9712; d) Painting Inspection: ABNT NBR 15218. NOTE: If these activities are carried out by non-certified professionals, the Supplier shall keep the training and qualification records of the professional of the respective activity.

6.1.2. The mandatory requirement of certified inspectors, as above, will be indicated in the respective Complementary Quality Requirement of the applicable family of material or any other technical specification. 6.1.3. For Suppliers abroad, I-ET-0000.00-0000-970-PSQ-001 presents certifications equivalent to describe in 6.1.1.

7. METROLOGY 7.1. The calibration of the test and measurement instruments used should be carried out in laboratories accredited according to ISO/IEC 17025, in accordance with the scope of the calibration service performed or using the standard traceable to International Laboratory Calibration Network that participates in programs of recognition of competence. Internal laboratories may be used since the procedures fully comply with the standards applicable to the performance of the tests and/or calibration. 7.2. The requirements of ISO 9001 shall be met, especially, but not limited to, the following: 7.2.1. The Supplier shall have a calibration and maintenance control of the instruments used, demonstrating the periodicity of calibration according to the normative criteria.

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7.2.2. The Supplier shall evaluate and ensure that the measurement uncertainty of the calibration standards used in its process and the Subsupplier meets the design requirements. 7.2.3. All monitoring, control and recording systems (software and hardware, transducers, sensors, registers etc.) shall be calibrated and certified at specified intervals or before use.

8. MANUFACTURING INSPECTION 8.1. General 8.1.1. The Supplier shall contract the a AIB, except when it is not required to contract under item 8.3, in which case the Supplier shall maintain a RIF to perform and record all required Manufacturing Inspection activities. NOTE: Supplier assigned as Reseller or Distributor, the AIB may be contracted by Manufacturer.

8.1.1.1. The AIB or RIF, as applicable, is responsible for the release of the material, through the issuance/approval of the CLM (Comunicado de Liberação de Material), which is equivalent to the MRN (Material Release Notice). In case of rejection, a Rejection Notice, CRM (Comunicado de Rejeição de Material), shall be issued. MRN will not be subject of approval by PETROBRAS Quality of Materials Department.

8.1.2. The hiring of the Inspection Service does not release the responsibility of the Supplier for the quality of the materials supplied, including items purchased from Subsuppliers. 8.1.3. The responsibility for the Planning and Execution of the Manufacturing Inspection is always attributed to an AIB, except when provided in item 8.3, that AIB can be replaced by RIF. 8.1.4. The Supplier is responsible for transmitting all contractual technical specifications to the Responsible for Manufacturing Inspection to perform the necessary verifications in order to attest the conformity of the materials provided to the one established in the contractual instrument. 8.1.5. This Materials Quality General Requirement and the Complementary Quality Requirement, when applicable, shall form part of the scope of the contract between the Supplier and the AIB/RIF.

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8.2. Requirements of Manufacturing Inspection Service 8.2.1. The service of Manufacturing Inspection shall be performed by an Accredited Inspection Body according with ISO/IEC 17020 Type A contracted by the Supplier.

8.2.1.1. In case of AIB according with ISO/IEC 17020 Type A is not available, when hiring the Inspection Service, the Supplier shall guarantee the fulfillment of the following premises:

a) Certification of the Inspection Body according to valid ISO 9001, whose

scope shall be Manufacturing Inspection; b) Signature of a Impartiality and Independence term between the Supplier

and the Inspection Body under the premises of ISO/IEC 17020; c) Availability of Inspector of Manufacturing certified according to ABNT NBR

16278 or API SI in the modalities and levels applicable to the scope of the inspection. Other similar certifications, issued by independent bodies, internationally recognized, shall be submitted to prior approval of PETROBRAS Quality of Materials Department;

d) Record of Technical Responsibility at Engineering or Technical Council. This record shall contain, at least, the contract(s), scope and purchase order(s) to be inspected. Each record may contain many contracts or purchase orders, but only one Supplier.

8.2.2. Supplier shall maintain the original inspection records, paper or electronic files, for, at least, 5 years. 8.2.3. Inspection records issued by the Manufacturing Inspector shall be prepared according to section 12 and Annex II, identified and signed.

8.2.3.1. The identification of the professional shall contain at least the full name, certifications, registration number in the certifying entity and company to which he is associated.

8.2.4. The Responsible for Manufacturing Inspection shall issue a CLM (MRN) to attest the conformity of the material with the contractual requirements. 8.3. Dispensation of Hiring the AIB for a Family of Material 8.3.1. The Supplier may be waived of hiring an AIB, as required by items 8.1 and 8.2, if the following criteria are fully met:

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a) IQF average of 97.0% or more in the last 3 complete audits or holding API Monogram active for the material to be supplied or holding a Classification Society certificate, member of IACS (International Association of Classification Societies), for the material to be supplied;

b) Absence of untreated Technical COD; c) Absence of IR-NCR or CRM (Material Rejection) reporting High or Severe

Nonconformities in the last 12 months; d) Specific criteria can be provided in the Complementary Quality Requirement

applicable to the respective family of material.

8.3.2. The release of hiring an AIB requires the maintenance of a RIF, which shall carry out all required Manufacturing Inspection activities. 8.3.3. The RIF shall issue/approve the CLM (MRN) upon the release of the material and other records of Manufacturing Inspection. 8.3.4. The waive of hiring an AIB applies to the family of material and plant audited. It shall be formalized by PETROBRAS Quality of Materials Department.

8.3.5. This exemption from the hiring of the AIB does not exempt the Supplier from issuing the documents, executing and recording the inspections and meetings required by this Quality Requirement, as well as the Complementary Quality Requirement, which shall be included in the Quality System and be available for audit at anytime.

8.3.6. Upon obtaining such waiving, the Supplier shall maintain the above premises for its maintenance. In case of missing any premises, the Supplier shall hire an AIB within 30 days at its own expenses, during this period any delivery shall be approved by the contract manager of PETROBRAS.

8.3.7. If the Supplier obtains IQF less than 90.0% in subsequent audits to the granting of the waive, Supplier shall hire an AIB within 30 days, at its exclusive expenses, during this period any delivery shall be approved by the contract manager of PETROBRAS.

8.3.8. If the Supplier obtains IQF between 90.0% and 96.9% in audits subsequent to obtaining the release, it will have a period of 180 days to adjust its Quality System, i.e., to obtain IQF equal or greater than to 97.0 % in the next quality audit of materials. If IQF is not obtained above 97.0%, it shall contract AIB, at its exclusive expense, within 30 days, without prejudice to contractual conditions.

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9. MANUFACTURING INSPECTION PLANNING 9.1. Inspection and Testing Plan - ITP 9.1.1. Inspection and Testing Plans (ITP) shall be issued by the Supplier and shall comply with the Quality Requirements and other documents defined in the contract and/or purchase order, including all the production processes, installation and services associated with the supply. Annex I presents a Guidelines for the preparation of the ITP in order to assist in its preparation. 9.1.2. Inspection and Test Plans shall be issued prior to commencement of manufacturing activities to meet the following guidelines: a) Description of the inspection and monitoring events throughout the

manufacturing process, including those performed in the Subsuppliers, indicating the verifications to be carried out, the type and extent of the exams, tests and verifications;

b) Identification of the type of participation (document approval, document review, monitoring point, witness point and hold point) of the manufacturer and of the Responsible for Manufacturing Inspection throughout the manufacturing cycle;

c) Indication of the necessary qualification and certification for personnel performing the inspection, exams, testing, checking and special production processes;

d) Indication of procedures, technical specifications and standards applicable to each activity and level of reference quality (API Q1 or API PSL2, for example);

e) Indication of the documents to be approved by the Responsible for Manufacturing Inspection, as defined in this Materials Quality General Requirement and Complementary Quality Requirement, when applicable;

f) Indication of the acceptance criteria applicable to all characteristics and quality requirements of each activity, as established in the procedures, technical specifications and applicable standards;

g) Identification and preparation of quality records, indicating the type of record applicable to the respective activity. Use the nomenclature defined in EN 10204 for inspection record type.

9.1.3. The Inspection and Testing Plan shall be approved by the Responsible for Manufacturing Inspection.

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9.2. Guidelines for ITP preparation 9.2.1. The steps indicated in the table in Annex I shall be detailed in the description field and numbered in the item field. 9.2.2. The ITP shall list contractual technical specifications and documentation such as Material Requisition (RM), Technical Specifications (ET), Data Sheet (FD) and Quality Requirements. 9.3. Execution, Inspection and Testing Procedures 9.3.1. Procedures considered critical by the Responsible for Manufacturing Inspection shall be approved by RIF. 9.3.2. PETROBRAS Quality of Materials Department may request, at any time, the submission of procedures considered critical. 9.3.3. The Responsible for Manufacturing Inspection shall ensure that the procedures deemed critical to the supply comply with the Quality Requirements and other contractual technical requirements. This verification shall appear as an activity in the ITP and be recorded in the Inspection Report. 9.4. Procedure Qualification 9.4.1. The required inspection, exams and testing procedures shall have the qualified procedure, according to the contractual premises, with witnessing and approval of certified professional when required for the activity. 9.4.2. If previously qualified procedures are used, their adequacy to the design shall be endorsed by a certified professional, when required. 9.5. Sampling Inspection 9.5.1. When not established in the Complementary Quality Requirement, technical specifications or applicable standards, PETROBRAS Quality of Materials Department shall be consulted regarding the authorization for Execution of the Sampling Manufacturing Inspection.

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9.6. Pre Inspection Meeting (PIM) 9.6.1. Pre inspection meeting (PIM) shall be held with the participation of the Responsible for Manufacturing Inspection and Supplier. 9.6.2. The participation of the Quality of Materials Department shall be at the discretion of PETROBRAS and shall be notified at least 10 calendar days in advance for national supplies and 30 calendar days for international supplies, with ITP and production schedule of the material attached. 9.6.3. The agenda and draft minutes of the PIM shall be distributed for comment of the participants in the act of notifying the meeting. 9.6.4. The PIM shall include at least the following objectives: a) Presentation of the organizational chart, communication channels and contacts

and responsibilities of the parties involved; b) Presentation of the Responsible for Manufacturing Inspection, including the

certification of the professionals involved; c) Ratification of the scope of supply and technical requirements applicable; d) Establishment of deadlines (notifications, inspection attending, issuance of

reports etc.), flow of communication and notification of inspection; e) Clarification of doubts about technical requirements of manufacture and

possible deviations from technical documentation; f) Planning of manufacturing, assembly and testing, including Subsuppliers; g) Presentation of the Inspection and Test Plan (ITP) – establish the participation

of the parties in relation to the manufacturing stages, inform Subsuppliers, certificates/reports and tests that shall be included in the ITP and the types of interventions to be performed (AD, HP, WP, RD and MP) by the Responsible for Manufacturing Inspection and Classification Society;

h) Define procedures to be analyzed for compliance with contractual requirements; i) Systematic for registration and treatment of Nonconformities; j) Clarification of statutory and regulatory compliance requirements (regulatory

standards) and those of the organization; k) Availability of quality records during manufacturing for the inspection team; l) Presentation of HSE guidelines adopted at the plant; m) Presentation of the Information Security guidelines adopted at the plant,

including restrictions on photographic registration (NOTE: the Responsible for Manufacturing Inspection shall be authorized to photographically register the inspected materials);

n) Presentation of all documents and records evidencing the acceptance of deviations from the technical requirements and concessions signed between PETROBRAS Contract Manager and the Supplier, for direct and indirect

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purchases, from the proposal stage.

10. MINIMUM MANUFACTURING INSPECTION ACTIVITIES

10.1. The minimum activities, to be carried out by the Responsible for Manufacturing Inspection, are defined below, and shall be complemented according to the respective Quality Requirements and approved ITP:

a) Analysis and approval of the Inspection and Testing Plan; b) Approval of documents as provided in the Quality Requirements; c) Verification of raw material certificates and quality records; d) Verification during manufacturing (personnel qualification and certification,

methods and manufacturing processes, intermediate controls and tests); e) Testimonial of hydrostatic and/or pneumatic, functional and/or performance

tests, when applicable; f) Execution of the visual inspection, testimony of the final dimensional

examination and PMI, when applicable; g) Verification of the data book and technical documentation; h) Issuance of Inspection Records; i) Identification, preservation and packaging.

NOTE: The AIB shall evaluate its participation during manufacture, (d), considering the complexity of the material and the manufacturing process. 10.2. The AIB shall detail its participation in the manufacturing activities upon the approval of the ITP in order to ensure the conformity of the material with respect to the contractual documentation.

11. MANUFACTURING INSPECTION EXECUTION 11.1. All Manufacturing Inspection activities required in the approved ITP shall be indicated in the Inspection Records issued by the RIF. 11.2. Nonconformity Treatment 11.2.1. When receiving an IR-NCR or CRM from RIF, the Supplier shall issue its own NCR, according to the Implanted Quality System, to address deviations pointed out in the IR-NCR or CRM. 11.2.2. When issuing IR-NCR or CRM, the RIF shall indicate the degree of deviation in Light, Medium, High or Severe, according to the criteria established in Table 1.

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11.2.3. When issuing an NCR, the Supplier shall indicate the degree of deviation in Light, Medium, High or Severe, according to the criteria established in Table 1. 11.2.4. All NCRs classified as High or Severe shall be immediately sent to Contract Manager and Quality of Materials Department at PETROBRAS. 11.2.5. The Supplier shall send to PETROBRAS Quality of Materials Department the corrective actions regarding to NCRs indicated in item 11.2.4 within 5 business days of issuance and further results of corrective actions.

Table 1: Matrix to indicate the degree of the detected deviation. Deviation Degree

Nonconformity Characteristic

Light Nonconformity with the Supplier Quality System, whose implication does not affect the performance of the equipment, which may affect the contractual term, or generate reinspection.

Medium Nonconformity observed in the Equipment, with the possibility of correction through a Contractual Standard, which may imply in the term, or generate reinspection.

High

Nonconformity in the Equipment, with compromise of the intrinsic quality, performance of the equipment and without possibility of correction through a Contractual Standard, which may affect the contractual term, or generate reinspection.

Severe Nonconformity related to bad faith, adulteration of document or component identification by Supplier or its supply chain.

11.3. Technical Documentation of Manufacture - Data Book 11.3.1. All the documents that make up the data book shall have the approval of the Supplier evidenced by identification and signature. Supplier approval may be evidenced by electronic systems that ensure traceability and reliability. 11.3.2. The Supplier shall provide a data book containing all documents mentioned on ITP and applicable technical specification. 11.3.3. The section quality and manufacturing of the data book shall be verified and approved, as a Hold Point in the ITP, by the Responsible for Manufacturing Inspection before shipment of the equipment. The Responsible for Manufacturing Inspection shall certify all the documents reviewed through identification and signature or electronic systems that guarantee the traceability and reliability.

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11.3.4. Throughout the manufacturing process, the Supplier shall keep available for the Responsible for Manufacturing Inspection all quality and inspections records performed in previous steps as required in the Inspection and Test Plans. 11.3.5. The raw material certificates shall be in accordance with BS EN 10204 type 3.1, not being accepted certificates of resellers and distributors. If material certificates according with BS EN 10204 type 3.1 are not available, qualification tests of the material will be acceptable by means of witnessing of the RIF. 11.4. Access of the Inspector to Material Scope of Supply 11.4.1. The Supplier shall ensure free access of the Responsible for Manufacturing Inspection to all components and manufacturing facilities related to the supply or manufacture of the material upon request. 11.4.2. The RIF shall always have free access to all manufacturing areas where manufacturing and inspection activities are performed on the material scope of supply. 11.4.3. The Responsible for Manufacturing Inspection shall be authorized to obtain a photographic record of the inspected materials. In case of restriction of the use of cameras, by third parties, in the manufacturing plants, the Supplier shall provide the required photographic record to the RIF.

12. RECORDS OF MANUFACTURING INSPECTION 12.1. The Responsible for Manufacturing Inspection shall issue the inspection records (IR, IR-NCR, CLM or CRM) for all the events with its participation, as indicated in the ITP, according to the type of intervention defined (AD, HP, WP, RD and MP). 12.1.1. The inspection records CLM (MRN), CRM (Rejection), and IR-NCR shall be issued within 7 days the inspection is completed. 12.2. Once all the steps of the Manufacturing Inspection have been completed with satisfactory results, the RIF shall issue the CLM (MRN), according to model on ANNEX II, attesting the conformity of the equipment with the contractual technical documentation. 12.3. Inspection Records (IR, IR-NCR, CRM and CLM) shall contain at least the following information:

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a) Report number; b) Order number or purchase order; c) Item of the purchase order; d) Quantity inspected; e) Date or period of the inspection event; f) Identification of the Supplier and manufacturer, in case of Subsupplier; g) Purpose; h) Description, identification and traceability of the property and its inspected

components (tag, serial number etc.); i) Reference documents used in the inspection; j) List of Annexes; k) Stage (s) of ITP; l) Description of the activities developed, and parameters evaluated; m) Process stage (before, during or after manufacture); n) Result of the inspection: satisfactory or unsatisfactory; o) General notes, in the case of additional clarifications; p) Identification of Manufacturing Inspector of RIF, including signature,

registration number in the certification body, level and modality of certification;

q) Identification of the person responsible for Supplier Quality, including signature, attesting to the receipt of the issued registration;

r) Distribution list of report; s) Location of the activity; t) Nonconformity Characteristics (only for IR-NCR and CRM); u) Photographic records.

NOTE: Nonconformity Characteristic: When issuing an IR-NCR or CRM, the Manufacturing Inspector shall indicate the degree of deviation detected in Light, Medium, High or Severe, as established in Table 1. 12.3.1. ANNEX II provides a Guidelines for Issuance of Manufacturing Inspection records.

13. CERTIFICATE OF CONFORMITY 13.1. All materials supplied shall have the Certificate of Conformity issued according to BSI EN 10204 type 2.1. 13.2. The Certificate of Conformity shall contain at least:

a) Supplier's logo; b) Information of the Supplier (name, address and number);

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c) Identification of the Purchasing Company (name, address and number); d) Number of Purchase Order; e) Item of Purchase Order, quantity and its description; f) Serial number and/or TAG of the equipment; g) Date of issue; h) Declaration of conformity to contractual documents; i) Approval of the Quality Control Manager; j) Approval of the RIF; k) Number of the Homologation and/or Naval Certification registry, when

applicable

14. QUALITY AUDIT 14.1. General 14.1.1. During the supply of the equipment, PETROBRAS Quality of Materials Department may perform presential audits at the Suppliers and Subsuppliers facilities or remote method at PETROBRAS premises, through the analysis of technical documentation sent by the Supplier, with the Purpose to verify compliance the quality management system, the manufacturing process, the product and the records issued by the RIF.

14.1.1.1. PETROBRAS Quality of Materials Department shall communicate the performance of the audit with 30 calendar days in advance, together with the list of documents that shall be available within 10 calendar days of the communication. Failure to comply with the aforementioned deadlines constitutes a breach of contract, subject to the application of a fine.

14.1.1.2. During the audit, Organization shall provide an appropriate room for the audit team, with an air-conditioned environment and data network.

14.1.2. PETROBRAS Quality of Materials Department reserves the right to audit, at any time, the application and maintenance of the requirements defined in this document at the Suppliers, Subsuppliers, Inspection Bodies and Manufacturing Inspectors involved in the supply. 14.1.3. The periodicity of the audits will be defined by PETROBRAS Quality of Materials Department, considering, among other aspects, the criticality of the material for the operation, the complexity of the manufacturing process, the Supplier's history and the market in which it operates, the occurrence of failures on site, pioneering design and unprecedented supply.

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14.1.4. Supplier's representative shall take part in Quality Audit at Subsuppliers. 14.2. Responsibility for Quality Audits PETROBRAS Quality of Materials Department will be responsible for planning and performing presential and/or remote audit, at the Supplier and Subsupplier, the compliance checks regarding the contractual requirements during the supply of the material. 14.3. Scope of the Quality Audit The Quality Audit in the Supplier and Subsupplier shall include the following aspects: 14.3.1. Quality Management System: verification of compliance with the contractual requirements of the Organization's Quality Management System, as well as the requirements of ISO 9001. 14.3.2. Material Manufacturing Process: verification of compliance with contractual requirements in the manufacturing process of the material, such as manufacturing procedures, inspection and testing, quality meeting minutes, inspection and tests records generated during manufacturing, among other documents required by the Quality Requirements. 14.3.3. Final Product: verification of conformity in relation to the contractual requirements of the finished product. 14.3.4. Responsible for Manufacturing Inspection: verification of compliance with the requirements of this Quality Requirement and the Complementary Quality Requirement (when applicable), such as issuance of inspection records, participation in manufacturing events and performance with independence and impartiality. 14.4. Execution of the Quality Audit 14.4.1. PETROBRAS Quality of Materials Department will carry out an opening meeting on the first day of the audit, with the participation of the auditing team and the Supplier Quality representatives. 14.4.2. Subsequent audits may have reduced scope with Purpose to focus on deviations detected in the previous audit.

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14.4.3. During the audit, the audited organization shall designate a focal point to provide all requested documentation, evidence the attendance of each item of verification and make available the resources demanded by the audit team to verify compliance with the contractual requirements. 14.4.4. PETROBRAS Quality of Materials Department will carry out a closing meeting of the audit with the presence of the audit team and the representatives of the Quality of the Organization, when they will be informed the points of improvement and nonconformities observed in each phase. 14.5. Records of the Quality Audit 14.5.1. At the end of the closing meeting, minutes will be issued where the points of improvement and Nonconformities identified in each phase will be informed, for the signature of all participants. 14.5.2. The audit report, containing the findings of the audit team, including IQF, with the respective evidence, will be forwarded to the Supplier within 15 calendar days after the end of audit.

14.5.2.1. The Supplier, upon receipt of the audit report, may submit an appeal to the findings of PETROBRAS Quality of Materials Department.

14.5.3. To obtain a maximum grade in IQF, items 6.1.1 and 7.1 shall be met. 14.6. Control and Monitoring of Nonconformities 14.6.1. The Organization shall submit to PETROBRAS Quality of Materials Department a Corrective Action Plan to mitigate all Nonconformities observed in the audit within 15 calendar days of receipt of the final audit report. 14.6.2. The Corrective Action Plan shall contain the proposed actions, scope, implementation deadlines and Supplier Quality Focal Points responsible for each proposed action. 14.6.3. The Corrective Action Plan shall be submitted to PETROBRAS Quality of Materials Department for review and approval, which will respond within 15 calendar days. 14.6.4. PETROBRAS may verify the effectiveness of the Corrective Action Plan implemented at any time.

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ANNEX I

Guideline for ITP Preparation

STAGE ITEM DESCRIPTION RECORD REFERENCE DOCUMENT

ACCEPTANCE CRITERIA

INTERVENTIONS NOTES

FA MI

Documentation

Inse

rt s

eque

ntia

l num

berin

g of

insp

ectio

n ac

tiviti

es in

the

orde

r of

exe

cutio

n

Drawings, procedures, welding plans, personnel qualification, etc.

Def

ine

the

type

of r

ecor

d to

be

issu

ed b

y th

e m

anu

fact

urer

for

the

resp

ectiv

e ac

tivity

List

sta

ndar

ds, p

roce

dure

s, te

chni

cal s

peci

ficat

ions

app

licab

le to

thei

r ac

tivity

. R

epor

t edi

tion

and

revi

sion

of d

ocum

ents

.

Info

rm th

e ite

ms

of th

e st

anda

rds,

pro

cedu

res,

tech

nica

l spe

cific

atio

ns a

pplic

able

to th

eir

activ

ity.

Indi

cate

the

part

icip

atio

n of

the

man

ufac

ture

r's Q

ual

ity C

ontr

ol (

docu

men

t app

rova

l, do

cum

ent r

evie

w, m

onito

ring

poin

t, w

itnes

s po

int a

nd h

old

poin

t).

Indi

cate

the

part

icip

atio

n of

the

RIF

or

AIB

in th

e a

ctiv

ities

of i

nspe

ctio

n an

d te

sts

(do

cum

ent a

ppro

val,

docu

men

t re

view

, mon

itorin

g po

int,

witn

ess

poin

t and

hol

d po

int)

. In

clud

e an

y ad

ditio

nal i

nfor

mat

ion

requ

ired

Raw material and Qualification of welding procedures, NDE, tests etc.

Receiving Inspection for plates, forgings, tubes, consumables etc.

Inspections, exams, tests during manufacturing

Relate inspections, examinations, tests and tests throughout manufacturing

Heat treatment for stress relief

Full or partial Equipment, oven or located

Factory Acceptance Tests

Production, hydrostatic, leak, functional, performance, etc.

Post-test Inspection

Relate inspections and exams after final tests

Painting and Coating

Surface preparation, controls during the application and inspections, tests and assays

Final inspection PMI, Visual, Dimensional and Inspection Records

Material Release

Spare parts, packaging, conditioning, data book etc.

Subtitles: FA (Fabricator): Manufacturer MI (Manufacturing Inspection): RIF or AIB

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ANNEX II

Guideline for Issuance of Manufacturing Inspection Records

The content proposed below applies to issue any type of Manufacturing Inspection record. NOTE: The itemization and assigned titles are merely exemplary and may be replaced by others that best represent reality in each inspected process. Report Topics

II.1 - Inspected Material: Identify, with as much information as possible, the actual inspected material. It is essential to refer information that is marked on the material in an indelible form. If this is not possible, the material shall be punctured with the seal of the inspector. Here are some examples: - Name of the equipment/material inspected (mainly when referring to a part or component of an item of the order); - Identification with low stress puncture; - TAG and Dimensions (diameter, length, thickness, width etc.); - PROJECT reference; - Other references (serial number, process fluid, etc.). NOTE: In case of documentation review, the Inspected Material will be considered the one to which this documentation refers. II.2 - Activities Developed: Describe all the activities developed during the period in which the inspection was performed and the participants of the event. Here are some examples: - Analysis of documentation; - Testimony of Tests and Assays; - Monitoring of manufacturing; - Other analyzes and checks. II.3 - Results: Describe the result obtained in relation to "Item II.2 - Developed Activities". NOTE1: In the case of an IR (Informative Inspection Report), describe as satisfactory the inspections performed and in the case of IR-NCR describe the deviations observed with the appropriate contractual references. NOTE2: This item may be deleted if the result of each activity developed is described in "Item II.2 - Developed Activities".

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II.4 - Conclusion: Report the conclusion regarding the acceptance of the inspection event based on the results found and the impact of these results in relation to the Manufacturing Inspection process, when applicable. In addition to the results found, information on the impact of this result on the manufacturing process shall be included, such as: - In the case of IR, report that the material will go to further phase and a new notification of inspection shall be made for next inspection step, when applicable. - In the case of IR-NCR, inform the deviation issues that shall be treated before a new notification of inspection, or other pertinent information, is issued. II.5 - Notes: Present, where applicable, other information regarding the inspection performed, for example: - Supplier's NCR closing or any type of pending event from previous reports; - The monitoring of inspection by a 3rd party, Classification Society, User of the equipment, among others; - User requests for equipment serviced by the Inspection Service; - Other remarks. II.6 Models of Inspection Report: The Supplier may use the following models of inspection report to be issued by RIF (RI, RI-RNC, CLM and CRM).

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MODEL OF INSPECTION REPORT

FORNECEDOR NÚMERO DO PEDIDO

SUB-FORNECEDOR REFERÊNCIAS DA CONTRATADA XXXXXX Nº DO CONTRATO

ORDEM INTERNA LOCAL DA INSPEÇÃO CONVOCAÇÃO DE INSPEÇÃO

PESSOA DE CONTATO NO FORNECEDOR

NOME XXXX SETOR XXXX

ORGÃO REQUISITANTE PERÍODO DE INSPEÇÃO

XX/XX/XXXX a XX/XX/XXXX

Deve ser indicado o período de início e fim do(s) evento(s) descritos no relatório

ENTREGA PARCELADA PERMITIDA MATERIAIS / EQUIPAMENTOS

ITEM QUANTIDADE TIPO DESCRIÇÃO

DOCUMENTOS DE REFERENCIA ANEXOS

PIT PEDIDO NORMA 1 NORMA 2 Devem ser incluídos os documentos de referência para as atividades descritas. Exemplo: PIT, Normas referentes aos eventos descritos, etc.

DOCUMENTO ANALISADO 1 DOCUMENTO ANALISADO 2 CARTA GRÁFICA DO TESTE 1 FOTO 1 No caso de RI para análise de documentos (PIT, EPS, etc) deve ser anexado o documento. Poderão também ser anexados documentos gerados durante o evento que foi acompanhado (exemplo: arquivo de resultados de teste, fotos, etc)

ASSUNTO Deve ser indicado o(s) evento(s) do relatório. Exemplos: ANÁLISE DE PIT ANÁLISE DE EPS TESTE HIDROSTÁTICO RECIBEMENTOS INSPEÇÃO VISUAL TRATAMENTO DA RNC nº ABCD-00000000111222333/2013

RELATÓRIO

1 OBJETIVO: Descrever de forma clara o objetivo do relatório detalhando o equipamento inspecionado. Análise do Plano de Inspeção de Testes do Equipamento XXXXX – Rastreabilidade YYYYYYYY Acompanhamento do FAT do Equipamento XXXXXXX Inspeção visual – detalhes 2 MATERIAL Detalhar o equipamento Equipamento XXXXX – Rastreabilidade YYYYYYYY Características zzzzz 3 ATIVIDADES DESENVOLVIDAS: Atividade 1: XXXXXX (descrição RESUMIDA da atividade. Exemplo: Análise de data book; Acompanhamento de testes funcionais; Inspeção dimensional, Inspeção Visual Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (SATISFATÓRIO) Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração Observações: XXXXX (informações relevantes) Atividade n: XXXXXX (descrição RESUMIDA da atividade. Exemplo: Análise de data book; Acompanhamento de testes funcionais; Inspeção dimensional, Inspeção Visual Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (SATISFATÓRIO) Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração Observações: XXXXX (informações relevantes)

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4 CONCLUSÃO Todas as atividades acima citadas apresentaram resultados satisfatórios.

RESPONSÁVEL PELAS PROVIDÊNCIAS PRAZO PARA SOLUÇÃO

ESTÁGIO DA INSPEÇÃO


INSPETOR

QUALIFICAÇÃO NÚMERO DE REGISTRO NA CERTIFICADORA

DISTRIBUIÇÃO

FORNECEDOR EMISSOR APROVADOR APROVADOR PETROBRAS

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MODEL OF RI-RNC








Deve ser indicada a data de identificação da Não Confomidade



DOCUMENTOS DE REFERENCIA ANEXOS PIT PEDIDO NORMA 1 NORMA 2 Devem ser incluídos os documentos de referência para as atividades descritas. Exemplo: PIT, Normas referentes aos eventos descritos, etc. É importante incluir o documento que define a justifica a Não Conformidade (Exemplo: norma que deixou de ser atendida).

DOCUMENTO ANALISADO 1 DOCUMENTO ANALISADO 2 CARTA GRÁFICA DO TESTE 1 FOTO 1 No caso de RNC para análise de documentos (PIT, EPS, etc) deve ser anexado o documento. Deverão ser anexados, sempre que possível, evidências do desvio (exemplo: arquivo de resultados de teste, fotos, etc)

ASSUNTO Deve ser indicado o(s) evento(s) do relatório. Exemplos: ANÁLISE DE PIT ANÁLISE DE EPS TESTE HIDROSTÁTICO RECEBIMENTO INSPEÇÃO VISUAL

RELATÓRIO

1 OBJETIVO: Descrever de forma clara o objetivo do relatório. Análise do Plano de Inspeção de Testes do Equipamento XXXXX – Rastreabilidade YYYYYYYY Acompanhamento do FAT do Equipamento XXXXXXX Inspeção visual – detalhes 2 MATERIAL Detalhar o equipamento Equipamento XXXXX – Rastreabilidade YYYYYYYY Características zzzzz 3 ATIVIDADES DESENVOLVIDAS: Atividade 1: XXXXXX (descrição RESUMIDA da atividade. Exemplo: Análise de data book; Acompanhamento de testes funcionais; Inspeção dimensional, Inspeção Visual Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (INSATISFATÓRIO) Desvios identificados: XXXXXX Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração Observações: XXXXX (informações relevantes) Atividade n: XXXXXX (descrição RESUMIDA da atividade. Exemplo: Análise de data book; Acompanhamento de testes funcionais; Inspeção dimensional, Inspeção Visual Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (INSATISFATÓRIO) Desvios identificados: XXXXXX Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração

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Observações: XXXXX (informações relevantes) 4 CONCLUSÃO As atividades acima citadas não apresentaram resultados satisfatórios.




INSPETOR


DISTRIBUIÇÃO


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MODEL OF CLM (MRN)














ASSUNTO Deve ser indicado o(s) evento(s) do relatório. Exemplos: INSPEÇÃO FINAL

RELATÓRIO

1 OBJETIVO: Descrever de forma clara o objetivo do relatório Inspeção Final do Equipamento XXXXX 2 MATERIAL Detalhar o equipamento Equipamento XXXXX – Rastreabilidade YYYYYYYY Características zzzzz 3 ATIVIDADES DESENVOLVIDAS: Atividade 1: XXXXXX (descrição detalhada da atividade contendo todas as informações pertinentes e rastreabilidade dos componentes inspecionados e documentos verificados, se for o caso) Exemplo: Análise de data book; Acompanhamento de testes funcionais; Inspeção dimensional, Inspeção Visual Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (SATISFATÓRIO) Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração Observações: XXXXX (informações relevantes) Atividade n: XXXXXX (descrição detalhada da atividade contendo todas as informações pertinentes) Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (SATISFATÓRIO) Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração Observações: XXXXX (informações relevantes) 4 DESVIOS TÉCNICOS ACEITOS Desvio: XXXXXXXXXXXXXXXX descrever o desvio (exemplo: falta do teste YYY, dimensão XXX difere da ET) Ações corretivas e mitigadoras aplicadas: as atividades acima descrever as ações corretivas e mitigadoras relacionadas ao desvio (exemplo: Realizado teste XXXX em substituição ao previsto contratualmente) Risco: Os desvios não implicam em aumento do risco de falha do(s) equipamento(s) Não devem ser aceitos desvios que implicam

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em aumento do risco de falha do(s) equipamento(s) 5 CONCLUSÃO Todas as atividades acima citadas apresentaram resultados satisfatórios. Ou O material está liberado tendo em vista os resultados das atividades e a aceitação dos desvios técnicos indicados acima.




INSPETOR


DISTRIBUIÇÃO


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MODEL OF CRM (Rejection Notice)














ASSUNTO Deve ser indicado o(s) evento(s) do relatório. Exemplos: INSPEÇÃO FINAL

RELATÓRIO

1 OBJETIVO: Descrever de forma clara o objetivo do relatório Inspeção Final do Equipamento XXXXX 2 MATERIAL Detalhar o equipamento Equipamento XXXXX – Rastreabilidade YYYYYYYY Características zzzzz 3 ATIVIDADES DESENVOLVIDAS: Atividade 1: XXXXXX (descrição detalhada da atividade contendo todas as informações pertinentes e rastreabilidade dos componentes inspecionados e documentos verificados, se for o caso) Exemplo: Análise de data book; Acompanhamento de testes funcionais; Inspeção dimensional, Inspeção Visual Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (SATISFATÓRIO ou INSATISFATÓRIO) Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração Observações: XXXXX (informações relevantes) Atividade n: XXXXXX (descrição detalhada da atividade contendo todas as informações pertinentes) Documentos de referência: XXXXXXX Item(ns) do PIT referente ao(s) evento(s): XXXXXX Resultado: XXXX (SATISFATÓRIO ou INSATISFATÓRIO) Instrumentos utilizados: XXXXXX indicar os instrumentos utilizados e suas condições de calibração Observações: XXXXX (informações relevantes) 4 CONCLUSÃO O material está REJEITADO considerando o(s) resultado(s) INSATISFATÓRIO(S) apontados no item 3.



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INSPETOR


DISTRIBUIÇÃO


title: sbs quality of materials general requirements … · 2019-08-15 · api source inspector –...

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