Building ITP

Understanding Inspections
and Test Plan

Agenda for this presentation

Need for this presentation.

Definition of ITP and QAP.
Purpose of ITP and what does it deliver.
ITP document Template analysis.
Summary

Importance to ITP

Clients may ask TPI to certify ITPs submitted by vendors making them more responsible for the
assignment.
Clients may want ITPs to be verified for correctness submitted by the vendor.
Clients may ask for ITP submission in order to verify TPIs understanding on the inspection
assignment.
Building ITPs could be discussed during the pre bid meetings and the TPI organizations will be
shortlisted to bid after technical qualifications.
A correctly organized and methodically documented ITP will allow the inspection engineer to
deliver services to the expectations of the client.

What is an ITP/QAP and QA/QC

AnInspection and Test Plan (ITP)or test plan is a document detailing a systematic approach to
testing a system or product(e.g. material, component, machine, package, software, etc) such as a
visual inspection, dimension inspection, welding inspection, function test, factory acceptance test,
etc. and participation of all parties.

A Quality Assurance Plan (QAP) generally involves a process for rejection until improvements
have been made. This discussion is outside the scope of this presentation.

Whats QA/QC
QA is process oriented Activity while QC is product Oriented Activity
QA is an proactive activity and is done before the product is manufactured or services are delivered.
QC is an reactive activity and is done during or after the manufacturing process.
QA focuses on prevention of defects to improve quality.
QC focuses on detection of defects to improve quality.

ITP

Purpose

The purpose of an Inspection and Test Plan is to put together a single document that records all
inspection and testing requirements relevant to a specific process.
Why do we need to make a test plan?
Guarantee the product quality and ensure the product function achieved the requirement of design.
ISO 9001:2008 Clause 7.4.3 Verification of purchased product requires that the organization shall
establish and implement the inspection or other activities necessary for ensuring that purchased product
meets specified purchase requirements.
Where the organization or its customer intends to perform verification at the suppliers premises, the
organization shall state the intended verification arrangements and method of product release in the
purchasing information.

What does the ITP Deliver?

Inspection and Test Plans, when properly implemented, help ensure that, and verify whether, work
has been undertaken to the required standard and requirements, and that records are kept.
An Inspection and Test Plan identifies the following:
a. The items and work to be inspected or tested.
b. Testing Authority and stages or frequency of testing.
c. Identifies Hold and Witness Points.
d. Identifies references to relevant standards.
e. Define acceptance criteria and the records to be maintained.

Quote taken from Alstom Project quality Plan Document

Inspection and Test Plans

Before commencement of work including site work, Contractors or Subcontractors shall supply ITPs
for their scope of work for approval and shall incorporate the elements of ITP Guidelines as a
minimum and shall form a requirement of the purchase order. All ITPs shall be technically reviewed
by the appropriate engineer and quality officer and approved by the Project Manager.
*Alstom could approve appoint a third party agency for taking responsibility for ensuring purchased
product or services meet the specified requirements. In that context the appointed organization
which is usually a TPI will have to review and approve the ITP submitted by the contractors or sub
contractors.
Visit following url for complete document:
http://www.alstom.com/Global/Australia/Resources/Documents/Supplier%20and%20contractor%20
information/A01.F07%20Project%20Quality%20Plan%20REV%20E.pdf
.

Documenting Test plan

Documenting the test plan(s) has multiple uses, such as:

Assuring conformance to customer requirements

Assuring conformance to external and internal standards and procedures

Facilitating traceability. ( from Raw material procurement testing till finished Product FAT , standards
and drawings))

Providing objective evidence. (Quality)

Preparing ITP. guideline

Read contract document and list requirements and technical

specifications.
Read Scope of work and divide in to areas of inspections and
separate ITPs if required. For example: in-process and
finished goods inspection or packaging inspections.
Make a note of hold and witness points required by customer
and make a note of consequences of action.
Make certain that the ITP covers major elements like: Test
Coverage, Tests methods and tests responsibilities and
intervention points by the customer and or the TPI agency.
Make certain that the ITP lists Customer name, Project Name
and contract number and or purchase order details .

Test coverage
Test coverage in the test plan states what
requirements will be verified during what
stages of the product life.
Test methods in the test plan state how
test coverage will be implemented. Test
methods may be determined by
standards, regulatory agencies, or
contractual agreement, or may have to
be created new. Test methods also
specify test equipment to be used in the
performance of the tests and establish
pass/fail criteria.
Test responsibilities include what
organizations will perform the test
methods and at each stage of the product
life. This allows test organizations to plan,
acquire or develop test equipment and
other resources necessary to implement
the test methods for which they are
responsible.

Documents which have mention in ITP.

Purchase Order or Contract.

Manufacture Quality Control Plan.(if required in final dossier or in process inspection)
Approved Data Sheet.
Approved Drawings. (arrangements, schematics, wiring, single line).
Procedures and Procedure Qualification Records (if applicable e.g. welding).
Material Test Reports.
National or international specifications.
Manufacturer Standards (approved by client)
The ITP shall be version controlled and approved by the responsible.

ITP for site in process installations should reflect Project Quality, Risk and Safety Management Plans.

Terminologies in ITP

Hold point(H): Hold on the production till TPI Inspector performs inspection and supervises the required test.
In general, attendance to the PIM meeting, raw material inspection and identification, Post Weld Heat
Treatment Review, Hydrostatic Test, Performance Test, Run-Out Test and Final Inspection are Hold points.
Witness Point (W): The manufacturer shall notify the client and TPI Inspector, but there is no hold on the
production. The client can waive this inspection based on its discretion and inform the TPI Inspector.
Spot Witness (SW): for items with spot witness, the manufacturer shall notify the TPI inspector as fulfilling
the monitoring. For example one random visit for all of the UT Tests or one or two visits for whole surface
preparation work for painting.
Review (R): Review means Review document, which includes the review of quality control records, test
reports, etc

Basic ITP Template.

Example of ITP

Typical ITP

Summary.

An efficiently drafted testing plan will ensure that all the activities as
requested by client are carried out in order and also ensures necessary
quality is obtained in the resulting products or services. These also include
checking for the workmanship and conformance in accordance with the
relevant standards.