spencermandClaude Fable 5.1
00531cb329
The Q.C. screen (KPIs, boards, project folders), the Q.C. tab on the packet page (check items from the qc_check_items settings row, visual exam per weld, NDE, hardness with the NACE label, notes), accept with a route and a signature gated by qc_missing_empty, reject with a reason or an NCR number closing the inspection into qc_history, Q.C. folder documents per project and unit with superseding revisions, packet documents as a closed set with take-out reasons, the digital ITP per unit from the frozen template (line initials with CAS, unsign, N/A, customer codes, rejects with NCR, block signatures, sign-off with the PDF hook, admin reopen, the ITP log), hold-point warnings by department page group, the scoped policy check for unit and project writes, migration 0007, tests, Playwright scenarios and docs. Co-Authored-By: Claude Fable 5.1 <[email protected]>
660 lines
28 KiB
Python
660 lines
28 KiB
Python
"""The Q.C. ITP template, ITP_Generation_Revised_2.
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Copied verbatim from the old build's src/js/itp.js line 4 (ITP_TMPL), which Q.C. took from the workbook
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ITP_Generation_Revised_2.xlsm (COP Template sheet). Starting an ITP freezes a copy of it into itps.template, so a
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later change here never alters an ITP already in use.
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Sections: n, t (title), page (WP Weld Parts, C Code, FA Final Assembly), sig (a QN # / remarks / PESCO Q.C. signature
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block follows the section), final (the last block, COP complete) and items. Items: n, t (title), code (the PESCO
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code), cust (the customer code), crit (acceptance criteria).
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"""
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from __future__ import annotations
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from typing import Any
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ITP_TEMPLATE: dict[str, Any] = {
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"ver": "ITP_Generation_Revised_2",
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"legend": "O = Observe R = Review A = Approve I = Inspect AU = Audit W = Witness (Hold) "
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"H = Hold NA = Not Applicable",
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"sections": [
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{
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"n": "1",
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"t": "GENERAL FABRICATION and DATA",
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"page": "WP",
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"sig": False,
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"items": [
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{
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"n": "1.1",
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"t": "Material Test Reports",
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"code": "R",
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"cust": "R",
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"crit": "MTR chemistry and mechanical properties meet PO/material spec; heat "
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"numbers on MTR match material received. (API Q1 5.5.3, 5.6.5 / ISO 9001 "
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"8.4.2, 8.5.2)",
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},
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{
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"n": "1.2",
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"t": "Welding Procedures",
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"code": "A",
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"cust": "R",
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"crit": "WPS/PQR qualified per ASME IX and approved before use; current revision "
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"matches the weld map assignment. (API Q1 5.6.3 / ISO 9001 8.5.1)",
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},
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{
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"n": "1.3",
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"t": "Welder Qualifications Records",
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"code": "A",
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"cust": "R",
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"crit": "Welder current on the qualified welder log for the process, position and "
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"material used; qualification not expired. (API Q1 4.3.2 / ISO 9001 7.2)",
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},
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{
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"n": "1.4",
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"t": "QA/QC Manual",
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"code": "A",
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"cust": "R",
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"crit": "Manual reflects current API Q1 / ISO 9001 requirements and is the "
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"controlled, released revision. (API Q1 4.4 / ISO 9001 7.5.3)",
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},
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{
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"n": "1.5",
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"t": "Weld Map(s)/Fabrication Drawings",
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"code": "A",
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"cust": "R",
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"crit": "Released revision used; as-built weld numbers, WPS and welder ID recorded "
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"on the map before the final documentation package is assembled. (API Q1 "
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"5.6.3, 5.6.5 / ISO 9001 8.5.2)",
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},
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{
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"n": "1.6",
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"t": "Radiographic Testing and Reports",
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"code": "R",
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"cust": "R",
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"crit": "RT reports reference weld map location and heat number; results accepted "
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"to governing code/spec; technician currently certified. (API Q1 5.6.9.4 / "
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"ISO 9001 7.1.5, 8.5.2)",
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},
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{
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"n": "1.7",
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"t": "Ultrasonic Testing and Reports",
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"code": "R",
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"cust": "R",
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"crit": "UT reports reference weld map location and heat number; results accepted "
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"to governing code/spec; technician currently certified. (API Q1 5.6.9.4 / "
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"ISO 9001 7.1.5, 8.5.2)",
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},
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{
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"n": "1.8",
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"t": "Hydrostatic Testing and Reports",
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"code": "A",
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"cust": "R",
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"crit": "Test pressure and hold time meet code/spec; no leaks or pressure drop; "
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"gauges in current calibration. (API Q1 5.6.9.3, 5.8)",
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},
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{
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"n": "1.9",
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"t": "Pneumatic Testing and Reports",
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"code": "R",
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"cust": "R",
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"crit": "Used only where hydrotest is not permitted by code/client spec; test "
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"pressure and hold time meet code/spec; mark NA if hydrotest performed.",
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},
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{
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"n": "1.10",
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"t": "Insulation Application and Test Reports",
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"code": "O",
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"cust": "R",
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"crit": "Insulation type and thickness per spec; test reports (where required) "
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"meet the acceptance values in the spec.",
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},
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{
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"n": "1.11",
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"t": "Nonconformance Reports (NCR/QN Log)",
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"code": "R",
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"cust": "R",
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"crit": "All QNs/NCRs from this build are dispositioned and closed, or carried to "
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"the customer as an open item before shipment; concessions are "
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"customer-approved. (API Q1 5.9 / ISO 9001 8.7)",
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},
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{
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"n": "1.12",
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"t": "Export Packing Plan",
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"code": "R",
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"cust": "R",
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"crit": "Packing plan meets PO, ISPM-15 and destination country requirements.",
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},
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{
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"n": "1.13",
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"t": 'Certified "As-Built" Data and Drawings',
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"code": "A",
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"cust": "R",
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"crit": "As-built drawings match the final fabricated configuration; all field "
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"changes/redlines incorporated and approved.",
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},
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{
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"n": "1.14",
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"t": "Nameplate/Tagging Etching/Stenciling",
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"code": "R",
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"cust": "R",
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"crit": "Nameplate data matches the approved drawing/data sheet and code stamp (if "
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"applicable); stamped/etched by a qualified person.",
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},
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],
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},
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{
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"n": "2",
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"t": "STRUCTURAL",
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"page": "WP",
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"sig": False,
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"items": [
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{
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"n": "2.1",
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"t": "Structural Fit-up/Dimensional Check prior to Weldout",
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"code": "I",
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"cust": "R/AU",
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"crit": "Fit-up dimensions per approved drawing tolerance; heat numbers "
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"transferred from mill cert to cut members; welder ID/WPS recorded against "
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"the weld map before weld-out. (API Q1 5.6.5 / ISO 9001 8.5.2)",
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},
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{
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"n": "2.2",
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"t": "Post Welding Dimensional Check",
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"code": "I",
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"cust": "R/AU",
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"crit": "Final dimensions within drawing tolerance; visual weld quality meets AWS "
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"D1.1 (or governing code) acceptance criteria.",
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},
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{
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"n": "2.3",
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"t": "Interface Structural and ICP Dimensional Locations",
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"code": "I",
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"cust": "R/AU",
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"crit": "Interface/ICP dimensional locations within drawing tolerance; verified "
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"and recorded before release to the next department.",
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},
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],
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},
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{
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"n": "3",
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"t": "PIPING",
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"page": "WP",
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"sig": True,
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"items": [
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{
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"n": "3.1",
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"t": "Visual Quality Inspection",
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"code": "O",
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"cust": "R/AU",
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"crit": "Welds free of surface defects (undercut, porosity, cracking) per code "
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"acceptance criteria; weld map and heat numbers current.",
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},
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{
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"n": "3.2",
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"t": "Post Welding Dimensional Check",
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"code": "O",
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"cust": "R/AU",
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"crit": "Dimensions and alignment per isometric/drawing tolerance.",
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},
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{
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"n": "3.3",
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"t": "Ultrasonic, Radiographic and Magnetic Particle Testing and Reports",
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"code": "R",
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"cust": "R/AU",
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"crit": "NDE method and extent per code/spec; results reference weld map location "
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"and welder ID; NDE technician currently certified. (API Q1 5.6.9.4 / ISO "
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"9001 8.5.2)",
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},
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{
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"n": "3.4",
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"t": "Final inspection/Hydrostatic test",
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"code": "A",
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"cust": "W",
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"crit": "Test pressure and hold time per code/spec; no leaks or pressure drop; "
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"witnessed where required by the PO. (API Q1 5.6.9.3)",
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},
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],
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},
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{
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"n": "4",
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"t": "VESSELS",
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"page": "C",
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"sig": True,
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"items": [
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{
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"n": "4.1",
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"t": "Seam/Joint Fit-up and Dimensional Check prior to Weldout",
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"code": "O",
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"cust": "R/AU",
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"crit": "Fit-up/gap/alignment per WPS and drawing; heat numbers transferred to "
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"shell/head components; welder ID/WPS recorded against the weld map.",
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},
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{
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"n": "4.2",
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"t": "Prior to vessel closing Heads Fit-up and Weldout (Internal Inspection)",
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"code": "O",
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"cust": "H",
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"crit": "Internal surfaces, welds and attachments accepted before the vessel "
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"becomes inaccessible. Hold point justified: internal access is "
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"permanently lost after closure.",
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},
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{
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"n": "4.3",
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"t": "Prior to Stress Relieving",
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"code": "O",
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"cust": "R/AU",
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"crit": "Vessel meets drawing configuration and code requirements before heat "
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"treatment; PWHT procedure/chart approved.",
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},
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{
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"n": "4.4",
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"t": "Final Inspection/Pre-hydrotest",
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"code": "O",
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"cust": "H",
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"crit": "All welds, NDE and dimensional checks complete and accepted before the "
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"vessel is pressurized. Hold point justified: an unverified vessel "
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"presents a personnel-safety risk under test pressure.",
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},
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{
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"n": "4.5",
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"t": "Hydrostatic Testing and Reports",
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"code": "A",
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"cust": "H",
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"crit": "Test pressure and hold time per ASME code/spec; no leaks, no permanent "
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"deformation; customer witness where required by the PO. (API Q1 5.6.9.3)",
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},
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{
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"n": "4.6",
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"t": "Ultrasonic, Radiographic and Magnetic Particle Testing and Reports",
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"code": "R",
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"cust": "R/AU",
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"crit": "NDE method/extent per code; results reference weld map location, heat "
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"number and welder ID. (API Q1 5.6.9.4 / ISO 9001 8.5.2)",
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},
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],
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},
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{
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"n": "5",
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"t": "INTERNAL COATING",
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"page": "C",
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"sig": True,
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"items": [
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{
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"n": "5.1",
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"t": "Post Surface Preparation/Blasting",
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"code": "W",
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"cust": "W",
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"crit": "Surface profile and cleanliness (e.g., SSPC-SP/NACE) meet the coating "
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"spec. Witness point justified: surface condition cannot be re-verified "
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"once coated.",
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},
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{
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"n": "5.2",
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"t": "Post Application of Primer Coat",
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"code": "W",
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"cust": "R/AU",
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"crit": "DFT within spec range; no holidays, runs or contamination before overcoat.",
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},
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{
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"n": "5.3",
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"t": "Post Application of Intermediate Coat(s)",
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"code": "W",
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"cust": "R/AU",
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"crit": "Cumulative DFT within spec range; recoat window per data sheet met.",
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},
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{
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"n": "5.4",
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"t": "Post Application of Top Coat",
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"code": "A",
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"cust": "R/AU",
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"crit": "Total DFT, color and finish per coating spec/data sheet.",
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},
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{
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"n": "5.5",
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"t": "Holiday Testing",
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"code": "H",
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"cust": "H",
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"crit": "Holiday (spark) test at voltage per NACE SP0188/coating data sheet; zero "
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"holidays before service. Hold point justified: final acceptance test for "
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"lining integrity.",
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},
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],
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},
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{
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"n": "6",
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"t": "EXTERNAL COATING",
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"page": "C",
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"sig": True,
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"items": [
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{
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"n": "6.1",
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"t": "Post Surface Preparation/Blasting",
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"code": "W",
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"cust": "W",
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"crit": "Surface profile and cleanliness meet the coating spec. Witness point "
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"justified: surface condition cannot be re-verified once coated.",
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},
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{
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"n": "6.2",
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"t": "Post Application of Primer Coat",
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"code": "W",
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"cust": "R/AU",
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"crit": "DFT within spec range; no holidays, runs or contamination before overcoat.",
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},
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{
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"n": "6.3",
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"t": "Post Application of Intermediate Coat(s)",
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"code": "W",
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"cust": "R/AU",
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"crit": "Cumulative DFT within spec range; recoat window per data sheet met.",
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},
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{
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"n": "6.4",
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"t": "Post Application of Top Coat",
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"code": "A",
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"cust": "R/AU",
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"crit": "Total DFT, color and gloss per coating spec/data sheet.",
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},
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{
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"n": "6.5",
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"t": "Final External Coating Inspection",
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"code": "A",
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"cust": "R/AU",
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"crit": "Visual inspection (holidays, runs, mechanical damage) and DFT survey meet "
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"spec; touch-ups accepted before release.",
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},
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{
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"n": "6.6",
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"t": "Holiday Testing Under Insulation (If Applicable)",
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"code": "H",
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"cust": "H",
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"crit": "Low-voltage holiday test per spec where insulation is applied over "
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"coating. Hold point justified: coating is inaccessible once insulated. "
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"Mark NA if not insulated.",
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},
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],
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},
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{
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"n": "7",
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"t": "INSTRUMENTATION, ELECTRICAL and CONTROLS",
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"page": "FA",
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"sig": True,
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"items": [
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{
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"n": "7.1",
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"t": "Verify Component Parts and Model Numbers to Specs/Data Sheets",
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"code": "R",
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"cust": "R/AU",
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"crit": "Model, range, materials and area classification match the approved "
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"instrument data sheet, cross-checked to the instrument index.",
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},
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{
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"n": "7.2",
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"t": "Contractor's Inspection Records",
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"code": "R",
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"cust": "R",
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"crit": "Sub-tier inspection records complete and signed; sub-tier NCRs closed "
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"before acceptance. (API Q1 5.6 / ISO 9001 8.4)",
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},
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{
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"n": "7.3",
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"t": "Calibration Verification – Test/Measuring Equipment Used",
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"code": "R",
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"cust": "R",
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"crit": "Megger, torque wrench and other test/measuring equipment used for "
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"acceptance are within current calibration; cal-due dates recorded on the "
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"inspection record. (API Q1 5.8 / ISO 9001 7.1.5)",
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},
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{
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"n": "7.4",
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"t": "Verify Grounding and Design Documents/Specs",
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"code": "R",
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"cust": "R/AU",
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"crit": "Grounding installed per design/one-line drawing and NEC Article 250; "
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"ground resistance recorded.",
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},
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{
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"n": "7.5",
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"t": "Megger / Insulation Resistance and Continuity Check of Cables",
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"code": "W",
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"cust": "R/AU",
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"crit": "Continuity end-to-end, cores correctly identified, insulation resistance "
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"within limits. (Ref: NETA ATS; cable test schedule)",
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},
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{
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"n": "7.6",
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"t": "Static checks of control switches (as required)",
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"code": "O",
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"cust": "R/AU",
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"crit": "Switch actuation and fail-safe position verified against the loop "
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"diagram; set points and fail-safe action per data sheet. (Static check "
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"record)",
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},
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{
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"n": "7.7",
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"t": "Verify Nameplate Layout, Lettering and Size",
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"code": "I",
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"cust": "R/AU",
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"crit": "Text, size, material and mounting per client labeling spec. (Nameplate checklist)",
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},
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{
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"n": "7.8",
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"t": "Verify Wire Size, Terminations and Tagging",
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"code": "I",
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"cust": "R/AU",
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"crit": "Wire size per load and NEC Art. 310; terminations torqued; tags match "
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"wiring drawings. (Termination check sheet)",
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},
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{
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"n": "7.9",
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"t": "Electrical Motor Testing",
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"code": "W",
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"cust": "R/AU",
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"crit": "IR, winding resistance and rotation within NEMA MG-1/NETA ATS limits. (Motor test report)",
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},
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{
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"n": "7.10",
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"t": "Instrument loop checks",
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"code": "I",
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"cust": "R/AU",
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"crit": "Signal proven at 0/50/100% of range; alarms and trips actuate at set "
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"point per loop diagram/C&E. (Signed loop check sheets)",
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},
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{
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"n": "7.11",
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"t": "Factory Acceptance Test (FAT)",
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"code": "W",
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"cust": "W",
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"crit": "All FAT steps pass per the approved FAT procedure; A-items cleared before "
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"shipment. (API Q1 5.6.9.3 / signed FAT report)",
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},
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],
|
||
},
|
||
{
|
||
"n": "8",
|
||
"t": "FINAL ASSEMBLY",
|
||
"page": "FA",
|
||
"sig": True,
|
||
"items": [
|
||
{
|
||
"n": "8.1",
|
||
"t": "Equipment Assembly, Mounting and/or Alignment",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Alignment within vendor/GA drawing tolerance; mounting hardware and "
|
||
"anchor bolts torqued to spec. (Alignment record)",
|
||
},
|
||
{
|
||
"n": "8.2",
|
||
"t": "Functional Testing and Reports",
|
||
"code": "O",
|
||
"cust": "R/AU",
|
||
"crit": "All functions operate per the approved functional test procedure with no "
|
||
"defects. (Functional test report)",
|
||
},
|
||
{
|
||
"n": "8.3",
|
||
"t": "Full Operation Testing and Reports (PRESSURE UP CONNECTIONS)",
|
||
"code": "O",
|
||
"cust": "R/AU",
|
||
"crit": "System holds test pressure with zero leaks at all connections per the "
|
||
"approved test procedure. (ASME B31.3 §345 / operational test report)",
|
||
},
|
||
{
|
||
"n": "8.4",
|
||
"t": "Stud Bolt & Nut Torqueing",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Torqued in pattern to the specified value with a calibrated wrench. (ASME "
|
||
"PCC-1 / torque record)",
|
||
},
|
||
{
|
||
"n": "8.5",
|
||
"t": "Stud Bolt Length & Grade",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Correct grade marks; minimum 2 threads past the nut. (ASME B16.5, "
|
||
"A193/A194 / bolting checklist)",
|
||
},
|
||
{
|
||
"n": "8.6",
|
||
"t": "Relief Valve(s) Set Pressure",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Set pressure verified per vendor data sheet / ASME Section VIII (or API "
|
||
"526 for PRVs) on a calibrated test bench; seal/wire intact after test. "
|
||
"(PRV test/certification record)",
|
||
},
|
||
{
|
||
"n": "8.7",
|
||
"t": "Weir Nipple Installation",
|
||
"code": "O",
|
||
"cust": "R/AU",
|
||
"crit": "Weir nipple size and orientation per P&ID and vendor requirement; "
|
||
"installed per manufacturer instructions.",
|
||
},
|
||
{
|
||
"n": "8.8",
|
||
"t": "Pressure Gauge Inspection",
|
||
"code": "O",
|
||
"cust": "R/AU",
|
||
"crit": "Gauge range 25–75% of span at normal operating pressure; gauge in current "
|
||
"calibration. (ASME B40.100 / gauge list + certs)",
|
||
},
|
||
{
|
||
"n": "8.9",
|
||
"t": "Regulator(s) Set Pressure",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Outlet pressure within the stated tolerance of the vendor data sheet. (Set-point record)",
|
||
},
|
||
{
|
||
"n": "8.10",
|
||
"t": "Pressure Controller(s) Set Pressure",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Set point and control action per the approved instrument data sheet. (Set-point record)",
|
||
},
|
||
{
|
||
"n": "8.11",
|
||
"t": "Flow Direction of all Valves, etc.",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Flow arrows and valve orientation match the approved P&ID. (P&ID walk-down checklist)",
|
||
},
|
||
{
|
||
"n": "8.12",
|
||
"t": "Gasket Specification",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Gasket type, material, rating and size per spec; never reused. (ASME "
|
||
"B16.20/B16.21 / gasket verification record)",
|
||
},
|
||
{
|
||
"n": "8.13",
|
||
"t": "Valve Actuation",
|
||
"code": "O",
|
||
"cust": "R/AU",
|
||
"crit": "Full stroke, travel time and fail position per the vendor manual/C&E "
|
||
"matrix. (Valve stroke record)",
|
||
},
|
||
{
|
||
"n": "8.14",
|
||
"t": "Nonconformance Check – Final Assembly",
|
||
"code": "R",
|
||
"cust": "R/AU",
|
||
"crit": "No open QNs/NCRs from the assembly stage before release to Paint/Final "
|
||
"Inspection. (API Q1 5.9)",
|
||
},
|
||
],
|
||
},
|
||
{
|
||
"n": "9",
|
||
"t": "FINAL INSPECTION/ SHIPPING PREPARATION",
|
||
"page": "FA",
|
||
"sig": True,
|
||
"items": [
|
||
{
|
||
"n": "9.1",
|
||
"t": "Verify Tagging/Markings are complete",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Everything tagged per the index; legible and permanent. (Client tagging "
|
||
"spec, UG-116 / tagging checklist)",
|
||
},
|
||
{
|
||
"n": "9.2",
|
||
"t": "Flange Face Protection",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "All flanges protected, threaded connections plugged; lifting points and "
|
||
"shipping restraints verified per the packing plan. (API Q1 5.6.8; PO "
|
||
"packing spec / ISO 9001 8.5.4 / preservation checklist)",
|
||
},
|
||
{
|
||
"n": "9.3",
|
||
"t": "Verify Punch List Items are complete",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "All A-items closed; B/C items agreed in writing with the customer. "
|
||
"(Client punch list procedure / signed punch list)",
|
||
},
|
||
{
|
||
"n": "9.4",
|
||
"t": "Packing of Ship Loose Items",
|
||
"code": "I",
|
||
"cust": "R/AU",
|
||
"crit": "Ship-loose items tagged, protected and listed on the packing list. "
|
||
"(Approved packing plan, ISPM-15 / signed packing list)",
|
||
},
|
||
{
|
||
"n": "9.5",
|
||
"t": "Final Pre-shipping Inspection",
|
||
"code": "A",
|
||
"cust": "R/AU",
|
||
"crit": "Every ITP line signed off; no open holds or QNs. (API Q1 5.6.9.3, 5.7 / "
|
||
"final inspection report)",
|
||
},
|
||
{
|
||
"n": "9.6",
|
||
"t": "RELEASE TO SHIP (RTS)",
|
||
"code": "A",
|
||
"cust": "H",
|
||
"crit": "Written release issued by PESCO QA and the client; QN register closed "
|
||
"with all concessions customer-approved before shipment. (API Q1 5.7, 5.9 "
|
||
"/ ISO 9001 8.6, 8.7 / signed RTS certificate)",
|
||
},
|
||
{
|
||
"n": "9.7",
|
||
"t": "DATABOOK SIGNED OFF BY QA",
|
||
"code": "R",
|
||
"cust": "H",
|
||
"crit": "Data book complete and indexed per PO requirements. (API Q1 4.5 / ISO "
|
||
"9001 7.5.3 / signed data book)",
|
||
},
|
||
],
|
||
"final": True,
|
||
},
|
||
],
|
||
}
|