OUR SERVICES
Third Party Process Piping QAR
Construction Inspection and Verification
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Compliance Assurance: Regular inspections to align construction activities with industry standards and regulations, emphasizing cleanliness, contamination control, and environmental requirements.
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Material and Equipment Inspection: Meticulous inspections of materials and equipment to confirm compliance with project specifications and stringent quality standards. We verify quality, dimensions, traceability, and proper installation or calibration.
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Process Piping System Inspection: Specialized inspections of process piping systems, including welds, fittings, supports, and connections, to ensure integrity and adherence to industry best practices.
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Documentation Review: Comprehensive review of project documentation, including construction plans, specifications, and quality control procedures, ensuring accurate representation of the construction process and necessary corrective actions.
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Non-Destructive Testing (NDT) Oversight: Coordination and oversight of NDT activities, utilizing testing methods such as radiographic, ultrasonic, liquid penetrant testing, and visual inspection to accurately assess welds and process piping systems.
What makes us different ?
At QAS, we believe in empowering your organization to achieve excellence through our comprehensive process methodology. Partner with us to ensure regulatory compliance, product integrity, meticulous documentation, and industry-leading quality assurance. Together, we'll navigate challenges, prioritize effectively, and maintain the highest standards in the life sciences industry.
PROJECT ORGANIZATION
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Project Quality Plan : At QAS, we offer comprehensive quality assurance services to ensure the successful execution of your projects. Our systematic approach and experienced team guarantee the highest standards of quality throughout the entire project lifecycle.
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Front-End Validated Process System Planning : We begin by aligning the fabricator's processes, our QAS services, and your validation team's expectations with project specifications. This ensures that the installation and Turnover Package (TOP)/Installation Qualification (IQ) documentation meet project requirements even before the first weld is made.
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Project-Specific Training : Our project team develops customized training courses covering GDP protocol, weld documentation, welding and installation requirements, and acceptance criteria. All fabrication and QAS personnel working on validated process systems undergo this training, ensuring a well-informed and skilled workforce.
RESOURCES
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Staff : Our management team and VT Level 2 PI inspectors are highly experienced in the industry. They hold Pharma Industry (PI) certifications, indicating their specialized training, successful completion of industry-specific examinations, and fulfillment of experience requirements.
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Equipment: We maintain our inspection and material testing equipment to OEM specifications through our dedicated equipment department. All equipment undergoes functional testing before being deployed to projects, and calibration documents are provided for all calibrated inspection equipment.
MATERIALS OF CONSTRUCTION
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Validated Material Inspection: Our procedures ensure that the materials of construction (MOC) meet quality standards, have traceable documentation, and conform to the engineering design. We adhere to the ASME BPE standards and ensure compliance with product contact materials and material documentation requirements.
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PVDF and PFA Systems : For PVDF or PFA systems, which have different material traceability and documentation requirements than stainless steel systems, we plan meticulously to address challenges related to purchase specifications, material documentation, and validation requirements.
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WELDING VERIFICATION
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Welding Procedure Specification (WPS): We evaluate Auto-GTAW process WPS/PQR for conformance to ASME Section IX and/or BPE standards, obtaining approval from project engineering.
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Welding Operator Performance Qualification (WOPQ): Auto-GTAW process WOPQ is evaluated for conformance to ASME Section IX and/or BPE standards and approved by VT Level 2 inspectors.
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Welding Backing/Shielding Gas: We verify that each gas source used for hygienic welding is traceable to documentation demonstrating conformance to project specifications for purity and specified impurities and impurity limits.
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Fabrication and Installation Surveillance: We conduct surveillance activities to ensure that production welding, welding operators, and overall fabrication and installation processes conform to approved WPS/WOPQ, SOPs, and the engineering design. Weld sample coupons are made as per project requirements.
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WELD INSPECTION, WELD AUDIT & MOC
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Weld Inspection (SS, PVDF, PFA): We inspect production welds using direct visual inspection, video, or fiber-optic borescopes, based on the project inspection plan. Welds are evaluated against project-specific acceptance criteria. Detailed weld, welding operator, MOC, welding machine, and welding gas data are recorded in our Documentation System.
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Weld Documentation Audits: We audit ISO drawings and weld logs during inspection and prior to turnover to ensure compliance.
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XRF/PMI Testing : We perform alloy verification testing during incoming material inspection and/or after fabrication to confirm materials of construction. XRF testing is particularly useful when multiple grades of material are being installed.
Installation Verification (IV)
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Final Inspection : During IV, we verify the system's conformance to ISO drawings and the engineering design. Final inspection is conducted upon mechanical completion of the system.
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Hangers/Supports: We verify hangers and supports against ISO drawings and hanger detail requirements, ensuring compliance with installation, welding, material, and surface finish specifications.
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Slope: We measure slope direction and degree in accordance with P&ID/ISO drawings after accepting hangers and supports. This includes evaluating dead leg and valve drain angle verification.
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As-Built: We verify the overall installation against ISO drawings, making red lines on the drawings to provide an accurate representation of the system for future P&ID verification.
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Final Weld Audit: A final weld audit is conducted before turnover to evaluate any changes made during the project.
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Punch/Task List:Deviations recorded per ISO drawing are tracked, re-inspected, or re-verified until corrected. QAS IV Stamps are used to document final ISO drawing acceptance.
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Testing & Cleaning Verification
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Pressure Test: We verify the pressure test's conformance to the engineering design and/or piping code. The pressure test package is reviewed for compliance with project-specific requirements.
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Cleaning, Flushing, or Blowdown : We verify the system conditioning required by the engineering design, including circuit, boundary, criteria, and documentation requirements.
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Passivation: System passivation is verified for circuit, boundary, and other parameters specified by the owner.
Turnover Package
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Original Paper TOP: We provide the original paper TOP in a well-organized manner, mirroring the electronic TOP. Each document is traceable to the electronic TOP.
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Electronic TOP: The TOP documents are provided in a text-searchable PDF format, allowing for easy searching of tag numbers and other relevant information. Real-time access to the TOP can be granted to the customer, transmitted to local drives, or uploaded to any file sharing platform.
Contact
Quality Assurance Solutions
Today
At QAS, we ensure that your projects meet the highest quality standards and adhere to industry-specific requirements. Our comprehensive services cover all aspects, from planning and training to verification and documentation. Trust us for reliable project quality assurance.