This content provides you with a corrective action plan template for industrial plant construction projects. It includes corrective actions in shop and site manufacturing and construction activities.
1. Introduction
The XXX Company has been contracted by the XXX to conduct the EPC for XXX Project. This Project includes offshore facilities, platform and undersea pipelines, and onshore facilities for the processing of the reservoir fluid.
2. Project Overview
XXX
3. Corrective Action Plan Template – General
3.1 Purpose
This procedure prescribes the action (corrective action), with related responsibilities and authorities to document and record, to close out the non-conformance reports (NCR) and to eliminate the cause of nonconformities in order to prevent recurrence.
3.2 Scope
This procedure applies to the corrective action for the nonconformities relating to the Quality Management System and Materials for XXX onshore facilities, covering engineering, procurement and Construction activities.
3.3 Definitions
Company: XXX Owner
Contractor: XXX EPC Contractor
Subcontractor: The company or organization engaged by the CONTRACTOR to perform the works
Non conformity: Non-fulfillment of a requirement
Corrective action: Action taken to eliminate the causes of a detected nonconformity or other undesirable situation.
Quality Manager: Manager of Site Quality Department
CAR: Corrective Action Request
NCR: Non-conformities are defined as non-fulfillment of specified requirement of project specifications and developments
3.4 Referenced Documents
XXX Project Quality Plan Document
XXX Audit Procedure
ISO 9001 – 2010 Quality management system – Requirements
3.5 Conflict
In case of conflict between this procedure and the above referenced documents, the most stringent shall apply.
3.6 Responsibility and Authority
3.6.1 The Project Quality Manager is responsible for assuring that condition adverse to quality or nonconformance is promptly identified and corrected for approving and closing out by Corrective Action Request (CAR).
3.6.2 The QA/QC Engineer is responsible for preparing the Corrective Action Request (CAR) and distributing to responsible organization and evaluating CAR responses, conducting verification of corrective action implementation, and closing or rejecting CAR response.
4. Corrective Action Plan Template – Corrective Action
4.1 Basic Activities
The following are the basic activities of Corrective Action Close Out:
1. Reviewing nonconformities “NCR Sheets” (including Company complaints),
2. Determining the cause of nonconformities,
3. Evaluating the need for action to ensure that nonconformities do not recur,
4. Determining and implementing the action needed,
5. Maintaining records,
6. Reviewing the corrective action taken,
7. Reporting / Notification.
8. Close out of the related NCR by Contractor /Company.
4.2 Procedures for Corrective Action
The Quality Manager, as person responsible, shall prepare the request for corrective action, based on the relevantly opened NCR, and will forward it to the concerned Manager.
The format for the Corrective Action Request is shown in Attachment
1 – Project Quality Assurance Corrective Action Request. The Quality Manager shall prepare and maintain the documentation for Corrective Action Control with Formatting as follows: Attachment.
2 – Project Corrective Action Control Record & Attachment.
3 – Project Corrective Action Request Log.
All corrective actions required and subsequent investigations in the form of concessions, waivers, defect reports etc., that impinges on or related to Company requirements shall be issued to Company for approval. The Quality Manager as the lead in Corrective Actions process shall confirm with Field Engineering and / or Designers that the proposed correction is technically acceptable.
Where changing of staff or subcontractors becomes necessary, the local labour law and contract conditions procedures shall be strictly followed.
The Manager who has a nonconforming product (material or workmanship out of specification or tolerance) for which he is responsible or nonconformity relevant to implementation of the Quality Management System (QMS) (documentation or information flow) shall perform the following:
1. Take timely corrective action which shall be appropriate to eliminate the Effects of the non-conformities encountered.
2. Quarantine non-conforming material to ensure it cannot be incorporated in the works.
3. Agree a completion schedule for the Corrective Action.
4. Record the status and the results of action taken.
5. Report and notify the Quality Manager when actions are complete.
5. Review of the Effectiveness of Corrective Action
The Section Manager shall verify the effectiveness of the Corrective Action taken and report to the Quality Manager. The Quality Manager and Field Manager shall review the effectiveness of Corrective Action taken for the nonconformity of product and implementation of Quality Management System (QMS).
6. Corrective Action Plan Template – Records
6.1 Management of Corrective Action
The Quality Assurance Manager shall ensure that the status and results of corrective action taken in the project are monitored, documented and reported to the Project Manager. Copies of closed out Corrective Action Requests shall be attached to the relevant NCR and submitted to Company for review and close out of the relevant NCR.
Upon identification of a deviation or non-conformance, the corrective actions required shall be logged and analyzed statistically to determine the root cause of occurrence.
6.2 Preservation of Corrective Action Records
Original records of corrective actions and their follow-up activities shall be preserved and maintained, as quality records, by the Quality Manager, sequentially numbered as they occur.
The serial number of each CAR shall be the same as the relevant NCR.
7. Corrective Action Plan Template – Improvement and Close Out
7.1 Input for Improvement of the Quality Management System The Quality Manager shall obtain information on the performance of corrective actions taken by the departments or sections of the project, determine whether or how the actions are related to the continual improvement and effectiveness of the Quality Management System (QMS), report to the Site/Shop Manager (SM) who shall ensure that the relevant Management Procedures and Technical Standards are revised, once the effectiveness of the action taken is proven.
7.2 Preventative Actions
When the root cause of the non-conformance may potentially reoccur, the steps required to eliminate problems shall be determined and, where required, procedures shall be revised and submitted to Company for approval in order to prevent further occurrences. Continual assessments of construction methods and procedures will be undertaken mindful of site conditions and skill of personnel. Construction methods will be changed, if a more appropriate method is uncovered, and personnel trained or re-trained as required.
Executive Summary & Industrial Inspection Scope
In demanding industrial environments across Oil, Gas, Petrochemical, Offshore, and Heavy Process Infrastructure, rigorous compliance with ISO 9001 / ASME / API is essential to ensure operational integrity, personnel safety, and compliance with statutory regulatory frameworks. This technical specification provides QA/QC managers, procurement engineers, welding inspectors, and third-party inspection (TPI) agencies with an authoritative, field-tested guideline for “Corrective Action Plan Template”.
Ensuring compliance regarding corrective action plan template minimizes the risk of catastrophic asset failures, costly unscheduled shutdowns, and supplier non-conformances. The following technical sections delineate the scope of inspection, mandatory verification protocols, acceptance criteria, documentation deliverables, and root cause mitigation strategies.
Governing International Engineering Codes & Specifications
Verification and validation of Corrective Action Plan Template must strictly conform to the latest editions of the following international engineering codes and project specifications:
• **Primary Standard Reference:** ISO 9001 / ASME / API
• **Quality Management & Inspection Systems:** ISO 9001:2015 & ISO/IEC 17020 (Requirements for the operation of various types of bodies performing inspection)
• **Material Compliance & Traceability:** EN 10204 Type 3.1 / 3.2 Inspection Certificates for metallic and non-metallic pressure-retaining components
• **Personnel Qualification:** ASNT SNT-TC-1A / ISO 9712 for NDT personnel, CSWIP 3.1 / AWS CWI for welding inspection, and NACE / AMPP Level 2/3 for coating and corrosion personnel
• **Statutory & Health Safety Directives:** ASME Boiler & Pressure Vessel Code (BPVC), API Standards, OSHA, and regional local authority regulations.
Step-by-Step Quality Control & Inspection Procedure
The execution of quality surveillance for Corrective Action Plan Template is structured across four progressive QA/QC intervention phases:
Stage 1: Pre-Inspection & Engineering Document Review (Review Point – R)
Prior to commencement of any physical activities or manufacturing operations related to Corrective Action Plan Template, the contractor or vendor must submit all technical submittals to the Owner or TPI agency for formal review and approval.
- Verification of approved Inspection and Test Plan (ITP) identifying all Hold (H), Witness (W), Review (R), and Surveillance (S) intervention points.
- Cross-examination of Material Test Reports (MTR / Mill Certificates) against standard design specifications (ISO 9001 / ASME / API).
- Review and approval of specific Procedure Qualification Records (PQR), Welding Procedure Specifications (WPS), or calibration certificates.
- Verification that all measurement instruments, gauges, and NDT equipment hold valid calibration certificates from ISO/IEC 17025 accredited calibration laboratories (within 6 to 12 months validity).
Stage 2: In-Process Witnessing & Fabrication Control (Witness / Hold Point – W/H)
During the active execution phase, the certified inspector performs physical surveillance to ensure strict adherence to certified drawings, manufacturing procedures, and code tolerances.
- Verification of material traceability (heat number, heat treatment lot, plate number) transferred accurately onto fabricated components.
- Dimensional verification and visual inspection using calibrated gauges, micrometer depth dials, or laser alignment systems.
- Monitoring ambient environmental parameters (relative humidity, dew point, substrate temperature) when applying surface treatments, welding preheat, or pressure testing.
- Witnessing non-destructive examination (RT, UT, MT, PT, PMI) at specified percentages according to project critical rating and code requirements.
Stage 3: Final Acceptance, Pressure/Performance Testing & Marking (Hold Point – H)
The culminating milestone where the fully assembled or completed item is subjected to definitive acceptance tests in the presence of the Owner’s Third-Party Inspector (TPI).
- Execution of pressure proof tests (Hydrostatic at 1.3x to 1.5x MAWP or Pneumatic test) with dual calibrated pressure gauges and temperature recorders.
- Full visual inspection of completed surfaces, welds, protective coatings, and flange contact faces for absence of mechanical damage or code defects.
- Validation of permanent stamping, low-stress die markings, nameplate data verification, and barcoding in strict conformity with project specs.
- Clearing all open punch-list items, non-conformance reports (NCRs), and concession requests prior to issuance of the release note.
Stage 4: Packing, Preservation & Inspection Release (Inspection Release Certificate – IRC)
Ensuring the inspected equipment is adequately protected against atmospheric corrosion, mechanical shock, and marine transit degradation.
- Inspection of rust preventative coatings, desiccant bags, flange face blind protectors, and vapor corrosion inhibitor (VCI) packaging.
- Verification of heavy-lift sea fastening lugs, center-of-gravity markings, and export crating compliance (ISPM 15 wooden crating).
- Compilation and signing of the final Inspection Release Certificate (IRC / Shipping Release) and manufacturer data dossier (MDR).
Technical Acceptance Criteria & Tolerances Matrix
All measurements and physical characteristics must comply with the engineering tolerances and acceptance thresholds tabulated below:
| Inspection Parameter / Test Item | Applicable Standard & Clause | Permissible Tolerance / Acceptance Limit | Verification Method | Intervention Type |
|---|---|---|---|---|
| Material Chemical & Mechanical Verification | ISO 9001 / ASME / API / EN 10204 3.1 | 100% compliance with minimum tensile, yield, elongation, and impact values (Charpy V-Notch at design temp) | Optical Emission Spectrometry (OES) / MTR Verification | Review (R) |
| Visual & Dimensional Tolerances | ISO 9001 / ASME / API / Project Specs | Zero cracks, lack of fusion, severe pitting; dimensional tolerances within ±1.0mm to ±3.0mm per code drawings | Calibrated Vernier, Bridge Cam, Depth Micrometer | Witness (W) |
| Non-Destructive Examination (NDT) | ASME Sec V / ASNT SNT-TC-1A | 100% compliant with code acceptance criteria; zero planar defects or unpermitted volumetric indications | Radiographic (RT) / Ultrasonic (UT) / Magnetic Particle (MT) | Hold (H) |
| Pressure / Proof Testing (Hydrostatic) | ISO 9001 / ASME / API / ASME Sec VIII | Test pressure maintained for minimum 30 to 60 mins; zero pressure drop, zero leakage or visible sweating | Dual calibrated Bourdon pressure gauges + Chart Recorder | Hold (H) |
| Surface Prep & Protective Coating Quality | SSPC-SP / NACE / ISO 8501 | Surface profile 50 – 75 µm; Dry Film Thickness (DFT) within 80/20 rule of specified nominal thickness | Replica Tape (ASTM D4417) & Magnetic Gauge (SSPC-PA 2) | Witness (W) |
| Nameplate & Final Preservation Verification | API / ASME / Client Specs | 316L SS nameplate securely affixed with correct design code, MAWP, design temp, and national board stamping | Physical visual check & VCI preservation verification | Hold (H) |
Mandatory QA/QC Dossier & Inspection Deliverables
Prior to the final issuance of the Inspection Release Certificate (IRC), the contractor and vendor must compile and submit the verified manufacturer data record containing:
- Approved Inspection & Test Plan (ITP) with sign-off stamps by Contractor, Client, and TPI.
- Material Test Reports (MTR / Mill Test Certificates EN 10204 Type 3.1 or 3.2).
- Certified Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance Qualifications (WPQ).
- Calibration Certificates for all test instruments and measuring equipment (NABL / ISO 17025 accredited).
- Non-Destructive Examination Reports (RT, UT, MT, PT, PMI, Ferrite Content) evaluated by Level II/III inspectors.
- Heat Treatment & PWHT Time-Temperature Recorder Charts with thermocouple layout drawings.
- Hydrostatic / Pneumatic Pressure Proof Test Certificate with calibrated chart recorder logs.
- Surface Preparation and Protective Coating Inspection Reports (Daily environmental log, blast profile, DFT summary).
- Non-Conformance Report (NCR) and Concession Disposition Closeout Log.
- Official Inspection Release Certificate (IRC / Shipping Release Note) permitting packing and dispatch.
Common Non-Conformances & Field Mitigation Strategies
Based on extensive third-party inspection field records in oil & gas projects, the following deviations require heightened surveillance:
Defect / Hazard: Material Grade Substitution & Lack of Heat Traceability
Root Cause: Uncontrolled workshop storage, missing color coding, or unverified supplier sub-tier procurement without EN 10204 3.1 documentation.
Preventative Action: Enforce strict 100% Positive Material Identification (PMI) prior to cutting, and mandatory material receiving inspection with physical stamping cross-referenced to original mill test certificates.
Defect / Hazard: Out-of-Tolerance Fit-Up & Alignment Mismatch
Root Cause: Poor thermal cutting, thermal distortion from excessive preheat, or inadequate jigging and tacking arrangements.
Preventative Action: Establish a mandatory Witness/Hold point at joint fit-up before root pass deposition. Use calibrated Hi-Lo gauges to verify bevel angle, root face, and root gap according to the qualified WPS.
Defect / Hazard: Premature Coating Delamination & Blistering Under Film
Root Cause: Excessive soluble salt contamination (>20 mg/m²) left on the substrate, blast cleaning below dew point (<3°C above dew point), or oil/moisture in the blasting compressor air line.
Preventative Action: Perform Blotter Test (ASTM D4285) daily on compressed air, enforce Bresle patch chloride testing, and apply primer within 4 hours of abrasive blasting before rust blooming initiates.
Defect / Hazard: Pressure Drop During Final Hydrostatic Proof Testing
Root Cause: Micro-leakage through temporary test flange gaskets, entrapped air pockets inside vessel high points, or inadequate temperature stabilization.
Preventative Action: Ensure thorough venting at all high-point vents until bubble-free fluid emerges, allow minimum 15-minute temperature stabilization between filling medium and ambient metal, and torque all blind flanges with calibrated torque wrenches.
Frequently Asked Questions (FAQ)
Q: What are the mandatory qualifications for inspectors verifying Corrective Action Plan Template?
A: Inspectors must hold recognized international certifications applicable to the discipline. For welding and fabrication: CSWIP 3.1/3.2, AWS CWI, or API 510/570 Source Inspector. For NDT: ISO 9712 or ASNT SNT-TC-1A Level II minimum. For coatings: NACE / AMPP Level 2 or FROSIO Level III. Additionally, the inspection agency must operate under an ISO/IEC 17020 accredited quality management system.
Q: How does PtroTek resolve non-conformances (NCRs) encountered during vendor surveillance?
A: When a deviation from certified drawings or ISO 9001 / ASME / API is detected, the inspector issues a formal Non-Conformance Report (NCR) within 24 hours. The vendor must submit a Root Cause Analysis (RCA) and proposed disposition (Rework, Repair, or Concession). Work on the affected component is halted (Hold Point) until the Owner’s engineering authority approves the disposition and a re-inspection confirms full compliance.
Q: What is the difference between Witness (W) and Hold (H) points in an Inspection & Test Plan (ITP)?
A: A Hold Point (H) is a mandatory milestone where fabrication or testing CANNOT proceed without the physical presence of the designated client or third-party inspector. Written clearance or stamping is strictly required. A Witness Point (W) requires prior notification (typically 24 to 48 hours) to the inspector; however, if the inspector fails to attend at the scheduled time, fabrication or testing may proceed with subsequent review of the test records.
Q: Can international clients review inspection reports and photos in real time?
A: Yes. PtroTek provides comprehensive Flash Reports issued within 24 hours of inspection completion, followed by detailed formal inspection reports accompanied by high-resolution calibrated photographic evidence, dimension logs, and signed vendor test records for complete global transparency.
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