PRE-ORDER INSPECTION TEST PLAN FOR

ROTORK ELECTRIC VALVE ACTUATORS

JOB NUMBER: Please enter Job Number CUSTOMER ORDER NO: Please enter Customer Order No
CUSTOMER: Please enter Customer PAINT SPEC: Please enter Paint Spec
PROJECT: Please enter Project

THIS ITP/QP IS FOR QUOTATION PURPOSES ONLY AND A JOB SPECIFIC QUALITY PLAN WILL BE RAISED AT ORDER PLACEMENT SUBJECT TO COMPLETION OF THE REQUESTED DATA.
ORDER CONTENT

LINE NO
SIZE/TYPE/ GEARBOX QTY
(Please VALVE TAG NO
DESCRIPTION (IF APPLICABLE) (Please complete
complete (Please complete below)
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below)
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A Pre Inspection Meeting, following a customer provided agenda can be arranged if required. We ask that this should be arranged at order placement stage. The final Rotork IQ & IQT actuator test is carried out on a Rotork designed computer controlled test rig. The software controlling
the test rig is written in house using National Instruments Lab View. The test process meets the requirements of ISO12490 Section 13.5.

The test software is written to ensure all IQ & IQT actuators meet the requirements of the Engineering Test Requirements and agreed customer specification, where applicable.
Electric actuators manufactured by Rotork Controls Limited are compliant with BS EN15714-2.
Rotork Controls Limited operate a quality management system that has been certified by Bureau Veritas Certification Holding SAS to meet the requirements of ISO9001:2015. Certificate Number UK010971.

General Statement Regarding OEM Products

Rotork Controls Limited, Bath make a range of actuators that are essentially OEM products, with the option to tailor certain aspects of the build and product specification to meet customer requirement within. All units are manufactured and tested to the same in-house processes.
Customer bespoke testing is not offered.

Rotork Documented Procedures

Rotork documented procedures are confidential documents and as-such cannot be sent to customers or taken away by inspectors. They can, however, be seen during inspection visits if requested.
It is acknowledged that inspectors may need to keep a copy of our test process document and so an explanatory, non-confidential version has been written and can be provided to inspectors and interested parties.

Paint Finishes

Rotork actuators can be specified with a number of different paint coatings, depending on the customer’s requirements and the end-use of the units. Where specialist coatings are not required, products are supplied with the standard powder-coat finish or for certain products relatively
simple paint finishes can be applied in-house and these processes are listed in row J of this quality plan. Specialist coatings are applied by approved sub-contractors and so these processes are not included in this quality plan, however, the paint specialists do provide their own inspection
reports and we carry out visual examination of sub-contract painted items or actuators when they are returned for final processing. When specialist coating inspection is requested, such inspection will be separate from this ITP.
PAGE 1 OF 3 PRE-ORDER ITP/QP -19/09/19
 INSPECTION POINTS
Item Operations Instructions/Purpose RCL Internal Reference Certification/ Documentation/Record Remarks
R P 3
To select suppliers who can maintain supply of
Audit of potential This process is independent of the
A items to RCL consistently and to specific quality Generic: QM01.01, QC3T, SP04.03, BY01.01 Vendor Assessment Report
suppliers assembly processes
requirements
Routine surveillance and This is an on-going process that is
Supplier audit reports, vendor rating
B vendor rating of To monitor supplier performance Generic: QM01.01, QC3T, SP04.03, BY02.03 independent of the assembly
reports
approved suppliers processes
As the products produced by RCL are
Order placed on To ensure that the correct items are ordered and OEM, orders for components are
C approved suppliers - over that the correct specifications are made available Generic: QM01.01, BY01.01, BY01.02 Purchase Order placed depending on demand. Orders
check to the supplier are not normally placed for specific
customer orders.
Stock booking-in records. Rotork Controls electric actuators are
Supplier inspection records. not pressure containing as per the
Generic: QM01.01, QC3T, QC58, QC336,
To ensure that purchased items meet the Hazardous area castings undergo Pressure Equipment Directive (PED),
D Component Inspection QC345, P130, PI790, PI794, PI796
requirements of the order pressure test and dimensional ASME Boiler & Pressure Vessel
A: QC290
inspection as required by product Code (BPVC) and so material
certification and records are retained certification is not applicable
Stores processes are independent of These process stages are carried out either
E Stores Process To ensure that items are correctly stored Generic: QM01.01, PI615, PI682 Operator ID, Job Schedule
the assembly processes prior-to or early in our manufacturing
Contract review should be carried out process and so do not align with the main
by the customer interface actuator build or test stages of production.
Order receipt, contract This means that during an inspection visit it
organisation. Therefore orders
review (if order is not To ensure that customer requirements can be met
received directly by the factory will is possible to witness these processes if
F received via subsidiary and any variation from the order specification - -
undergo contract review by the required, however, they will not be carried
office) order registration, can be
factory team, otherwise contract out on the order products.
configuration
review must be carried out by the Procedural documents can also be seen
subsidiary office. during an inspection visit, although, because
G Production Planning - - - - they are confidential to Rotork, copies cannot
be taken away.
Motor sub assembly and testing takes
Motor sub-assembly
H Assembly and flash testing of electric motors Generic: QM01.01, P110, PI653, PI219 Operator ID, Job Schedule place prior to the main assembly
processes
processes and functional testing.
FLIQ100, PI201, PI210, PI214, PI215, PI216, Sub assembly takes place prior to the
Assembly and testing of component assemblies
I Sub assembly processes PI218, PI219, PI220, PI222, PI223, PI806, Job schedule, Operator ID main assembly processes and
prior to the main actuator build PI683, PI309, PI310, PI311 functional testing
Generic: QM01.01, QC58
A: PI631, A605, A606, A210, A211, A212
IQ: PI683, PI684, PI694, P113
IQ3: PI203, PI204, PI205, PI206, PI207, PI210,
PI211, PI212, PI214, PI215, PI216, PI218,
Main Build Assembly Actuators are built to meet the
J Assembly, visual inspection, functional testing PI219, PI220, PI222, PI223, PI233, PI234 Operator ID, Job Schedule
Processes specific requirements of the order.
IQT3: PI214, PI220, PI234, PI310, PI300, PI301,
PI304, PI309, PI311, PI312, PI313
CVA: PI254, PI260, PI261, PI262, PI263, PI264,
PI265, PI266, PI267, PI268, PI269, PI270,
PI271, PI272, PI273, PI274, FLF109, F134
Cold stall test not applicable due to
potential damage to motor. Cold stall
Performance test
detection method is electronically
including: circuit GENERIC: QM01.01, QC58, PI805
tested as part of the standard test
continuity test and option IQ3: PI212, PI805 IQ: FLF102
Functional testing and verification of completed process. Regarding ingress
K testing (actuator only).
actuator against the requirements of the order.
IQT: FLF104, PI304 A: ETP090 Actuator Test Certificate
protection, Rotork IQ Actuators are
Please Select Please Select Please Select
Electronic circuit test, CVA: FLF109
compliant with IEC60079-7 and
valve position limit QCTP-IQ-IQT
IEC60079-31 which both call up
switches, electric motor
IEC60529.. Every actuator undergoes
performance/functional test
Every actuator undergoes safety/flash
Testing of the completed actuator to ensure that
L Safety/Flash test
it is electrically safe
- - test. Only units that pass all tests are Please Select Please Select Please Select
released for delivery
KEY: R = ROTORK P = PURCHASER 3 = THIRD PARTY
H = HOLD POINT – ACTIVITY STOPS W = WITNESS POINT (10% OF TOTAL ORDER QUANTITY IS OFFERED FOR PERFORMANCE TESTING) RV = REVIEW - REVIEW OF AVAILABLE DOCUMENTATION

PAGE 2 OF 3 PRE-ORDER ITP/QP -19/09/19

 INSPECTION POINTS
Item Operations Instructions/Purpose RCL Internal Reference Certification/ Documentation/Record Remarks
R P 3
- - Rotork perform specific dimensional
inspection of component parts of the
actuator as required by product
certification. No subsequent
machining of parts is carried out
during assembly so Rotork do not
Visual Inspection/Final carry out a dimensional inspection at
Visual inspection carried out to ensure that the
M inspection including
actuator is complete and not damaged.
this stage of production. The Please Select Please Select Please Select
check of painted finish inspector is welcome to carry out
their own dimensional inspection of
the finished product during their visit.
The Rotork operator marks the job
schedule with his ID to verify visual
inspection has been completed in
accordance with P1710
Gearbox fitting and light If specified in the order gearboxes will be fitted - -
Not all actuators are fitted with
N run (if gearboxes and the actuator/gearbox combination will be
gearboxes Please Select Please Select Please Select
included with order) tested together
Job schedule, Operator ID. The Rotork
Operator marks the job schedule with
Verification of product quality, visual check of operator marks the job schedule with
Generic: QM01.01, F115, F116, PI710, QCTP- his ID to verify quality of painting
O Paint & actuator coating paint, RAL colour, labelling, tagging (if
IQ-IQT
his unique ID to verify visual
and labelling in accordance with
Please Select Please Select Please Select
included) and nameplate inspection has been completed in
P1710
accordance with PI710
Labelling and actuator - - Every actuator is assigned a unique
identification plate check Verification and application of labels as specified identification number that is traceable
P
in the order and job schedule. to the order, this number is included
Please Select Please Select Please Select
on the actuator nameplate
Final inspection - -
If a gearbox is fitted the actuator/gearbox
Q including check of
combination undergoes a final visual inspection
- Please Select Please Select Please Select
painted finish
Final inspection and Operator marks the job schedule with
release authority his ID to verify a final inspection has
R
(External release where
Verification of product quality Generic: QM01.01, PI710 Job schedule, Operator ID
been completed in accordance with
Please Select Please Select Please Select
applicable) P1710
Packing, shipment &
S
despatch
Release of finished goods Generic: QM01.01, PI615, F133, F134, PI822 Job schedule, despatch note - Please Select Please Select Please Select
Where specialist paint finishes are required they
Specialist Paint checks
are applied by an approved, coatings provider.
T (sub contract paint
Checks are carried out and reports are provided
- - - Please Select Please Select Please Select
process)
to meet customer requirements.

KEY: R = ROTORK P = PURCHASER 3 = THIRD PARTY

H = HOLD POINT – ACTIVITY STOPS W = WITNESS POINT (10% OF TOTAL ORDER QUANTITY IS OFFERED FOR PERFORMANCE TESTING) RV = REVIEW - REVIEW OF AVAILABLE DOCUMENTATION

THE FOLLOWING TESTS SHALL BE CARRIED OUT:

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PT. WANDA PUTRI PT. KPI RU VII KASIM
Rotation Speed/Time Syncrophase Monitor relay
Direction to close Position counter (Resolver) Indication relays
Open & close rated torque Sleep circuit ESD function
Open & close stall torque Battery power functionality Interlocks
Hand operation Customer remote supply Infra red
Cold Stall Timer Local controls Local display
Remote controls Option cards (where fitted)
Don Roy

PAGE 3 OF 3 PRE-ORDER ITP/QP -19/09/19