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Quality Assurance Program

Quality and EH&S ManagerThe ultimate goal of any project is to make the production process work per the customer’s specification. Quality Assurance is the monitoring and assessment of each project detail to achieve a high standard of quality and craftsmanship.

EPIC has a dedicated Quality Assurance Specialist who oversees our rigorous quality assurance (QA) program. This proprietary QA process features a multi-step system beginning from concept phase, to the machine assembly and continuing through our fabrication plant startup.

Our QA program covers many areas, including:

Welding

    • Welding
      • Our full-time certified Welding Inspector oversees all welding activities in the plant and performs all welding procedure qualification testing
      • All EPIC welders pass the necessary welding procedure qualifications and meet welding procedure specifications for each job
      • EPIC performs Non-Destructible Examinations (NDE’s) for every weld test
      • American Welding Society(AWS) standards adhered for every job
      • Our quality control program covers all welding completed in our fabrication plant, including Flux Core Arc Welding(FCAW), Gas Metal Arc Welding(GMAW), and Shielded Metal Arc Welding(SMAW)

Testing

    • Testing
      • Calibration standards are checked by our Quality Assurance Specialist, including pressure tests with up-to-date gauges
      • FAT testing – FAT testing is completed for every project fabricated in EPIC’s plant. It is overseen simultaneously by our Quality Assurance Specialist and Project Manager. 

Quality Checks

    • Quality Checks
      • A series of quality checks are performed throughout the assembly, fabrication and testing process. These checks include:
        • Dimensional checks
        • Pressure checks
        • Alignment checks
        • Plumb and level checks
        • Weld checks 

Complete Quality Assurance

Our complete quality assurance program includes machine assembly and quality control checks by our skilled craftsmen, our fabrication plant foreman, our quality control specialist, and the project manager.

Structural Fabrication

    • Machine AssemblyStructural fabrication
      • Structural member size verification
      • Equipment anchor bolt hole layout verification
      • Dimensional verification
      • Squareness & plumb/level check
      • Visual weld quality verification
      • Overall structural fabrication acceptance 

Structural Assembly

    • Structural Assembly
      • As built material matches machine print call out
      • Dimensional checks
      • Tolerance checks
      • Fastener grade matches print specifications
      • Bolt torque check
      • Squareness & plumb/level check
      • Material reports documented
      • Overall structural assembly acceptance 

Mechanisms

    • Mechanisms
      • Mechanisms slide with proper amount of friction
      • Mechanisms articulate with proper amount of friction
      • Mechanisms move through range of motion without binding
      • Meets range of motion specification as per design
      • Proper lubrication is present
      • Articulation points are captive 

Equipment

    • Equipment 
      • All equipment matches print specifications
      • User manual is present for applicable equipment
      • Connection to equipment is secure and to specifications
      • Alignment and gear box lubrication check

Surface Finishing

    • HydrotestingSurface Finishing
      • Correct metal finish
      • Correct paint finish and thickness
      • Acceptable galvanizing finish and thickness
      • Overall surface finish acceptance 

Electrical Panel Assembly

    • Electrical Panel Assembly
      • Component layout verified
      • Panel labeling complete
      • Cut outs verified
      • Fuse/CB size checks complete
      • Signal cable shield grounding verified
      • Wire color codes verified
      • Screw torque checks complete
      • Conduit entries/drip loops verified
      • Power/signal wiring separation
      • Point to point checks are complete
      • Power up tests are complete
      • Overall electrical panel acceptance 

Electrical Installation

    • Electrical Installation
      • All enclosures and control panels are clean and free of debris
      • Conduit entries/drip loops are in correct locations
      • Panel labeling verified
      • Enclosure doors open freely w/ no interference
      • Legend plates are square and tight
      • Wires do not kink when control panels are closed
      • Wires and air lines are numbered correctly
      • Conduit is properly routed and supported
      • Check that all labels are installed
      • Check that all conduit fittings are tights and have gaskets & covers installed
      • Check misc. hardware (enclosure mounting, etc.)
      • Point to point checks are complete
      • Power up tests are complete
      • Component accessibility verified
      • NEC requirements are met
      • NEC-Haz area requirements are met
      • Check EPIC label installed and straight
      • Client specifications are met
      • Grounding checks completed
      • Electrical ringout performed (yellow lined)
      • Overall electrical acceptance 

Packaging/Shipping

    • Packaging/Shipping
      • Overall system clean up and wipe down
      • Sensitive instruments are disassembled and packed securely
      • Cribbing, blocking, and banding installed
      • Temporary shipping braces are clearly identified for removal later
      • Loading and rigging plan reviewed with Project Manager
      • Equipment ordered for rigging
      • Overall packaging/shipping acceptance 

EPIC completes turnkey systems in our full service fabrication plant. For more information regarding EPIC’s turnkey projects or our quality control program, please contact and engineer today.

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