THERMAX LIMITED

BOILER & HEATER GROUP

INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO.: ITP/ PP0151 /N17
REVISION NO. : 0
COMBUSTER DATE : 20-09-2018
PAGE : 1

1.0 JOB SPECIFIC DATA :

CUSTOMER : Birla Carbon(SKI Carbon Black Inda)

CONSULTANT : NA PROJECT NO: PP0151

INSP. AGENCY : DESIGN CODE : Refer Drawing

2.0 QUALITY STAGES & INSPECTION :

SR. INSPECTION STAGES ACCEPTANCESTANDARD * INSP. BY

NO.
CHARACTERISTICS METHOD EXTENT REF.DOC./ PROCEDURE SUP TL CLI

1 MATERIAL IDENTIFICATION H **W

Review of Material TC Review 100% Drg/Specs.

Check Test, if no MTC Check_Test Code Material Specs.

Dimensions Measurement 10% Drawing/Code

Surface Condition Visual 100% Free From Surface

Defects

Identification & Stamp transfer Visual 100% Hard Stamp / Colour

coding

2 INSPECTION OF BUBBLE CAPS H V

Cap Dimensions, Drill Hole Sizes & Inclination Measurement 5 Samples Drawing
/Lot

Deburring & Finish Visual 100% Free From Burrs

Concentricity (Main Bore with Step Bore) Measurement 5 Samples Drawing

/Lot

3 INSPECTION OF COLD BEND PIPES H V

Orientaion Visual 100% Drawing

Dimensions on layout Layouit 5 Samples Drawing

matching /Lot

Ovality Measurement 5 Samples Max.10%

/Lot

*INSP.BY SUP -SUPPLIER TL -THERMAX LIMITED CLI -CLIENT/TPI

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN) Contd...

 THERMAX LIMITED
BOILER & HEATER GROUP

INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO.: ITP/ PP0151 /N17
REVISION NO. : 0
COMBUSTER DATE : 20-09-2018
PAGE : 2

SR. INSPECTION STAGES ACCEPTANCESTANDARD * INSP. BY

NO.
CHARACTERISTICS METHOD EXTENT REF.DOC./ PROCEDURE SUP TL CLI

4 SETUP & WELDING OF BUBBLE CAPS WITH BEND PIPES H V

SETUP INSPECTION:

Orientation & Alignment Visual & 100% Drawing

Measureme

Set-up dimensions Measurement 100% Drawing

INSPECTION AFTER WELDING:

Welding of Bubble caps with Bend pipe by TIG Process Verify 10% WTS

Weld Soundness PT 10% Procedure/Code

5 SETUP & WELDING OF 'L'SEAM OF MAIN SHELL H V

Set-up Dimensions Measurement 100% Drawing

NOTE: Root run by TIG process, if no backgauging

Weld inspection- Size & Finish Visual 100% Drawing

6 SETUP & WELDING OF 'C'SEAM OF MAIN SHELL H V

Orientation Visual 100% Drawing

Dimensions Measurement 100% Drawing

Straightness Measurement 100% Drawing

Set-up dimensions Measurement 100% Drawing

NOTE: Root run by TIG process, if no backgauging Visual

Welding Inspection-Size & finish Visual 100% Drawing

7 MARKING INSPECTION FOR DRILLING H V

Orienatation Visual 100% Drawing

Pitches & No.of holes Verify 100% Drawing

Alignment of hole centers Line dori 100% Drawing

*INSP.BY SUP -SUPPLIER TL -THERMAX LIMITED CLI -CLIENT/TPI

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN) Contd...

 THERMAX LIMITED
BOILER & HEATER GROUP

INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO.: ITP/ PP0151 /N17
REVISION NO. : 0
COMBUSTER DATE : 20-09-2018
PAGE : 3

SR. INSPECTION STAGES ACCEPTANCESTANDARD * INSP. BY

NO.
CHARACTERISTICS METHOD EXTENT REF.DOC./ PROCEDURE SUP TL CLI

8 INSPECTION AFTER DRILLING H V

Hole dimensions Measurement 100% Drawing

Pitches & No.of Holes Verify 100% Drawing

Hole finsh & deburing Visual 100% free from deburing

9 SETUP & WELDING OF BUBBLE CAPS WITH MAIN SHELL H V

SET-UP INSPECTION:

Orientation Visual 100% Drawing

Set-up dimensions & alignment Measurement 100% Drawing

INSPECTION AFTER WELDING:

Welding Inspection-Size & finsih Visual 100% Drawing

Weld soundness PT 10% Free from relevant

indications

10 FINAL INSPECTION BEFORE PAINTING H **W

Orientation Visual 100% Drawing

Overall Assembly dimensions Measurement 100% Drawing

Straightness Measurement 100% Drawing

Overall weld visual inspection Visual 100% Procedure VT

Nozzles in line Measurement 100% Within 5 mm

Compliance to drawing for scope Measurement 100% Drawing-BOM

Identification Marking (Job no, Drg no, Part No) Visual 100% Drawing

Aesthetics-Weld tacks,Hammer/Dent/Surface Marks,Sharp Corner Visual 100% Free from Surface

Discontinuities

*INSP.BY SUP -SUPPLIER TL -THERMAX LIMITED CLI -CLIENT/TPI

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN) Contd...

 THERMAX LIMITED
BOILER & HEATER GROUP

INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO.: ITP/ PP0151 /N17
REVISION NO. : 0
COMBUSTER DATE : 20-09-2018
PAGE : 4

SR. INSPECTION STAGES ACCEPTANCESTANDARD * INSP. BY

NO.
CHARACTERISTICS METHOD EXTENT REF.DOC./ PROCEDURE SUP TL CLI

11 PAINTING INSPECTION H V

Surface Preparation for Painting Visual 100% Drawing/Specs.

Paint Shade, Make, Batch No., Expiry Date Visual 100% Drawing, Painting
Specs.,Application b
efore expiry

Visual Inspection after painting Visual 100% Complete coverage of

area, No rundowns,
Peel-offs, Cracks

Paint-DFT Measurement 2Spots/m2 Drawing/ Painting

Specs.

Identification Marking (Job no.,Drg.no.,Part no) Visual 100% Drawing

Centreline Marking Visual 100% Drawing

12 INSPECTION RELEASE NOTE H V

Final Document Review Review 100% Drawing, Technical

Specifications

Inspection Release & Certification Issuance of 100% Drawing, Technical

IRN Specifications

3.0 NOTES :

1) Following documents, as applicable are to be reviewed during

inspection.

1. WPS,PQR,WPQ and Welding Technology sheet(WTS)

2. Material Test Certificates
3. Manufacturing Records
4. All the required Inspection Records.
5. Painting Procedure

IT IS MANDATORY FOR MANUFACTURER'S QUALITY CONTROL TO CARRY OUT

INSPECTION OF ALL THE STAGES COVERED IN THIS ITP.

*INSP.BY SUP -SUPPLIER TL -THERMAX LIMITED CLI -CLIENT/TPI

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN)

 THERMAX LIMITED
BOILER & HEATER GROUP

INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO.: ITP/ PP0151 /N17
REVISION NO. : 0
COMBUSTER DATE : 20-09-2018
PAGE : 5

4.0 INSPECTION POINTS

INSPECTION POINTS ARE INDICATE

R Record Review Point RECORD REVIEW POINT is a recording operation in the operation / production
cycle marked by the AI/Customer/TPI. Record of inspection is maintained
and will be made available to AI/Customer/TPI for review during next
HOLD/WITNESS stage Inspection,as applicable.

W Witness Point WITNESS POINT is defined as a notification operation in operation / production

cycle marked by the AI/Customer/TPI to exercise their option to witness
and verify a specific operation. Further processing shall proceed where the
AI/Customer/TPI do not validate their option. The notification shall be
documented in a manner acceptable to AI/Customer/TPI, as applicable.

H Hold Point HOLD POINT is defined as a verification of the operation by the requesting
authority AI,Customer/TPI.Further processing is prohibited until acceptance
of the operation & documentation is completed by the requesting authority.

- - Inspection option will not be exercised

**W Witness Point WITNESS POINT is defined as a notification operation in operation / production
cycle marked by the AI/Customer/TPI to exercise their option to witness
and verify a specific operation. Further processing shall proceed where the
AI/Customer/TPI do not validate their option. The notification shall be
documented in a manner acceptable to AI/Customer/TPI, as applicable.
NO THERMAX INSPECTION AT THERMAX SELF CERTIFIED VENDORS.

V Verification Vendor is not requested to notify the purchaser.The purchaser's inspector

will monitor the test/inspection during his visit or periodical inspection.

5.0 RECORD OF REVISIONS :

REV NO. DATE CHANGES

0 20-09-2018 FIRST ISSUE

PREPARED BY CHECKED BY APPROVED BY ACCEPTED BY CLIENT/CONSULTANT/TPI

Gautam Kulkarni- Suresh Chodankar Suresh Chodankar

DATE : 20-09-2018 DATE : 20-09-2018 DATE : 20-09-2018

*INSP.BY SUP -SUPPLIER TL -THERMAX LIMITED CLI -CLIENT/TPI

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN)