SAMPLE QUALITY ASSURANCE PLAN FOR WELDED CS BUTT WELD FITTINGS (SA 234)

PROJECT NAME KAPP-3,4

CLIENT NPCIL
SUPPLIER/MANUFACTURER
ITEM NAME & TAG NO. CS BUTT WELD FITTINGS (like elbow, tee, reducers)
REF. DOCUMENT / SPEC PC-M-599 AND RELEVANT ASME SE-III NC, ND
Material Specification AS SPECIFIED AT SOR, SA234
Component / Activity Acceptance Agency
Sl. No. Charactaristics Class Type of check Quantum of check Reference Document Format/Record Remarks
Description Standard P W R H
A Incoming Inspection - Row material
ASTM A 515 RMTC/Test
1 Plates Chemical, Mechianical Major Verification of MTC 100% ASTM A 515 Gr 60 2 - 1 1 Ref. Note 1
Gr 60 Certificate
Checks for Surface Defects, Inspection
2 Plates Major Visual Measurement 100% ASTM A 20 ASTM A 20 2 1 1 -
Dimensional checks Reports

B In process Inspection
ASME Sec IX WPS/PQR shall be
Procedure 100% of Welding ASME Sec IX & SEC III NPCIL approved approved by
1 Welding Approval of WPS/PQR Major & SEC III 2 1 1 -
Qualification parameters NC/ND WPS/PQR NPCIL Refer
NC/ND Remark ( C )
NPCIL
Manufacturing of Welded Inspection
2 Fittings Major Welding parameters 100% NPCIL approved WPS approved 2 1 1 - Remark D
fittings Reports
WPS
Check for weld surface Approved Remark D : 25%
ASME SEC V & SEC III Inspection
3 LPE of Weld Seam discontinuity after Root Major Weld Seam Surface 100% LPE 2 1 1 - by 1 After 100%
NC/ND, ASTM E 165 Reports by 2
Pass Procedure
Check for weld surface Approved Remark D : 25%
ASME SEC V & SEC III Inspection
4 LPE of Weld Seam discontinuity after Final Major Weld Seam Surface 100% LPE 2 1 1 - by 1 After 100%
NC/ND, ASTM E 165 Reports by 2
Pass Procedure
Films will be
Radiography (wherever ASME SEC V & SEC III Approved RT Radiography
5 Welded Fittings Major Weld Seam 100% 2 - 1 - reviewed by
specified / applicable) NC/ND Procedure Reports & Films
NPCIL
Monitoring of HT Chart & Refer Remark
6 Heat Treatment Heat Treatment Major 100% ASTM-A-234 ASTM-A-234 2 - 1 -
Temperature & Time record (A)

Testing on One
Chemical
7 Chemical Test Spectro Analysis Major Representative Sample ASTM-A-234 ASTM-A-234 Test Report 2 - 1 -
Composition
per heat

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 SAMPLE QUALITY ASSURANCE PLAN FOR WELDED CS BUTT WELD FITTINGS (SA 234)
PROJECT NAME KAPP-3,4
CLIENT NPCIL
SUPPLIER/MANUFACTURER
ITEM NAME & TAG NO. CS BUTT WELD FITTINGS (like elbow, tee, reducers)
REF. DOCUMENT / SPEC PC-M-599 AND RELEVANT ASME SE-III NC, ND
Material Specification AS SPECIFIED AT SOR, SA234
Component / Activity Acceptance Agency
Sl. No. Charactaristics Class Type of check Quantum of check Reference Document Format/Record Remarks
Description Standard P W R H
YS Testing on One
Tensile Test Major UTS Representative Sample ASTM-A-234 ASTM-A-234 Test Report 2 1 1 -
Elongation per HT Lot
8 Mechanical Test
Testing on One
Hardness Test Major Hardness Representative Sample ASTM-A-234 ASTM-A-234 Test Report 2 1 1 -
per HT Lot
C Final Inspection
Remark D : 25%
Visual check for surface Inspeciton
1 Visual Major Surface check 100% ASTM-A-234 ASTM-A-234 2 1 1 - by 1 After 100%
discontinuity Reports by 2
Remark D : 25%
Dimensional ANSI B 16.9 & PC-M- Inspeciton
2 Dimensions Dimension Check Major 100% B 16.9 2 1 1 - by 1 After 100%
Measurement 599 Reports by 2
Check for surface/sub- Surface & Sub- Approved
ASME SEC V & SEC III Inspeciton Refer Remark
3 NDT Examination surface discontinuity by Major Surface discontinuity 100% MPE/LPE 2 1 1 -
NC/ND Reports (B)
LPE/MPI examination Procedure
Inspeciton
4 Marking & Stamping Identification Major Visual 100% MSS SP-25 MSS SP-25 2 1 1 -
Reports
PC-M-599- Inspeciton
5 Cleaning & Protective coating Corrosion protection Major Visual 100% PC-M-599-Clause 7.3 2 - 1 -
Clause 7.3 Reports
Shipping Release & dispatch Compilation of all history Compliance with PO, PC-M-599-
6 Major 100% PC-M-599-Clause 7 MTC 2 - 1 1
clearance documents Applicable Specs. Clause 7
1- NPCIL QS or his authorised representative (Purchaser) 2- Vendor/Sub-Vendor
Legend
W- Witness Point H- Hold Point R- Review/Verification P- Performing Agency
Notes-
Co-related original material test certificate is acceptable. In absence of Co-related original MTC, sample per lot (Lot means all having same heat mark/material spec. requirement), shall be drawn for chemical &
I physical tests and shall be tested in NPCIL approved lab which shall be witnessed by NPCIL.
II A continuous white strip shall be painted on the major dimensions not extending over the machined surface and end preparation on each piece which has undergone non destructive examination.
REMARK (A): HT of fittings will be carried out in HT furnace duly calibrated within one year & also by using calibrated thermo couples, Chart recorders calibrated within 6 months.
REMARK (B): Where any surface (Internal & External) of a fitting is not completely accessible for examination by MPE then LPE shall be carried out. Sample fittings randomily selected from a lot shall be examined
completely for internal & external surface defects for which sample size will be 2% of a lot with minimum of 3 nos. of fittings. For LPE sample size shall be 10% per size of fittings.
REMARK (C) : NPCIL Q.S. shall witness at least one welder for WPS/WPQ qualification, however vendor has to witness all such WPS/WPQ for all the welders used & record shall be offfered for review.
REMARK (D) : NPCIL may witness LPE & Welding Parameters randomly 10% per size of the fittings by surprise visit.
REMARK ( E ): Calibrated Instruments shall be used during inspection examination and testing.

Approved by NPCIL

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