Quality Assurance Plan for Structural Fabrication & Erection

PROJECT : 4000 MT COAL SILO FOR WAGON LOADING Doc No. NSCL/AMPTPL/1236/QAP-001
Site AMPTPL Date: 8-Nov-2012
Rev: 0

Quantum of Scope of Inspection

Sl No Activity Description Characteristics of Inspection Method of Inspection Reference Document Acceptance Norms Record
Inspection NSCL Client

A Prior to Fabrication
Material Inward Reg/
Appd Drawing/ Appd Drawing/
A.1 Incoming Materials(NSCL Supply) Visual/Review Visual/Review 100% Format No.: W/R W/R
Packing Slip/Material TC Packing Slip/Material TC
NSCL/AMPTL/001

Review of Calibration Certificates of Review of Calibration Review of Calibration Calibration

A.2 100% Project Specification Project Spec W R
instruments/ Equipments (as applicable) Certificate Certificate Certificate

Chemical & Mechanical Review of Batch, Test ASME Sec II C/ ASME Sec II C/ Batch Test
A.3 Welding consumables Approval Each Batch W W/R
Properties Certificates & Visual Project Spec/ Appd Drg Project Spec/ Appd Drg Certificate
ASME Sec IX/ Project ASME Sec IX/ Project
A.4 WPS/PQR Welding Parameters Review of Records 100% WPS&PQR W H
Spec Spec
ASME Sec IX/ Project ASME Sec IX/ Project
A.5 Welder Performance Qualification (WPQ) Qualification Requirement Review of Records 100% WPQ W H
Spec Spec
Certificate and Approval of ASME Sec IX/ Project ASME Sec IX/ Project
A.6 Review of Documents Review of Documents 100% Welder Certificate W H
Welders Spec Spec

Lifting arrangement including test

A.7 Review of Certificate Review of Certificates 100% EHS Procedure EHS Procedure Test Certificates W R
certificates of lifting tackles

B Fabrication Activities (Structural steel & Hopper )

Fitup & Alignment of structural steel(silo Project Spec/Appd Drg/ Project Spec/Appd Drg/ Appd Format &
Fit-up Alignment
B.1 roof,plat form,stair case & lift room) / Visual & Dimensional 100% IS12843/IS7215/ AWS IS12843/IS7215/ AWS Format No.: W Rm
Orientation etc.
hopper/Transition hopper. D1.1/IS2062 D1.1/IS2062 NSCL/AMPTL/002

Visual check of welding including Surface Defects, Project Spec/Appd Drg/ Format No.:
B.2 Visual 100% Project Spec/Appd Drg W W
attachments Reinforcement, Undercut,etc AWS D1.1 NSCL/AMPTL/002

Root DP Test , weld thick < 8mm.(For AWS D1.1/Applicable Format No.:
B.3 Surface/sub surface Defects Visual 100% Appd Drgs/ ASME Sec V W W/R
Hopper grove welds only) Code NSCL/AMPTL/002
Ultrasonic Test for weld thick >8mm.
AWS D1.1/Applicable Clients inspection
B.4 (For Hopper only) ,(UT on AMPTPL Surface/sub surface Defects Visual 100% Appd Drgs/ ASME Sec V W W
Code Report
Scope)
Structure inspection before Inspection Register/
B.5 Readiness of Structure Visual & Measurement 100% Appd Drgs Appd Drgs W W
sand/shot blasting Report
Visual Inspection for
Project Spec/Appd Format No.:
Workmanship & Dry Film Visual 100% Project Spec/Appd Drg W Rm
Drg NSCL/R&S/AMPTL/007
B.6 Surface Prepration & Painting Thickness (DFT)
Project Spec/Appd Inspection Register/
Adhesion Test Visual At random Project Spec/Appd Drg W Rm
Drg Report

Prepared By Approved By
NSCL AMPTL
 Quality Assurance Plan for Structural Fabrication & Erection
PROJECT : 4000 MT COAL SILO FOR WAGON LOADING Doc No. NSCL/AMPTPL/1236/QAP-001
Site AMPTPL Date: 8-Nov-2012

Rev: 0
C Erection Activities(Structure/Hopper/Equipments)
Orientation of structure/hopper sections,
C.1 check for match mark,elevation Orientation,Marking etc Visual 100% Appd Drgs Appd Drgs Appd Drgs W W/R
mark,column no. etc
Alignment of structure/hopper at every Appd Drgs/AWS D1.1/ Appd Drgs/AWS D1.1/IS Format No.:
C.2 Tape/water level/Plumb Measurement 100% W W/R
stage/final stage of erection IS 12843 12843 NSCL/AMPTL/011

Erection,Assembly,Visual check of Surface Defects, Project Spec/Appd Drg/ Project Spec/Appd Format No.:
C.3 Visual 100% W W/R
welding including attachments Reinforcement, Undercut,etc AWS D1.1 Drg/AWS D1.1 NSCL/AMPTL/013

Root DP Test , weld thick < 8mm.(For AWS D1.1/Applicable Format No.:
C.4 Surface/sub surface Defects Visual 100% Appd Drgs/ ASME Sec V W W/R
Hopper grove welds only) Code NSCL/AMPTL/002

Ultrasonic Test for weld thick >8mm.

AWS D1.1/Applicable Clients inspection
C.5 (For Hopper only) ,(UT on AMPTPL Surface/sub surface Defects Visual 100% Appd Drgs/ ASME Sec V W W
Code Report
Scope)

C.6 Removal of Temporary supports Visual Visual 100% --- --- --- W ---

Visual Inspection for Project Spec/Appd Format No.:

Workmanship & Dry Film Visual 100% Project Spec/Appd Drgs W Rm
Surface preparation (Manual Drgs NSCL/AMPTL/007
C.7 Thickness (DFT)
Cleaning) & Painting(touchup/final)
Project Spec/Appd Inspection
Adhesion Test Visual At random Project Spec/Appd Drgs W Rm
Drgs Register/Report
Format No.:
C.8 Punch list preparation/liquidation Visual Visual 100% --- --- W W/R
NSCL/AMPTL/004

overall dimension, level,

Assembly & Erection of Idlers / pulleys Project Spec/Appd
C.9 orientation,alignment,fastne Measurement 100% Project Spec/Appd Drgs Inspection Report W W/R
with bearing Drgs
rs tightness
Dimension, orientation,
Assembly & Erection of Project Spec/Appd
C.10 alignment,fastners Measurement 100% Project Spec/Appd Drgs Inspection Report W W/R
Gearbox/couping/Drive units Drgs
tightness, level
Dimension, straightness,
Project Spec/Appd Inspection
C.11 Assembly & Erection of Belt joint bevel,surface Measurement 100% Project Spec/Appd Drgs W W/R
Drgs Register/Report
finish,belt tightness.
Readiness of Complete
Final Inspection for completion as per Format No.:
C.12 Structure,alignment, Visual & Dimensional 100% Appd Drgs Appd Drgs W H
Drawing NSCL/AMPTL/008
Level, etc
Assembly check,Oil level, Project Spec/Appd Inspection
C.13 Before Trial run Visual & Dimensional 100% Project Spec/Appd Drgs W W
noload test on cables Drgs Register/Report

Temperature rise on
C.14 Final Trial run/Commissioning bearings,E.stop,limit
switch/vibration.
Review of Test &
D Final Documentation
Inspection Documents
Project Spec/Appd Inspection
Visual & Dimensional 100% Project Spec/Appd Drgs W H
Drgs Register/Report
Review of Test & Project Spec/Appd Test & Inspection To be Submitted to Clientfor
100% Project Spec/Appd Drgs
Inspection Documents Drgs Documents review & record

Prepared By Approved By
NSCL AMPTL
 Quality Assurance Plan for Structural Fabrication & Erection
PROJECT : 4000 MT COAL SILO FOR WAGON LOADING Doc No. NSCL/AMPTPL/1236/QAP-001
Site AMPTPL Date: 8-Nov-2012

Rev: 0
Abbreveations

WPS :Welding Procedure Specification NDT :Non-Destructive Testing

PQR :Performance Qualification Record EHS :Environment, Health & Safety

WPQ :Welder Procedure Qualification

Legends
W :Witness Point

R : Review of Document IE: Inspection Engineer

Rm : Random Inspection

H : Hold Point

Prepared By Approved By
NSCL AMPTL
 IE

Prepared By Approved By
NSCL AMPTL
 R

**

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NSCL AMPTL
Prepared By Approved By
NSCL AMPTL