BHEL SQP:OF: 02 / Rev.

14 Page 2 of 9

RECORD OF REVISIONS

Rev.No./ Date Details of revision

Rev.04 02.09.2005 PSL-3G added in Cl.2.5, 2.8, Note-3, Note-5 & Note-6
Note-2 (7) – Bull plug, Valve removal plug added
Note-3(g) modified
Note-5 Edited
Rev.05 20.12.2007 Cl.2.5 revised. Hardness test for PSL-1 Tubing hangers included.

Rev.06 10.01.2015 Cl 1.1 become Cl.1.1 and Cl.1.2. Modified

Old Cl.1.2,1.3, become Cl.1.3,1.4
Cl.1.1,1.2 & 1.4-TDC reference included
Cl.2.2,2.3 modified.
Cl.3.2 modified.
Note-2 Table point 7 modified.
Note-3 Table modified.
Note-4 Cl.3.b.vi modified
Note-5 Cl.e modified.
Rev.07 03.10.2016 Note-7& 8 added
MT, PT, RT, UT procedure reference included in cl.2.3 and cl.2.5
Painting scheme reference changed in Cl 3.2
Rev.08 03.02.2017 Cl. 3.2 modified.
Rev.09 23.09.2019 Revised in entirety based on API 21st Edition requirements and for better
clarity
Rev.10 10.10.2019 Cl.2.1,2.2, 2,4,2.6, 3.2, Note 5e & 5f modified.
Note 2b added
Rev.11 10.08.2020 Revised in line with API 21st Edition Addendum 1 and for Better clarity
Cl.2.4 modified
Note 2b Table modified to include lot size requirement up to 500
Note 3 Table modified to include Volumetric NDE for Partial weld overlay for
PSL 3 to 4
Note 5e(iii) Table modified to include lot size requirement up to 500
Note 5e(iv) added
Note 5f(iv) added
Note 7 modified
Rev.12 20.10.2020 Format of record updated under Type of record column in SQP
Cl.2.7 modified
Note 2a modified
Note 5e(iv & vi) modified
Rev.13 27.09.2021 Note-2,3,5e modified

Rev.14 24.06.2022 Note 3 modified

 Check SQP: OF: 02/ Rev.14
SL. Cl Type Quantum Reference Doc. / Acceptance Type of Page 3 of 9
Component / Operations Characteristics Agency
No. Norms $ Record

REMARKS

1.0 MATERIALS Material as per BHEL approved drawings. Procured from BHEL
approved vendors.

1.1 Pressure Containing Part: Chemical , Mechanical A Review of 100% Specification/ TC QC Refer Note-1
Castings, Forgings & Hardness & documents as TDC:0:411
Barstock: Soundness as per TDC TDC:0:410
Casing head, Casing applicable
spool, Tubing spool &
Tubing bonnets, Adapter
spools, Spacer Spools &
Crossover Flanges, Back
pressure valves ,Valve
Removal Plug

1.2 Pressure Controlling Part: Chemical & Mechanical A Review of 100% Specification/TDC:0:409 TC QC Refer Note-1
Forgings & Barstock: Properties,Hardness & documents as
Casing Hanger (Slip & Soundness as per TDC
Spider) &Tubing Hanger, applicable
Anchor Screws, Locator
screw

1.3 RJ gasket Compliance to PO A Review of 100% Purchase Spec.& Drawing TC QC Procured with
documents relevant TC

1.4 Fasteners Compliance to PO A Review of 100% Drawing & TDC 5:164 * QC *Compliance Certificate
documents
1.5 Elastomers Shelf life (Elastomers) A Review of 100% Drawing & TDC 5:151 * QC *Compliance Certificate
documents
2.0 IN PROCESS CONTROL Refer Note-7

2.1 Personnel Qualification Visual Examination A Review of 100% QMI 21 / ASNT SNT-TC-1A QR QC QR-Qualification Record
records
Non Destructive A Review of 100% ASNT SNT-TC-1A QR ND
Examination records
Inspection A Review of 100% QMI 21 / Documented QR QC
records Procedure
2.2 Machining of Components Critical dimensions B Measurements 100% Drawing & QCP:003 DR QC Refer Note-2
 Check SQP: OF: 02/ Rev.14
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Component / Operations Characteristics Agency
No. Norms $ Record

REMARKS

Other features B Measurement Note 2b Drawing DR QC DR-Dimension Report/

Gauging B Measurement 100% Drawing & SIP:VS:24 DR QC Logbook

2.3 Welding Procedure & B Review of 100% ASME Sec IX PQR WTC/
Performance WPS/PQR/ API 6A WQR QC
Qualification WQR

2.4 Hardfacing /Weld overlay Soundness-NDE B MPI / 100% BHE:NDT:VV:OFE:MT:04 / NDE ND Refer Note-3
/ welding LPI / BHE:NDT:VV:OFE:PT:03 / Report
RT / BHE:NDT:VV: RT:07 /
UT BHE:NDT:VV:UT:18
PWHT B Review of 100% Drawing, WPS & QCP:003 Chart/ QC
Log
documents
Hardness (except weld B Measurement 100% Drawing/ASTM E10 or E18 or HR/ QC HR- Hardness Report
overlay& Hard facing) E110; Note: 1, 5e Log

2.5 Nitriding Hardness B Review of 100% Drawing, SIP:VS:04 / DR QC Ref. Note-4

Carburising Minimum thickness documents HTS-WI-08
Molybdenum disulphide
coating

2.6 Machined Parts: Hardness B Measurement Note 5 Drawing/ASTM E10 or E18 or HR/ QC
Body casing head, Body E110; Note: 1, 5e Log
tubing spool, Body casing
spool, Casing Hanger Soundness-NDE B MPI or LPI Note 5 MPI for ferromagnetic material: NDE ND MPI: Prod method
(spider), Mandrel type BHE: NDT: VV: OFE:MT:04 Report Prohibited
hanger (tubing hanger), -PSL 1 & 2:Dry method Refer Note-5f.
Anchor screw and Plugs -PSL3, 3G & 4 Wet florescent
Method
LPI for ferromagnetic & non-
ferromagnetic materials:
BHE:NDT:VV.OFE:PT:03
- PSL 1 to 4
2.7 Well head assembly/units Completeness B Visual 100% Drawing HC QC Ref.Note-5
(assy.of casing head, HC- History Card
 Check SQP: OF: 02/ Rev.14
SL. Cl Type Quantum Reference Doc. / Acceptance Type of Page 5 of 9
Component / Operations Characteristics Agency
No. Norms $ Record

REMARKS

casing spool &Tubing

spool)

2.8 Hydro testing Shell strength A Visual 100% SIP:VS:08 HC QC Refer Note-5

2.9 Gas test Performance A Visual 100% SIP:VS:12 (for PSL 3G & 4 HC QC Refer Note-5
only)

2.10 Dewatering Protection A Visual 100% SIP:VS:08 - QC

3.0 FINAL INSPECTION

3.1 Assemblies Marking & Stamping B Visual 100% SIP:VS:10 - QC Refer Note-5

3.2 Painting, preservation & Appearance & B Visual 100% SIP:PP:22 FR QC FR- Final Inspection
protection protection Report
DFT B Measurement random SIP:PP:22 FR QC

3.3 Certification Preparation of History B Compilation 100% Drawing * QC Refer Note 5 & 6,
Card / Certificate of *History Card/Certificate
Conformance of Conformance

$- Latest version of referred procedures/ documents shall be followed.

Legends: Cl: Class (A: Critical; B: Major) R: Review; TC: Test Certificate; DFT: Dry Film Thickness; OPS: Operations Process Sheet; RT: Radiographic Test;
UT: Ultrasonic test; MT: Magnetic Particle Test; PT: Penetrant Test; ND: NDTL; QC: Quality Control; WTC: Welding Technology Centre;
R: Test/Dimensional Reports; TC: Test Certificate; PQR: Procedure Qualification Record; WPS: Welding Procedure Specification;
WQR: Welder Qualification Record;
 SQP:OF:02 / Rev.14
BHEL Notes: Page: 6 of 9

Note-1: *Sealing bore depth Measured dimensions

Hardness requirement for raw materials normally used: 5 Tubing spool *RJ groove dimension Measured dimensions
*Flange thickness at top Measured dimensions
Materials Hardness(HBW) *Flange thickness at bottom Measured dimensions
60K 174-235 *Secondary packing sealing Measured dimensions
75K 197-235 bore diameter
100K (17-4 PH) 269-311 *Secondary packing sealing Measured dimensions
105K 255-311 depth
*Tubing hanger sealing bore Measured dimensions
Note-2: Tube hanger sealing depth Measured dimensions
*Bit pilot bore Measured dimensions
a) List of critical dimensions & other features of components of "Wellheads" of oil field Flange holes PCD and hole Measured dimensions
equipment that shall be verified after machining of components. The characteristics Diameter, No. of holes Measured dimensions
marked (*) are considered as critical and shall be checked & recorded in Dimension Threads Gauging
report/ Logbook by Quality Control. Others shall be checked & recorded in Dimension *Intersection of test port holes Status by visual inspection
report/ Logbook by task performer. 6 Casing spool *RJ groove PCD. Measured dimensions
Sl.No Component . Dimensions Remarks (Top & Bottom)
*Flange thickness at top Measured dimensions
1 Flanges Threads Gauging
*Flange thickness at bottom Measured dimensions
Drill Holes PCD, No. of holes, Measured dimensions
*Primary packing sealing bore Measured dimensions
Hole dia
diameter
*RJ groove dimension Measured dimensions
*Primary packing sealing depth Measured dimensions
*Flange thickness Measured dimensions
*Secondary packing sealing Measured dimensions
2 Slip *Inside diameter Measured dimensions
bore diameter
*Outer diameter Measured dimensions
*Secondary packing sealing Measured dimensions
*Taper ratio Status by Blue match/
depth
measurement
Bit pilot sealing bore dia. Measured dimensions
3 Spider Assy. Taper ratio Status by Blue match/ Flange holes PCD & hole Measured dimensions
measurement Diameter, No. of holes Measured dimensions
Minor end ID Measured dimensions Threads Gauging
Slot width Measured dimensions Taper ratio Status by blue match/
Slot length Measured dimensions measurement
4 Body casing Threads Gauging Intersection of test port holes Status by visual inspection
head Bottom bore diameter Measured dimensions 7 Plugs, Bull Threads Gauging
Min. Bore diameter Measured dimensions plug, Valve
*RJ groove dimension Measured dimensions removal plug
Drill holes PCD Measured dimensions 8 Body test plug *IFRI Threads Gauging
Taper ratio Status by blue match/ Other threads Gauging
measurement *`O' ring groove width Measured dimensions
*Flange thickness Measured dimensions *`O' ring groove depth Measured dimensions
*Sealing bore diameter Measured dimensions *`O' ring groove OD Measured dimensions
 SQP:OF:02 / Rev.14
BHEL Notes: Page: 7 of 9

9 Test plug * OD Measured dimensions Note-3: Weld NDE:

bushing *`O' ring groove width Measured dimensions Weld Type Stages PSL 1 PSL 2 PSL 3/ 3G PSL 4
*`O' ring groove diameter Measured dimensions
Pressure- Preparation* -- -- a a
Taper angle Gauging/Measurement
containing Completion** -- a, b & a, b, e & a, b, e & (c/d)
Taper major end diameter Gauging/Measurement
(c/d) (c/d)
10 Anchor Thread dimension Gauging
Non-Pressure Preparation* -- -- a a
screws Surface Finish Visual
containing Completion** -- a a&e a&e
Packing area Dimension Measured dimensions
Pressure- Preparation* -- h h h
Packing area Surface finish Visual
containing Completion** -- a, b & a, b, e & a, b, e & (f/g)
11 Flanges - Flange thickness Measured dimensions
repairs (f/g) (f/g)
Pack off & RJ Groove Dimension Measured dimensions
Weld metal Preparation* -- -- b b
DSA type, PCD of Bolt Holes Measured dimensions
overlay-partial Completion** -- b b&i b&i
Spools - Sealing / Packing Bores Measured dimensions
overlay(other
Spacer &
than ring
Crossover
grooves)
type
Weld metal Preparation* -- -- b b
overlay-partial Completion** -- b b b
overlay(on ring
b) critical dimensions and other features of Slip & Spider and Other features of other
grooves)
components (PSL 1 & 2)
Weld metal Preparation* a a a, b a, b
Lot Size Sample size Acceptance Criteria overlay-full Completion** a, b a, b a, b & i a, b & i
(Nos) (Nos) (as per ISO 2859-1:1999, Level II, 1.5 AQL) overlay
2 to 8 2 a - Visual examination
9 to 15 3 If one sample fails, entire lot shall be b – Liquid Penetrant Method (PT for all ferro magnetic material or non-ferro
16 to 25 5 dimensionally inspected magnetic material) or Magnetic Particle Method (MT for all ferro
26 to 50 8 magnetic material)
51 to 90 13 c - Radiation (radiography or imaging) examination
91 to 150 20 If two samples fail, entire lot shall be
151 to 280 32 dimensionally inspected d - Ultrasonic examination
281 to 500 50 If three samples fail, entire lot shall be e - Hardness test (weld)
dimensionally inspected f - Ultrasonic examination: For PSL 1& 2: For PSL 1 & 2: if weld repair is
greater than 25% of wall thickness or 25 mm (1 inch) whichever is less;
PSL 3,3G& 4(except Slip & Spider): each component shall be dimensionally For PSL 3,3G & 4: if weld repair is greater than 20% of wall thickness or
inspected 25 mm (1 inch) whichever is less, or if the extent of the cavity exceeds
approximately 65 cm 2 (10 in2)
g - Radiation (radiography or imaging) examination: For PSL 1 & 2: if
weld repair is greater than 25% of wall thickness or 25 mm (1 inch)
whichever is less; For PSL 3, 3G & 4: if weld repair is greater than 20%
of wall thickness or 25 mm (1 inch) whichever is less, or if the extent of
the cavity exceeds approximately 65 cm 2 (10 in2)
h - Liquid Penetrant Method or Magnetic Particle Method as applicable for
material (base or weld) defects only.
 SQP:OF:02 / Rev.14
BHEL Notes: Page: 8 of 9

i - Measurement of overlay thickness & Ultrasonic testing on Weld metal overlay
Preparation* = Surface preparation, joint preparation, fit up & preheat.
Completion** = After all welding, post weld heat treat and machining, except for volumetric NDE which
shall be done prior machining that would limit effective interpretation of results .
Note-5: The following shall be recorded in the history card.
a. Traceability:
For PSL 2 to 4
The traceability to Test Certificates of Body Casing Head, Body Tubing
Spool, Body Casing Spool, Tubing Hanger and Casing Hanger, Flanges

Note-4: For PSL 3, 3G & 4

1) Requirement for Nitriding (Wherever specified in the drawing.):
Material Grade
AISI 410 22 HRC max.
ASTM A 564 Type 630 33 HRC max.
Austenitic SS 22 HRC max.
Austenitic Precipitation
hardened SS 35 HRC max.
AISI 41XX Steels 22 HRC max.
AISI 5012 22 HRC max.
Surface case hardness:
AISI 41XX:450 HV (45 HRC) minimum
Other steels: 600 HV (55 HRC) minimum
In addition, the serial numbers of Body Casing Head, Body
Case depth mm Tubing Spool, Body Casing Spool, Tubing Hanger and
0.08 - 0.15 Casing Hanger of all assemblies.
0.05 - 0.10
0.05 - 0.10 b. Hydraulic Testing for PSL 3, 3G & 4: Identification of the recorder used.
0.05 - 0.10
c. Gas Testing for PSL-3G & 4:
0.08 - 0.15 Actual Test pressure & actual holding period duration
0.10 - 0.15
d. Heat Treatment Records:
For PSL-3, 3G: HT Records of actual temperature and actual time at soaking
temperature.
For PSL-4: HT charts showing temperature and time.

e. Hardness Test:
2) Wherever specified in the drawing, the following coating shall be used for
stainless and K-monel components to provide resistance against galling i. PSL 2 to 4 (All Material Class) and PSL 1(Material Class DD, EE, FF &
at temperature. upto 148.8 deg.C. HH): Each component shall be hardness tested.

a) Coating material: Molybdenum disulphide, Multi-Polymer binder ii. PSL 3, 3G & 4:

b) Process of application: Body & flanges: additionally, one hardness test shall be performed on each
i) Vapour degrease-trichlorethylene or perchlorethylene. finished part (body & flanges) with additional tests on each end connector
ii) For light roughening of surface to be coated face. When it is not possible to hardness test the end connector face, the
use dry bead of 120 grit size. hardness test shall be performed on the nearest accessible surfaces.
iii) Apply Multi-Polymer coating.
iv) Apply Molybdenum Disulphide coating. Tubing hangers: additionally, one hardness test shall be performed as
v) Bake at 176.7 - 190.6 deg.c for one-hour min. specified in drawing
vi) Minimum thickness shall be 0.01 mm per side
 SQP:OF:02 / Rev.14
BHEL Notes: Page: 9 of 9

iii. PSL 1 - up to 5000 psi working pressure (Material Class AA, BB & CC):  Pressure Test Records
 For 3G additionally Gas test records also to be furnished
Lot Size Sample size Acceptance Criteria
(Nos) (Nos) (as per ISO 2859-1:1999, Level II, 4.0 AQL) 2. For PSL-4: For components & assembled equipment.
2 to 8 2  All Records / Certifications as in 1.
9 to 15 3 If one sample fails, entire lot shall be hardness tested  Gas test records.
16 to 25 5  NDE Records.
26 to 50 8
51 to 90 13 If two samples fail, entire lot shall be hardness tested  Hardness test records.
91 to 150 20 If three samples fail, entire lot shall be hardness tested  Material test records.
151 to 280 32 If four samples fail, entire lot shall be hardness tested  Heat treatment records.
281 to 500 50 If six samples fail, entire lot shall be hardness tested
Note-7: Some of the machining, Welding, Heat treatment, Coating and Plating
iv. PSL 3 &4: When the WPS requires PWHT, hardness testing shall be activities are outsourced at the sub-contractor’s facility by OP&C. In such cases, the
performed after all heat treatment on the weld metal and the base metal requirements specified in this Quality Plan are applicable for the activities performed
within 13 mm (0.5 in.) from the weld to conform to above i to ii. When the at sub-contractor’s facility also.
WPS does not require PWHT, the weld metal at a minimum shall be
hardness tested to conform to above i to ii. Note-8: Packing:

v. For Spider: one sample per offered lot shall be hardness tested. if selected Packing shall be done as per the procedure LOG: WI: 012
sample fails, entire lot shall be hardness tested.

vi. The hardness shall be recorded in the Hardness Test report & History
card/Logbook, as applicable, and the same shall be punched on the
components

f. Surface NDE:
i. Surface NDE report reference shall be recorded
ii. PSL 1: one casting from each heat on all accessible wetted & sealing
surfaces. If the casting fails, Surface NDE shall be performed on all
Castings from that heat on all accessible wetted & sealing surfaces.
iii. PSL 2 to 4: Each finished component (refer Cl.2.6) shall be examined on
all accessible wetted & sealing surfaces.
iv. PSL 3 to 4: In addition to iii, additionally all accessible surfaces of each
finished part shall be examined

Note-6: The following records shall be furnished to the customer.

1. For PSL-3 & 3G: For assemblies.

 Certificate of conformance stating that "equipment meets the requirements
of current edition of API specification 6A and the temperature and materials
class."
 Assembly traceability Records