BHEL SQP:OF: 01 / 14 Page 2 of 10

RECORD OF REVISIONS

Rev.No./ Date Details of revision

Rev.05 29.08.2005 3G added in Cl.2,5, 2.8.4, Note-3, Note-5 & Note-6

Note-2 (16) – Bull plug, Valve removal plug added
Note-3(g) modified
Note-5 Edited

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

Old Cl.1.2,1.3,1.3.1,1.3.2,1.4 re-numbered as
Cl.1.3,1.4,1.4.1,1.4.2,1.5
Cl.1.1,1.2 & 1.5-TDC reference included
Cl.2.2,2.3, 2.5 modified
Note-2. Table Point 7 modified.
Note-3 Table modified.
Note-4 Cl.2.b.vi modified
Note-5 Cl.a and e modified.
Rev.07 03.10.2016 Title of the procedure modified
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 16.01.2017 Existing Cl.1.4.2 deleted and added in Cl.2.7.
New Cl.2.8-SSV/USV and actuators added.
Existing Cl.2.7 & Cl.2.8 become Cl.2.9 and Cl.2.10
Cl. 3.2 modified
Note-2 modified Sl.No.19 and Sl.No.20 added
Note-6 modified to include SSV/USV requirements.
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 1 modified to include material CA6NM in table
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
Note 2a modified
Note 5e(iv& v) modified
Rev.13 18.12.2021 Note-2,3,5e modified
Rev.14 24.06.2022 Note-3 modified
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Reference Doc. / Acceptance Type of
SL. No. Component / Operations Characteristics Cl Type Quantum Agency Page 3 of 10
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/ Properties, Hardness & documents as TDC:0:411
Barstock: Body, bonnet, Soundness as applicable per TDC TDC:0:410
stem, Flanges

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
FBV: Gate & Seat ring Soundness as applicable per TDC
Choke: Seat

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

1.4 Actuators: Sub delivery Compliance to purchase A Review of 100% Purchase Spec.& Drawing TC QC Procured with relevant
order documents TC

1.5 Fasteners Compliance to PO A Review of 100% Drawing, TDC 5:164 * QC *Compliance Certificate
documents
1.6 Elastomers Shelf life (Elastomers) A Review of 100% Drawing & TDC 5:151 * QC *Compliance Certificate
documents
1.7 Flow bean Compliance to purchase A Review of 100% Drawing & TDC 5:201 * QC *Compliance Certificate
order 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 Measurement 100% Drawing & QCP:003 DR QC Refer Note-2
Other features B Measurement Note 2b Drawing DR QC
Gauging B Measurement 100% Drawing & SIP:VS:24 DR QC DR-Dimension Report/
Logbook
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Reference Doc. / Acceptance Type of
SL. No. Component / Operations Characteristics Cl Type Quantum Agency Page 4 of 10
Norms $ Record
REMARKS

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

documents Log

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, Molybdenum Hardness & B Review of 100% Drawing & SIP:VS:04 DR QC Refer Note-4
disulphide coating Minimum thickness documents

2.6 Machined Parts: Hardness$ B Measurement Note 5 Drawing/ASTM E10 or E18 or HR/ QC $ Except Seat(Choke)
Body, Bonnet, E110 Note:1,5e Log and Gate & seat ring of
Stem, Flanges, PSL 1 & 2 of Material
Gate & Seat ring (FBV& Class AA, BB & CC.
SSV),Seat (choke) Soundness-NDE* B MPI or LPI Note 5 MPI for ferromagnetic NDE ND MPI: prod method
material: Report prohibited.
BHE:NDT:VV.OFE:MT:04- * PSL 1 to 4 – Body,
PSL 1 & 2:Dry method Bonnet, Stem & Flanges
-PSL3, 3G & 4 Wet florescent PSL 3 to 4 – Gate & Seat
Method ring (FBV, SSV), Seat
LPI for ferromagnetic & non- (Choke)
ferromagnetic materials: Refer Note-5f
BHE:NDT:VV.OFE:PT:03
- PSL 1 to 4

2.7 Assembly of full bore Completeness B visual 100% Drawing & OPS HC QC HC- History Card
valve Refer Note-5

2.8 Actuator Strength,Leak Tightness A visual 100% Drawing & SIP:VS:15 HC QC

& Functional Test
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Reference Doc. / Acceptance Type of
SL. No. Component / Operations Characteristics Cl Type Quantum Agency Page 5 of 10
Norms $ Record
REMARKS

2.9 SSV and Actuator Strength,Leak Tightness, A visual 100% Drawing & SIP:VS:01 HC QC
Bore passage &
Functional Test
Gas test for PSL 3G & 4 A visual 100% Drawing & SIP:VS:12 HC QC
2.10 Tree Assembly Completeness B visual 100% Drawing. & OPS HC QC Refer Note-5

2.11 Testing:

2.11.1 Shell test* Strength A visual 100% Drawing, SIP:VS:08 HC QC *Both as FBV & tree
assembly (Note-5)

2.11.2 Seat test# Leak tightness A visual 100% Drawing, SIP:VS:08 HC QC # Both FBV & Back
Pressure Valve

2.11.3 Drift test* Bore passage A visual 100% Drawing, SIP:VS:08 HC QC

2.11.4 Gas test (for PSL 3G & 4) Performance A visual 100% Drawing, SIP:VS:12 HC QC For FBV only

2.11.5 De-watering* Protection A visual 100% Drawing, SIP:VS:08 - QC

2.11.6 Torque test Opening torque A Measurement 100% Drawing, SIP:VS:08 HC 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 & protection B visual 100% SIP:PP:22 FR QC FR- Final Inspection
protection DFT B Measurement random SIP:PP:22 FR QC Report

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;
TC: Test Certificate; PQR: Procedure Qualification Record; WPS: Welding Procedure Specification; WQR: Welder Qualification Record;
 QP No.: SQP: OF:01
BHEL NOTES REV.: 14 Page: 6 of 10

Note-1: Flow beans sealing area Gauging

taper Gauging
Hardness requirement for raw materials normally used: *Flow beans thread
5 Full Bore *RJ groove dimension Measured dimensions
Materials Hardness (HBW) valve body *Flange thickness Measured dimensions
60K 174-235 *3rd flange bore dia. & depth Measured dimensions
75K 197-235 *Bonnet locating dia. & depth Measured dimensions
75K (CA6NM) 197-255 *Seat ring locating bore dia. Measured dimensions
100K (17-4 PH) 269-311 *Through bore diameter Measured dimensions
105K 255-311 Threads Gauging
Flange holes PCD & hole Measured dimensions
150K 327-371
diameter No. of holes
Note-2:
6 Seat ring *Inside & outside dia. Measured dimensions
a) List of critical dimensions & other features of components of "Full Bore valves, *Groove width & groove dia Measured dimensions
Surface Safety Valves and Tree Equipment" of oil field equipment that shall be *Overall length Measured dimensions
verified after machining of components. The characteristics marked (*) are 7 Gate Drill holes center distance Measured dimensions
considered as critical and shall be checked & recorded in Dimension report/logbook *Thickness Measured dimensions
by Quality Control. Others shall be checked & recorded in Dimension report/logbook Overall length Measured dimensions
by task performer. Top hole diameter Measured dimensions
Sl.No Component Dimensions Remarks Bottom hole diameter Measured dimensions
1 Tree Bonnet Threads Gauging Locating diameter Measured dimensions
Drilling holes PCD Measured dimensions Vertical hole diameter Measured dimensions
*Flatness Helium band 6- visual
*RJ Groove dimension Measured dimensions
Inspection
*Flange thickness Measured dimensions
*Sealing bore diameter Measured dimensions 8 Stem *Threads Gauging
Intersection of test port holes OK status by visual *Packing area diameter. Measured dimensions
inspection *Bearing Area Step length Measured dimensions
2 Studded Tee/ *RJ groove dimension Measured dimensions 9 Bonnet *Bottom step diameter. Measured dimensions
Cross/Flanged *Thickness Measured dimensions (FBV,SSV) *Step depth Measured dimensions
*Internal bore diameter. Measured dimensions *Packing bore diameter Measured dimensions
Threads (Except flanged) Gauging *Flange Thickness Measured dimensions
*PCD of studded holes Measured dimensions Drill Holes PCD Measured dimensions
Drill holes PCD Measured dimensions *Threads Gauging
3 Flow adapter *Flange Thickness Measured dimensions 10 Clevis Nut Threads Gauging
*Taper ratio Status by Blue match / Slot width and slot Measured dimensions
measurement Overall length depth
*Threads Gauging Bore diameter Measured dimensions
*Drill holes PCD Measured dimensions depth
*RJ groove dimension Measured dimensions Measured dimensions
4 Choke Body *Flange thickness Measured dimensions depth
*RJ groove dimension Measured dimensions 11 Gate Nut Outside diameter Measured dimensions
PCD of drill holes Measured dimensions Threads Gauging
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BHEL NOTES REV.: 14 Page: 7 of 10

OK status by visual *Seat ring locating bore dia. Measured dimensions

Lapping inspections *Through bore diameter Measured dimensions
12 Flow beans *Taper angle match OK status by blue Flange holes PCD & hole Measured dimensions
Bore dimension matching Measured diameter No. of holes
Threads dimensions Gauging 20 Actuator *RJ Groove dimension Measured dimensions
13 Tubing Hanger *Threads Gauging *Sealing bore diameter Measured dimensions
*OD (tree side) Measured dimensions *Thickness Measured dimensions
*OD (tubing spool side) Measured dimensions *Bottom step diameter. Measured dimensions
*Groove diameter Measured dimensions *Step depth Measured dimensions
*Taper angle (Casing hanger) Measured dimensions *Packing bore diameter Measured dimensions
14 WN Flange *Thickness Measured dimensions *Flange Thickness Measured dimensions
*RJ groove dimension Measured dimensions Drill Holes PCD Measured dimensions
*PCD of drill holes Measured dimensions *Threads Gauging
15 Companion *Thickness Measured dimensions Piston Rod OD Measured dimensions
Flange *RJ groove dimension Measured dimensions Cylinder ID & Piston OD Measured Surface
PCD of drill holes Measured dimensions Surface Finish Finish
Threads Gauging Cylinder & Piston Chrome Measured dimensions
16 Plugs, Bull Threads Gauging Plating thickness
Plug, Valve Stem Back seat angle Measured dimensions
removal plug
17 Back pressure Threads (On body) Gauging b) Other features:
Valve Packing OD Gauging PSL 1& 2:
`O' ring groove dimension (On Measured dimensions Lot Size Sample size Acceptance Criteria
(Nos) (Nos) (as per ISO 2859-1:1999, Level II, 1.5 AQL)
body)
18 Bonnet for Bonnet Seat Taper Measured dimensions 2 to 8 2
choke Packing Bore Measured dimensions 9 to 15 3 If one sample fails, entire lot shall be
16 to 25 5 dimensionally inspected
Packing Depth Measured dimensions 26 to 50 8
Threads Gauging 51 to 90 13
O-ring groove dimensions Measured dimensions 91 to 150 20 If two samples fail, entire lot shall be
19 Block Tree Threads Gauging 151 to 280 32 dimensionally inspected
(Multiple *RJ Groove dimension Measured dimensions 281 to 500 50 If three samples fail, entire lot shall be
Valves) *Flange thickness Measured dimensions dimensionally inspected
*Sealing bore diameter Measured dimensions
Intersection of test port holes OK status by visual
PSL 3,3G& 4: each component shall be dimensionally inspected
inspection
*Thickness Measured dimensions
*Internal bore diameter. Measured dimensions
Threads (Except flanged) Gauging
*PCD of studded holes Measured dimensions
Drill holes PCD Measured dimensions
*3rd flange bore dia. & depth Measured dimensions
*Bonnet locating dia. & depth Measured dimensions
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BHEL NOTES REV.: 14 Page: 8 of 10

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
Note-3: Weld NDE: the cavity exceeds approximately 65 cm 2 (10 in2)
Weld Type Stages PSL 1 PSL 2 PSL 3/ PSL 3G PSL 4 h - Liquid Penetrant Method or Magnetic Particle Method as applicable for
Pressure- Preparation* -- -- a a material (base or weld) defects only.
containing Completion** -- a, b & a, b, e & a, b, e & i - Measurement of overlay thickness & Ultrasonic Testing on Weld metal
(c/d) (c/d) (c/d) overlay
Non-Pressure Preparation* -- -- a a Preparation* = Surface preparation, joint preparation, fit up & preheat.
containing Completion** -- a a&e a&e Completion** = After all welding, post weld heat treat and machining, except for
volumetric NDE which shall be done prior to machining that would
Pressure- Preparation* -- h h h
limit effective interpretation of results.
containing Completion** -- a, b & a, b, e & a, b, e &
repairs (f/g) (f/g) (f/g)
Weld metal Preparation* -- -- b b
overlay-partial Completion** -- b b&i b&i Note -4:
overlay(other 1) Requirement for Nitriding (Wherever specified in the drawing.):
than ring Material Grade Case depth mm
grooves) AISI 410 22 HRC MAX. 0.08 - 0.15
Weld metal Preparation* -- -- b b ASTM A 564 Type 630 33 HRC max. 0.05 - 0.10
overlay-partial Completion** -- b b b Austenitic SS 22 HRC max. 0.05 - 0.10
overlay( on ring Austenitic Precipitation 0.05 - 0.10
grooves) hardened SS 35 HRC max.
Weld metal Preparation* a a a, b a, b AISI 41XX Steels 22 HRC max. 0.08 - 0.15
overlay-full Completion** a, b a, b a, b & i a, b & i AISI 5012 22 HRC max. 0.10 - 0.15
overlay
Weld metal Preparation* -- -- b b Surface case hardness:
overlay(Hard Completion** -- b b b AISI 41XX:450 HV (45 HRC) min.
facing)-Gate, Seat Other steels: 600 HV (55 HRC) min.
ring & Choke Seat
a - Visual examination 2) Wherever specified in the drawing, the following coating shall be used for
b – Liquid Penetrant Method (PT for all ferro magnetic material or non-ferro stainless and K-monel components to provide resistance against galling
magnetic material) or Magnetic Particle Method (MT for all ferro at temperature. upto 148.8 deg.C.
magnetic material)
c - Radiation (radiography or imaging) examination a) Coating material: Molybdenum disulphide, Multi-Polymer binder
d - Ultrasonic examination
e - Hardness test (weld) b) Process of application:
f - Ultrasonic examination: For PSL 1 & 2: if weld repair is greater than 25% i) Vapour degrease-trichlorethylene or perchlorethylene.
of wall thickness or 25 mm (1 inch) whichever is less; For PSL 3,3G & 4: if ii) For light roughening of surface to be coated
weld repair is greater than 20% of wall thickness or 25 mm (1 inch) use dry bead of 120 grit size.
whichever is less, or if the extent of the cavity exceeds approximately 65 iii) Apply Multi-Polymer coating.
cm2 (10 in2) iv) Apply Molybdenum Disulphide coating.
g - Radiation (radiography or imaging) examination: For PSL 1 & 2: if v) Bake at 176.7 - 190.6 deg.c for one-hour min.
weld repair is greater than 25% of wall thickness or 25 mm (1 inch) vi) Minimum thickness shall be 0.01 mm per side.
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Note-5: Following shall be recorded in the history card.
a. Traceability: For PSL 2 to 4:
The Traceability to Test Certificates of Body, Bonnet and Stem & Flanges.
For PSL 3, 3G & 4:
In addition to the above components the Traceability to Test Certificates of Gate
and Seat rings.
The serial numbers of Body, Bonnet, Stem, Flanges, Gate, Seat rings and Seat of
all assemblies.
b. Hydraulic Testing for PSL 3, 3G & 4: Identification of the recorder used.
c. Gas Testing for PSL-3G & 4:
Actual Test pressure & actual holding period duration
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.
iv. PSL 3 &4: When the WPS requires PWHT, hardness testing shall be
performed after all heat treatment on the weld metal and the base metal
within 13 mm (0.5 in.) from the weld to conform to above i to ii. When the
WPS does not require PWHT, the weld metal at a minimum shall be
hardness tested to conform to above i to ii.
v. 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.

e. Hardness Test 1. For PSL-3 & 3G: For assemblies.

i. PSL 2 to 4 (All Material Class) and PSL 1(Material Class DD, EE, FF & a) Certificate of conformance stating that "equipment meets the requirements
HH): Each component shall be hardness tested. of current edition of API specification 6A and the temperature & materials
class."
ii. For PSL 3, 3G & 4, additionally one hardness test shall be performed on b) Assembly traceability Records
each finished part (body, bonnet and flanges) with additional tests on each c) Pressure Test Records
end connector face. When it is not possible to hardness test the end d) For 3G additionally Gas test records also to be furnished
connector face, the hardness test shall be performed on the nearest
accessible surfaces. 2. For PSL-4: For component & assemblies.
a) All Records/Certifications of PSL-3 as in 1.
iii. PSL 1 - up to 5000 psi working pressure (Material Class AA, BB & CC): b) Gas test records.
Lot Size Sample Acceptance Criteria c) NDE Records.
(Nos) size(Nos) (as per ISO 2859-1:1999, Level II, 4.0 AQL) d) Hardness test records.
2 to 8 2 e) Material test records.
9 to 15 3 If one sample fails, entire lot shall be hardness tested f) Heat treatment records.
16 to 25 5
26 to 50 8 3. SSV: For assembly:
51 to 90 13 If two samples fail, entire lot shall be hardness tested
91 to 150 20 If three samples fail, entire lot shall be hardness tested
a) Functional test data sheet
151 to 280 32 If four samples fail, entire lot shall be hardness tested b) Shipping report
281 to 500 50 If six samples fail, entire lot shall be hardness tested c) Operating manual
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d) Assembly traceability record

Note-7: Some of the machining, Welding, Heat treatment, Coating and Plating
activities are outsourced at the sub-contractor’s facility by OP&C. In such cases, the
requirements specified in this Quality Plan are applicable for the activities performed at
sub-contractor’s facility also.

Note-8: Packing

Packing shall be done as per the procedure LOG: WI:012.