BHARAT PETROLEUM CORPORATION LIMITED, KOCHI REFINERY

ADVISORY SERVICES DEPARTMENT File No: KR.AS.INSP.9.03:900:08:2

QUALITY ASSURANCE PLAN Doc No: BPCL/KR/AS-ITP-006 Rev : 0

INSPECTION TEST PLAN FOR SA-193 GR B16 SA-194 GR 7 BOLTING MATERIAL

A. Scope : This Inspection and test plan covers the minimum testing requirements for SA-193 Gr B16
/SA-194 Gr7 bolting material
B. Reference Docs : Standard- ASME BPVC Sec IIA SA193/ ASME BPVC Sec IIA SA194/ AES-3562/ PO/PR/ Job
specifications and approved documents.

Inspection & Test Requirements for Manufacturers

Scope of
Reference inspection
Sl Characteristics/ Type Quantum of
Stage/ Activity standard/ Record
No of check check
Acceptance Norms Supplier TPIA

Test
Marking and ASME BPVC sec IIA-
Raw material certificate,
1 correlation with test 100% SA193 Gr B16/ SA H R
inspection inspection
certificate 194 Gr 7
report
Chemical composition
ASME BPVC sec IIA-
/ Macro/ Mechanical one sample Inspection
SA193 Gr B16/ SA H R
Properties/internal per heat report
Raw material 194 Gr 7
2 soundness
inspection
ASME BPVC sec IIA-
Inspection
Spectro analysis 100% SA193 Gr B16/ SA H R
report
194 Gr 7
Inspection
Heat treatment cycle ASME BPVC sec IIA- report/
3 Heat treatment (time and 100% SA193 Gr B16/ SA Heat H R
temperature) 194 Gr 7 treatment
charts
Thread Rolling, ASME BPVC sec IIA-
In Process Inspection
4 Forging Of Nuts, 100% SA193 Gr B16/ SA H _
Inspection report
Machining 194 Gr 7
Each HT Lot/ ASME BPVC sec IIA-
Selection of Inspection
5 Test piece marking Each Heat SA193 Gr B16/ SA H W
samples report
No/ Size 194 Gr 7
As per PO/ASME
Each HT Lot/
Nondestructive Surface and internal BPVC sec IIA- SA193 Inspection
6 Each Heat H RW
testing imperfections Gr B16/ SA 194 Gr 7 report
No/ Size
/ ASME Sec V
Mechanical properties Each HT Lot/ ASME BPVC sec IIA-
Destructive Inspection
7 YS, UTS, RA, Each Heat SA193 Gr B16/ SA H H
testing report
Elongation ,Proof Load No/ Size 194 Gr 7
Positive material As per PO/ASME
8 PMI identification (only for 100% BPVC sec IIA- SA193 PMI report P RW
AS & SS components) Gr B16/ SA 194 Gr 7
Visual marking, color
coding and 100% by As per PO/
dimensional check, supplier and Stamping Of Inspection
9 Final inspection H H
Final Stamping, grade at 10% by Accepted Bolting report
punch check, TPIA Material
lubrication

BPCL-KR/Advisory Services/ QAP/ File No: KR.AS.INSP.9.03:900:08:2 Page 2 of 4

 BHARAT PETROLEUM CORPORATION LIMITED, KOCHI REFINERY

ADVISORY SERVICES DEPARTMENT File No: KR.AS.INSP.9.03:900:08:2

QUALITY ASSURANCE PLAN Doc No: BPCL/KR/AS-ITP-006 Rev : 0

INSPECTION TEST PLAN FOR SA-193 GR B16 SA-194 GR 7 BOLTING MATERIAL

Scope of
Reference inspection
Sl Characteristics/ Type Quantum of
Stage/ Activity standard/ Record
No of check check
Acceptance Norms Supplier TPIA

100% by
Verification of
Coating (If supplier and As per PO / PR / Inspection
10 galvanized coating & H RW
Applicable) at 10% by Applicable Standard report
galvanizing thickness
TPIA
Test
Verification of
certificate
material test As per PO / PR /
Documentation (EN 10204
11 certificate, test report, 100% Material H H
& Release 3.2),
inspection reports & specification
Reports,
Issue of Release Note
IRN

Inspection & Test Requirements for Traders /Stockist

Reference Scope of
Sl Characterist Quantu
standard and inspection
N Stage / Activity ics / Type of m of Record
Acceptance
o check check Supplier TPIA
norms
ASME BPVC sec
MTC review for the physical
IIA- SA193 Gr
1 and chemical test, heat Verify MTC 100% Mill TC R R
B16/ SA 194 Gr
treatment, NDT
7
Physical co-relation of MTC ASME BPVC sec
Verify Heat Mill TC & TPI
Heat no./Batch no. to the Each Heat IIA- SA193 Gr
2 no./Batch no. Inspection P RW
fasteners under scope of No. / Lot B16/ SA 194 Gr
to the MTC report
supply. 7
Chemical
composition /
One ASME BPVC sec
Macro/
Sample selection & Check Sample IIA- SA193 Gr
3 Mechanical Test report H W
Testing per Heat / B16/ SA 194 Gr
Properties/In
Per Size 7
ternal
soundness
100% by
ASME BPVC sec
Dimensional checking supplier Dimensional
Measuremen IIA- SA193 Gr
4 (including Threads Check by and at inspection P RW
t B16/ SA 194 Gr
GO-NOGO gauge) 10% by report
7/ P.O.
TPIA
Visible
surface
defect / 100% by ASME BPVC sec
Visual inspection and
Corrosion. supplier IIA- SA193 Gr Internal
Verification of Marking of
5 and at B16/ SA 194 Gr Inspection P RW
Material spec./ Grade /
Verification 10% by 7 / Std. Engg. report
Heat No. / Lot No. / Size etc.
with respect TPIA Practice / PO
to Test
Certificate

BPCL-KR/Advisory Services/ QAP/ File No: KR.AS.INSP.9.03:900:08:2 Page 3 of 4

 BHARAT PETROLEUM CORPORATION LIMITED, KOCHI REFINERY

ADVISORY SERVICES DEPARTMENT File No: KR.AS.INSP.9.03:900:08:2

QUALITY ASSURANCE PLAN Doc No: BPCL/KR/AS-ITP-006 Rev : 0

INSPECTION TEST PLAN FOR SA-193 GR B16 SA-194 GR 7 BOLTING MATERIAL

Reference Scope of
Sl Characterist Quantu
standard and inspection
N Stage / Activity ics / Type of m of Record
Acceptance
o check check Supplier TPIA
norms
Positive
100% by
material As per PO/ ASME
supplier
identification BPVC sec IIA-
6 PMI and at PMI report P RW
(only for AS & SA193 Gr B16/
10% by
SS SA 194 Gr 7
TPIA
components)
Verification
of galvanized
P.O./ Std. Engg. Inspection
7 Coating (If Applicable) coating & Each item H RW
practice Report
galvanizing
thickness
Separate
TPIA stamping on all stamping for the
Each item Inspection
8 certified items of the Verification whole lot and for H H
of PO Report
inspected lot under the PO. the actual
witnessed items.
Verification
of Inspection As per PO / PR / Test
9 Documentation & Release Reports, MTC 100% Material certificate -- H
& Issue of specification Reports, IRN
Release Note

Legend
H - Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or 10% (min.1 No. of
each size and type of Bulk item), R-review, W-Witness (Give due notice, work may proceed after scheduled date).

Notes
1. This ITP contains the minimum inspection requirements. Vendor to comply all other requirements (if any) as per PO / PR.
2. In case of raw material supplied by sub suppliers/vendors; chemical composition / Macro/ Mechanical Properties/internal
soundness/ spectro analysis shall be performed by them and shall be witnessed by supplier as mentioned in Sl No-2
3. Hardness for studs/nuts shall be in range of 253-319 BHN.
4. As per AES-3562, magnetic particle inspection has to be carried out on 10% of each heat on finished bolts (1 number minimum and
maximum 20 numbers per size) in accordance with ASTM-E-709. (This is a supplementary requirement and shall not apply unless
specified in the PO)
5. Raw material or finished fastener macro etch examination to be verified by TPIA
6. B16 bolt and Gr7 nuts metallurgy must be punched on both ends of the studs and at the two end faces of nuts on both ends of the
studs and at two locations on the nuts.
7. All bolts shall be properly lubricated prior to dispatch/ supplying

BPCL-KR/Advisory Services/ QAP/ File No: KR.AS.INSP.9.03:900:08:2 Page 4 of 4