Document No.

Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
A. INCOMING MATERIAL INSPECTION

Visual W-P-21-01 MSS SP 55 100% Reject F-P-14-01 --- P ---

Chemical & Physical Relevant ASTM Relevant ASTM /
1 / Lot / Heat Reject SLC P R R/W
Properties / R-P-12-01 R-P-12-01
100% check, If
Dimensional W-P-21-03 Drawing Max. 4 / Lot F-P-14-01 --- P ---
sample reject
Hardness * W-P-21-10 API 6D / API 609 1 / Lot / Heat Reject SLC P R R/W
API 6D / API If application
1 Castings Impact Test * API 6D / API 609 1 / Lot / Heat Reject SLC P R R/W
609 temp. <290C.
Penetrant Test * W-P-21-06 API 6D - A7 F-P-07-05 Reject F-P-21-04 --- P R/W

Radiographic Test * W-P-21-07 API 6D - A2/A3 F-P-07-05 Reject ENR P R R/W

Ultrasonic Test * W-P-21-08 API 6D - A4/A5 F-P-07-05 Reject ENR P R R/W

Magnetic Particle Test * W-P-21-09 API 6D - A6 F-P-07-05 Reject ENR P R R/W

Visual W-P-21-01 MSS SP 55 100% Reject F-P-14-01 --- P ---

Chemical & Physical Relevant ASTM Relevant ASTM /
1 / Lot / Heat Reject SLC P R R/W
Properties / R-P-12-01 R-P-12-01
100% check, If
Dimensional W-P-21-03 Drawing Max. 4 / Lot F-P-14-01 --- P ---
sample reject
Hardness * W-P-21-10 API 6D / API 609 1 / Lot / Heat Reject SLC P R R/W
2 Forgings
API 6D / API If application
Impact Test * API 6D / API 609 1 / Lot / Heat Reject SLC P R R/W
609 temp. <290C.
Penetrant Test * W-P-21-06 API 6D - A10 F-P-07-05 Reject F-P-21-04 --- P R/W

Ultrasonic Test * W-P-21-08 API 6D - A8 F-P-07-05 Reject ENR P R R/W

Magnetic Particle Test * W-P-21-09 API 6D - A9 F-P-07-05 Reject ENR P R R/W

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 1 of 8
 Document No. Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
Visual W-P-21-01 MSS SP 55 100% Reject F-P-14-01 --- P ---
Supplier Audit /
3 Heat Treatment Process Control W-P-08-05 W-P-08-05 Delist Supplier F-P-01-01 --- P ---
Year
Relevant ASTM Relevant ASTM /
Physical Properties 1 / Lot / Heat Reject SLC P R ---
/ R-P-12-01 R-P-12-01
Visual W-P-21-01 W-P-21-01 100% Reject F-P-14-01 --- P ---
Relevant ASTM Relevant ASTM /
Chemical & Physical 1 / Lot / Heat Reject SLC P R R/W
/ R-P-12-01 R-P-12-01
100% check, If
4 Round Bars Dimensional (Dia.) W-P-21-03 Drawing 1 / Lot F-P-14-01 --- P ---
sample reject
Hardness * W-P-21-10 API 6D / API 609 1 / Lot / Heat Reject SLC P R R/W
ASME Sec. VIII -
Ultrasonic Test * W-P-21-08 F-P-07-05 Reject ENR P R R/W
Div. I
Visual W-P-21-01 W-P-21-01 100% Reject F-P-14-01 --- P ---
Chemical & Physical Relevant ASTM Relevant ASTM /
5 Metallic Materials 1 / Lot Reject SLC P R R/W
Properties / R-P-12-01 R-P-12-01
100% check, If
Dimensional W-P-21-03 Drawing 1 / Lot F-P-14-01 --- P ---
sample reject
Visual W-P-21-01 W-P-21-01 100% Reject F-P-14-01 --- P ---
Relevant ASTM Relevant ASTM /
6 Non-metallic Materials Physical Properties 1 / Lot Reject SLC P R R/W
/ R-P-12-01 R-P-12-01
100% check, If
Dimensional W-P-21-03 Drawing 1 / Lot F-P-14-01 --- P ---
sample reject
Visual W-P-21-01 W-P-21-01 100% Reject F-P-14-01 --- P ---
Chemical & Physical Relevant ASTM Relevant ASTM /
1 / Lot Reject SLC P R R/W
Properties / R-P-12-01 R-P-12-01
100% check, If
7 Stud Nuts (Fasteners) Dimensional W-P-21-03 Drawing 1 / Lot F-P-14-01 --- P ---
sample reject
Penetrant Test * W-P-21-06 API 6D - A16 F-P-07-05 Reject F-P-21-04 --- P R/W

Magnetic Particle Test * W-P-21-09 API 6D - A15 F-P-07-05 Reject ENR P R R/W

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 2 of 8
 Document No. Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
Visual W-P-21-01 On - Off Mark 100% Reject F-P-14-01 --- P ---
8 Handwheel
100% check, If
Dimensional W-P-21-03 Drawing 1 / Lot F-P-14-01 --- P ---
sample reject
Visual W-P-21-01 W-P-21-01 100% Reject F-P-14-01 --- P ---
100% check, If
9 Gear Box / Actuators Dimensional W-P-21-03 Drawing 1 / Lot F-P-14-01 --- P ---
sample reject
Torque Value Purchase Order Purchase Order 100% Reject SLC P R R/W

Visual Expiry Date Expiry Date 100% Reject Box P R ---

10 Welding Consumables
Chemical & Physical
WPS-PQR WPS-PQR 100% Reject SLC P R R/W
Properties
11 PT Consumables Visual Expiry Date Expiry Date 100% Reject Box P R ---

Visual W-P-21-01 Nil Crack 100% Reject --- --- P ---

12 Side Caps
Dimensional W-P-21-03 Fitting to Flange 100% Reject --- --- P ---

Visual W-P-21-01 W-P-21-01 100% Reject F-P-14-01 --- P ---

Outsourced Machined
13
Components 100% check, If
Dimensional W-P-21-03 Drawing 1 / Lot F-P-14-01 --- P ---
sample reject
B. INPROCESS INSPECTION
Reprocess / F-P-15-02 / F-
Visual W-P-21-01 W-P-21-01 100% --- P ---
Reject P-21-01
100% check, If F-P-15-02 / F-
Dimensional W-P-21-03 Drawing Max. 4 / Lot --- P ---
sample reject P-21-01
Machining (Pressure Drawing / 100% check, If F-P-15-02 / F-
1 Flange Serration W-P-21-01 Max. 4 / Lot --- P ---
Containing Parts) Roubert Chart sample reject P-21-01
Reprocess /
Penetrant Test * W-P-21-06 API 6D - A18 F-P-07-05 / 100% F-P-21-04 --- P R/W
Reject
Magnetic Particle Test * W-P-21-09 API 6D - A17 F-P-07-05 Reject ENR P R R/W

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 3 of 8
 Document No. Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
Reprocess / F-P-15-02 / F-
Visual W-P-21-01 W-P-21-01 100% --- P ---
Reject P-21-01
2 Drilling & Deburring
100% check, If F-P-15-02 / F-
Dimensional W-P-21-03 Drawing Max. 4 / Lot --- P ---
sample reject P-21-01
Reprocess / F-P-15-02 / F-
Visual W-P-21-01 W-P-21-01 100% --- P ---
Machining (Pressure Reject P-21-01
3
Controlling Parts) 100% check, If F-P-15-02 / F-
Dimensional W-P-21-03 Drawing Max. 4 / Lot --- P ---
sample reject P-21-01
Reprocess /
Voltage WPS-PQR WPS-PQR 100% F-P-15-03 --- P ---
Reject
Reprocess /
Current WPS-PQR WPS-PQR 100% F-P-15-03 --- P ---
Reject
Reprocess / F-P-15-02 / F-
Operator WPS-PQR WPS-PQR 100% --- P ---
Reject P-15-03
4 Overlay Welding
Reprocess /
Material WPS-PQR WPS-PQR 100% F-P-15-03 --- P ---
Reject
Reprocess /
Visual W-P-21-02 W-P-21-02 100% F-P-15-03 --- P ---
Reject
Reprocess /
Penetrant Test * W-P-21-06 API 6D - A21 F-P-07-05 / 100% F-P-21-04 --- P R/W
Reject
Reprocess /
Voltage WPS-PQR WPS-PQR 100% F-P-15-03 --- P ---
Reject
Reprocess /
Current WPS-PQR WPS-PQR 100% F-P-15-03 --- P ---
Reject
Reprocess / F-P-15-02 / F-
Operator WPS-PQR WPS-PQR 100% --- P ---
Reject P-15-03
Reprocess /
Material WPS-PQR WPS-PQR 100% F-P-15-03 --- P ---
Reject
Reprocess /
5 Weld Joints / Welding Visual W-P-21-02 W-P-21-02 100% F-P-15-03 --- P ---
Reject
Penetrant Test * W-P-21-06 API 6D - A14/A19 F-P-07-05 Reject F-P-21-04 --- P R/W

Radiographic Test * W-P-21-07 API 6D - A11 F-P-07-05 Reject ENR P R R/W

Ultrasonic Test * W-P-21-08 API 6D - A12 F-P-07-05 Reject ENR P R R/W

Magnetic Particle Test * W-P-21-09 API 6D - A13/A20 F-P-07-05 Reject ENR P R R/W

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 4 of 8
 Document No. Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
Visual W-P-21-01 Drawing Max. 4 / Lot Reprocess F-P-21-01 --- P ---

Lapping Material W-P-15-06 W-P-15-06 Max. 4 / Lot Reprocess --- --- P ---

6 Lapping Machine Speed W-P-15-06 W-P-15-06 Max. 4 / Lot Reprocess --- --- P ---

F-P-15-02 / F-
Operator W-P-15-06 W-P-15-06 Max. 4 / Lot Reprocess --- P ---
P-21-01

Surface Finish Roubert Chart Drawing Max. 4 / Lot Reprocess F-P-21-01 --- P ---

Visual W-P-21-01 W-P-21-01 100% Reprocess F-P-15-02 --- P ---

6 Assembly
Operational By Operate Free Operation 100% Reprocess F-P-15-02 --- P ---

C. FINAL INSPECTION OF VALVES

Supply Voltage W-P-21-12 Max. 12V F-P-07-05 / 10% Re-assembly F-P-21-01 --- P ---
Anti-Static Device
1
Test *
Resistance W-P-21-12 Max 10 F-P-07-05 / 10% Re-assembly F-P-21-01 --- P R/W

Finishing, Size, Class, Reprocess /

2 Visual Inspection W-P-21-01 W-P-21-01 100% F-P-21-02 --- P R/W
Logo, Heat No. Marking Reject
Dimensional F-F, FL. OD, FL. Thk, RF, Reprocess /
3 W-P-21-03 Drawing 100% F-P-21-02 --- P R/W
Inspection PCD, Holes, Bore Reject
Change the
Water Temperature W-P-21-04 50C - 500C Once in a Year SLC --- P ---
Water

Water Chloride Content W-P-21-04 < 30ppm Once in a Year Add rust inhibitor SLC --- P ---
Hydro Back Seat Test R-P-21-02 /
4 Pressure R-P-21-02 100% Reject F-P-21-02 --- P R/W
(Gland Leakage) F-P-07-06
R-P-21-02 /
Pressure Holding Duration R-P-21-02 100% Reject F-P-21-02 --- P R/W
F-P-07-06
1 Cycle /
Pressure Test Cycle W-P-21-04 100% Reject F-P-21-02 --- P R/W
F-P-07-06

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 5 of 8
 Document No. Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
Change the
Water Temperature W-P-21-04 50C - 500C Once in a Year SLC --- P ---
Water
Water Chloride Content W-P-21-04 < 30ppm Once in a Year Add rust inhibitor SLC --- P ---
Hydro Shell Test R-P-21-02 /
5 Pressure R-P-21-02 100% Reject F-P-21-02 --- P R/W
(Body) F-P-07-06
R-P-21-02 /
Pressure Holding Duration R-P-21-02 100% Reject F-P-21-02 --- P R/W
F-P-07-06
1 Cycle /
Pressure Test Cycle W-P-21-04 100% Reject F-P-21-02 --- P R/W
F-P-07-06
Change the
Water Temperature W-P-21-04 50C - 500C Once in a Year SLC --- P ---
Water
Water Chloride Content W-P-21-04 < 30ppm Once in a Year Add rust inhibitor SLC --- P ---
R-P-21-02 /
6 Hydro Seat Test Pressure R-P-21-02 100% Reject F-P-21-02 --- P R/W
F-P-07-06
R-P-21-02 /
Pressure Holding Duration R-P-21-02 100% Reject F-P-21-02 --- P R/W
F-P-07-06
1 Cycle /
Pressure Test Cycle W-P-21-04 100% Reject F-P-21-02 --- P R/W
F-P-07-06
R-P-21-02 /
Pressure R-P-21-02 100% Reject F-P-21-02 --- P R/W
F-P-07-06
Pneumatic Seat Test R-P-21-02 /
7 Pressure Holding Duration R-P-21-02 100% Reject F-P-21-02 --- P R/W
(Air) F-P-07-06
1 Cycle /
Pressure Test Cycle W-P-21-04 100% Reject F-P-21-02 --- P R/W
F-P-07-06
Break Away Torque Reprocess /
Pressure W-P-21-05 R-P-21-02 F-P-07-05 F-P-21-01 --- P R/W
(for Lever or Reject
8
Handwheel Operated Reprocess /
Torque Value W-P-21-05 < 360N (80lbf) F-P-07-05 F-P-21-01 --- P R/W
Valve) * Reject
Break Away Torque Working Reprocess /
Pressure W-P-21-05 F-P-07-05 F-P-21-01 --- P R/W
(for Lever or Pressure Reject
9
Handwheel Operated Reprocess /
Torque Value W-P-21-05 < 360N (80lbf) F-P-07-05 F-P-21-01 --- P R/W
Valve) * Reject
Reprocess /
10 Drift Test * Drift Passing W-P-21-11 W-P-21-11 F-P-07-05 F-P-21-01 --- P R/W
Reject

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 6 of 8
 Document No. Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
Approved Reprocess /
11 NDT (Leak Testing) Helium Leak Test F-P-07-05 F-P-07-05 ENR P R R/W
Procedure Reject
Approved Reprocess /
12 Fire Safe Test Fire Safe Test API 607 F-P-07-05 SLC --- P R/W
Procedure Reject
Approved Reprocess /
13 Cryogenic Test Cryogenic Test F-P-07-05 F-P-07-05 SLC P R R/W
Procedure Reject
D. POST FINAL INSPECTION PROCESSES

Material Brand Name Expiry Date 100% Reject F-P-15-04 --- P ---

Operator Operator Validation Record 100% Requalification F-P-15-04 --- P ---

Soaking Time W-P-09-01 45 - 60 Mins. 100% Reprocess F-P-15-04 --- P ---

1 Painting / Coating Humidity W-P-09-01 250C +100C Once in a Year Requalification F-P-16-01 --- P ---
Instrument - Object
W-P-09-01 6" - 8" Once in a Year Requalification F-P-16-01 --- P ---
Distance
Visual W-P-09-01 W-P-21-01 100% Reprocess F-P-15-04 --- P R/W

Coating Thickness * W-P-09-01 > 70micron 100% Reprocess F-P-15-04 --- P R/W

2 Name Plate Marking Visual W-P-21-01 Drawing 100% Re-marking F-P-21-03 --- P ---
Friction Lock or
3 Packing Visual Side Caps 100% Reprocess F-P-21-03 --- P ---
Bolting Type
E. SERVICING OF VALVES

1 INCOMING INSPECTION

1.1 Visual Inspection As per C2 W-P-21-01 W-P-21-01 100% Reject F-P-14-01 --- P ---
Dimensional
1.2 As per C3 W-P-21-03 Drawing 100% Reject F-P-14-01 --- P ---
Inspection
1.3 Pressure Testing As per C4, C5, C6

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 7 of 8
 Document No. Q-004
Aira Euro Automation Private Limited Rev. No. & Date 0 / 01.05.2014
Reviewed By MR
Quality Plan for Valves Approved By Head QA/QC
Inspection/Process Reference Acceptance Sampling Agency
Sr. Item / Process Sample Record Remarks
Parameter Criteria Criteria Acceptance S A C
2 INPROCESS INSPECTION

Visual W-P-21-01 W-P-21-01 100% Reject F-P-21-01 --- P ---

Dis-assembly of
2.1
Valves
Dimensional W-P-21-03 Drawing 100% Reject F-P-21-01 --- P ---
Processing of
2.2 As per Inprocess Inspection Section B
Internal Parts
Final Inspection of
2.3 As per Final Inspection Section C
Valves
Note: where standard reference are give, latest edition of standard shall be applicable.
Tolerance Criteria for Castings / Forgings
Up to 10" +2mm 2 Flange Diameter +5mm
1 Face - Face
12" & Above +3mm 3 Flange Thickness +5mm
Tolerance Criteria for Inprocess Inspection, Final Inspection & Outsourced Machined Components
Up to 10" +1.6mm Gland Bush, Bush Ring, Valve Guide, OD -1.0mm
1 Face - Face 10
12" & Above +3.2mm Guide Plate ID +1.0mm
2 Flange OD +1.5mm Offset of Align Flange Centrelines - <= 4" Valve Max. 2.0mm
11
3 Flange Thickness +3mm / -0mm Lateral Alignment > 4" Valve Max. 3.0mm
4 PCD +1.5mm 12 Parallelist of Flange Faces - Angular Alignment +2.5mm
5 RF Dia. +0.75mm <= 4" Valve Max. 2.0mm
13 Allowable Misalingment of Bole Holes
6 RF Height +0.2mm > 4" Valve Max. 3.0mm
7 Flange Holes Dia. +0.75mm 14 Straightness of entire length of Stem (Max.) 0.001mm/mm
8 Groove Dia. +1.5mm 15 Stem Dia +0.5mm
9 Tongue Dia. -1.5mm 16 Stem Length +2mm

S: Supplier, A: Aira Euro, C: Customer SLC: Supplier / Laboratory Material Test Certificate CONTROLLED COPY *: If required by Customer

P: Perform, R: Review‐Verify, W: Witness ENR: External NDT Report Page 8 of 8