OWNER PMC

Talcher Fertilizers Limited (TFL) Projects & Development India Ltd (PDIL)

WUHUAN Project No.:

WUHUAN ENGINEERING CO., LTD. Ammonia-Urea Plant, Talcher
17269

ZETWERK MANUFACTURING BUSNIESSES PRIVATE LIMITED

Vendor Doc. No.: CN_KA-22890/23-24/QAP/106 Rev.02 Dt.06.07.2023

QUALITY ASSURANCE PLAN
Scale/Size: Sheet 01 of 05 Rev.: 2

QUALITY ASSURANCE PLAN

PO No.: 17269-ASM1801-PO

Item Name: STEEL STRUCTURES OF AMMONIA-UREA PLANT

Item No.: As per the Drawing

02 IFA R. SHANMUGANATHAN RAMESH BABU B RAMESH BABU B

01 IFA R. SHANMUGANATHAN RAMESH BABU B RAMESH BABU B
00 IFA R. SHANMUGANATHAN RAMESH BABU B RAMESH BABU B
Rev. DESCRIPTION DEGND CHEKD APPRD AUTHD DATE
 ZETWERK MANUFACTURING BUSINESSES PVT LTD.,
Oriental Towers No.461, 1st & 2nd Floor, 4th Sector,
ZETWERK MANUFACTURING BUSINESSES PRIVATE LIMITED 17th Cross, HSR Layout Bengaluru, India - 560 102.
Website: www.zetwerk.com
CUSTOMER WUHUAN ENGINEERING CO., LTD QAP NO CN_KA-22890/23-24/QAP/106 Rev.02 DATE : 06.07.2023
CUSTOMER
CLIENT TALCHER FERTILIZERS LIMITED (TFL) 17269-ASM1801-PO DATE : 27-Mar-2023
PO.NO
PMC PROJECTS & DEVELOPMENT INDIA LTD (PDIL)

PROJECT AMMONIA UREA PLANT, TALCHER

PRODUCT / NAME FABRICATION AND SUPPLY OF STRUCTURAL STEEL AND OTHER STEEL, IRON OR METAL ITEMS
DOCUMENT REF: 1. 17269 -002000- AR01 Rev.0C - General Specification of Architecture 4. 17125/17269-PP67-001 Rev.1 - Instructions for QAP/ITP Preparation
2. 17269 - 00200- ST0504 Rev.2A - Specification for Steel Fabrication 5. 17269-PP41-001 Rev.0A - Packing and Marking Specification
3. 17269-ASM1801-PO Rev.2A Technical Appendix for Structural Steel and Other Steel, Iron or Metal Items (Material 6. 17269-PP79-01 Rev.2 - Vendor Document Handling procedure
and fabrication of Ammonia-Urea Plant)
QUALITY ASSURANCE PLAN
INSPECTION & QUANTUM RESPONSIBILITY
CHARACTERISTIC REFERENCE STANDARD/ FORMAT/
Sl. No. TESTING TYPE OF CHECK OF ACCEPTANCE CRITERIA WUH TFL/ REMARKS
TO BE VERIFIED DOCUMENT/ RECORDS MFG TPIA
DESCRIPTION CHECK UAN PMC
1 2 3 4 5 6 7 8 9 10 11 12 13
Pre Inspection Verification of all Approved
0.0 W H H -
Meeting Documents
1.0 DOCUMENT APPROVAL
Quality Assurance Requirements as per the TA, STD & TA/Applicable Code &
1.1 - - TA/Applicable Code & Standards - P - R R
Plan Applicable Code Standards
*WPS,PQR & WPQ for TPI Witness for NEW establishment
Welding parameter, characterstics,
1.2 WPS,PQR,WPQ - - ASME Sec IX / AWS D1.1 ASME Sec IX / AWS D1.1 - P W/R* R - Review for Existing WPS,PQR & WPQ
qualification
Spec/TA/Applicable code / Spec/TA/Applicable code /
1.3 NDE Procedures Procedures - - - P R R -
Applicable Drawings Applicable Drawings
Surface Preparation & Spec/TA/Applicable code / Spec/TA/Applicable code /
1.4 procedures - - - P R R I
Painting Applicable Drawings Applicable Drawings
2.0 RAWMATERIAL CONTROL

Visual Visual 100% Mill test certificate is mandatory for all bought out
Visual/ Dimension / Marking
Inspection materials.
Rawmaterials : Identification of materials as In accordance with
Report and Approved Make :Refer Below note
2.1 Plate, Rolled Sections Dimensional Check Measurment 10% per relevant material relevant material Specification & P RW* - -
MTC / test
etc… Specification Approved Drawings
certificate *10 % Random Witness by TPIA during Incoming
& Approved Drawings
Physical & Chemical Review of Mfg TC 100% Inspection of RM (plate, Rolled Sections, Other
section etc..)
3.0 BOUGHTOUT ITMES

1.Verification of Batch Test Document In accordance with Standards/ In accordance with Standards/ List of Approved Make :
3.1 Paint Certificates Review/BTC 100% WUHUAN Specification & WUHUAN Specification & TC/BTC P R - - Refer Below Note & Painting Procedure No:
2. Visual Review Approved Drawing Approved Drawing CN-KA-22890-ZET/WECL/SPP/01 Dt.11-05-2023

1.Verification of Batch Test Document In accordance with Standards/ In accordance with Standards/
Fastneres
3.2 Certificates Review/BTC 100% WUHUAN Specification & WUHUAN Specification & TC/BTC P R - -
(Bolt, Nut & Washers)
2. Visual Review Approved Drawing Approved Drawing

1.Verification of Batch Test Document Electrodes Confirming to List of Approved Make :

Welding In accordance with Standards/
3.3 Certificates Review/BTC 100% ASME Sec II Part C Ed'2019 TC/BTC P R - - Refer Below Note
Consumbales WUHUAN Specification &
2. Visual Review /IS:814:2004

In accordance with
In accordance with Calibration
Calibration for testing 1.Verification of Calibration Record manufactures
3.4 Document Review 100% manufactures recommendation List / P R - -
Measuring Equipment 2. Ensure Calibration recommendation and NABL
and NABL norms Record
norms

Form No : ZET-QA-F-01 REV.00 Dt.03.08.2020 Page 1 of 4

 ZETWERK MANUFACTURING BUSINESSES PVT LTD.,
Oriental Towers No.461, 1st & 2nd Floor, 4th Sector,
ZETWERK MANUFACTURING BUSINESSES PRIVATE LIMITED 17th Cross, HSR Layout Bengaluru, India - 560 102.
Website: www.zetwerk.com
CUSTOMER WUHUAN ENGINEERING CO., LTD QAP NO CN_KA-22890/23-24/QAP/106 Rev.02 DATE : 06.07.2023
CUSTOMER
CLIENT TALCHER FERTILIZERS LIMITED (TFL) 17269-ASM1801-PO DATE : 27-Mar-2023
PO.NO
PMC PROJECTS & DEVELOPMENT INDIA LTD (PDIL)

PROJECT AMMONIA UREA PLANT, TALCHER

PRODUCT / NAME FABRICATION AND SUPPLY OF STRUCTURAL STEEL AND OTHER STEEL, IRON OR METAL ITEMS
DOCUMENT REF: 1. 17269 -002000- AR01 Rev.0C - General Specification of Architecture 4. 17125/17269-PP67-001 Rev.1 - Instructions for QAP/ITP Preparation
2. 17269 - 00200- ST0504 Rev.2A - Specification for Steel Fabrication 5. 17269-PP41-001 Rev.0A - Packing and Marking Specification
3. 17269-ASM1801-PO Rev.2A Technical Appendix for Structural Steel and Other Steel, Iron or Metal Items (Material 6. 17269-PP79-01 Rev.2 - Vendor Document Handling procedure
and fabrication of Ammonia-Urea Plant)
QUALITY ASSURANCE PLAN
INSPECTION & QUANTUM RESPONSIBILITY
CHARACTERISTIC REFERENCE STANDARD/ FORMAT/
Sl. No. TESTING TYPE OF CHECK OF ACCEPTANCE CRITERIA WUH TFL/ REMARKS
TO BE VERIFIED DOCUMENT/ RECORDS MFG TPIA
DESCRIPTION CHECK UAN PMC
1 2 3 4 5 6 7 8 9 10 11 12 13
4.0 PROCESS QUALIFICATION

NDE Personnels Review of NDE

4.1 Personal Qualification 100% SNT - TC - 1 A or Equivalent SNT - TC - 1 A or Equivalent P R - -
Qualification documents Certificates

Welding Procedure Specification

Welding Procedure Specifications already
(WPS) & Procedure Qualification Review of Record Approved
Welding / Welder ASME Sec IX / AWS D1.1 & established with supporting Procedure
4.2 Record (PQR) / 100% ASME Sec IX / AWS D1.1 WPS, PQR P R - -
Qualification Approved Drawings Qualification record shall be submitted for review
Welder Performance Qualifcation As Applicable & WPQ
& Approval
(WPQ)
5.0 INPROCESS CONTROL

Marking and cutting Approved

Profile Cutting,Drawing Dimension Measurement / In accordance with Approved Drawing ,
5.1 of plates, beam, 100% Drawing/ P R - -
& NoTwist / Bend Visual IS 7215 & IS 1852
channels etc. Cutting Plan

Assembly of Parts, Holes Location,

Fit-up of Fabricated Measurement/ Inspection
5.2 Size, Orientation, Twist, Bend, 100% In accordance with Approved Drawing & is 7215 P R - -
Parts Visual Report
Straightness

Welding / All Welding Shall be as Per

Check WPS/WPQ, Weld Parameter Measurment / Inspecton
5.3 Weld Visual 100% IS : 816 and IS 9595 Using Electrodes Confirming To P RW - - Witness for final weld Visual
Weld Visual & Size Visual Report
Examination IS:814, AWS D1.1 & ASME Sec IX

In accordane with Approved ASME Sec V'Ed 2019 / AWS D1.1

NDT on Final Fillet Random Witness by TPIA /WUHUAN during final
5.4 Weld discontinuity on surface area DP Test 10% Drawing & ASME SEC V , 2020 Clause 8.14.5, & Approved DPT Report P RW - -
Weld Inspection
SE 165 Procedure
*1. UT Test Should 100% for all Beams connected
with columns, Vertical brace, Crane beams and all
ASME Sec V Ed'2019/ AWS D1.1 -
NDT on Butt weld 100%/ * In accordane with Approved cantilever parts.
5.5 Weld Joint defects UT Test 2020 - Clause No. 8.13 & UT Report P RW - -
Joint - UT if any 20 % Drawing & ASME Sec V 2.UT test should 20% on others excluding the first
Approved Procedure
items.
Random Witness by TPIA during final Inspection
Dimensional Overall Dimensions of Assembly,
In Accordance with Approved
Inspection after Holes Location, Size, Orientation as Measurment / In accordance with Approved Inspeciton
5.6 100% Drawing, Specification & P RW - - Completeness check
Welding (Black) per Drawing. Visual Drawing Report
IS 7215
(Before Painting) Twist, Bend, Straightness

Form No : ZET-QA-F-01 REV.00 Dt.03.08.2020 Page 2 of 4

 ZETWERK MANUFACTURING BUSINESSES PVT LTD.,
Oriental Towers No.461, 1st & 2nd Floor, 4th Sector,
ZETWERK MANUFACTURING BUSINESSES PRIVATE LIMITED 17th Cross, HSR Layout Bengaluru, India - 560 102.
Website: www.zetwerk.com
CUSTOMER WUHUAN ENGINEERING CO., LTD QAP NO CN_KA-22890/23-24/QAP/106 Rev.02 DATE : 06.07.2023
CUSTOMER
CLIENT TALCHER FERTILIZERS LIMITED (TFL) 17269-ASM1801-PO DATE : 27-Mar-2023
PO.NO
PMC PROJECTS & DEVELOPMENT INDIA LTD (PDIL)

PROJECT AMMONIA UREA PLANT, TALCHER

PRODUCT / NAME FABRICATION AND SUPPLY OF STRUCTURAL STEEL AND OTHER STEEL, IRON OR METAL ITEMS
DOCUMENT REF: 1. 17269 -002000- AR01 Rev.0C - General Specification of Architecture 4. 17125/17269-PP67-001 Rev.1 - Instructions for QAP/ITP Preparation
2. 17269 - 00200- ST0504 Rev.2A - Specification for Steel Fabrication 5. 17269-PP41-001 Rev.0A - Packing and Marking Specification
3. 17269-ASM1801-PO Rev.2A Technical Appendix for Structural Steel and Other Steel, Iron or Metal Items (Material 6. 17269-PP79-01 Rev.2 - Vendor Document Handling procedure
and fabrication of Ammonia-Urea Plant)
QUALITY ASSURANCE PLAN
INSPECTION & QUANTUM RESPONSIBILITY
CHARACTERISTIC REFERENCE STANDARD/ FORMAT/
Sl. No. TESTING TYPE OF CHECK OF ACCEPTANCE CRITERIA WUH TFL/ REMARKS
TO BE VERIFIED DOCUMENT/ RECORDS MFG TPIA
DESCRIPTION CHECK UAN PMC
1 2 3 4 5 6 7 8 9 10 11 12 13
6.0 SURFACE PREPARATION & PAINTING

Surface shall be Free from visible Surface Preparation : :All steel works shall be blasted to a
Oil, Grease and dirt and from mill Visual 100% minimum standard as per IS 8501 Part 1 - SSPC -SP10 P R - -
scale,rust & foreign matter (Sa-2-1/2), Swedish standard SIS 05 5900.
All structures steel
works Surface
6.1 one coat of two pack zinc rich epoxy primer meeting SSPC Paint Paint Report Total DFT : 50+120 = 170 Miconrs
Preparation & PRIMER PAINT
Painting 20 level 1 DFT : 50 microns Ref : SPECIFICATION FOR PAINTING DOCU No.TS -
Visual & DFT
100% P RW - - 2001 (Attachement for 17269-002000-AR01)
Check
1 final coat of two packs, Polyamide Cured Epoxy. DFT : 120 Painting Testing Requ : Pls refer the Procedure No
FINAL PAINT
Microns per coat (Colour : Grey RAL No: 7010) : CN-KA-22890-ZET/WECL/SPP/01 Dt.11-05-2023

1. Hammer Test
Total DFT :
Surface Treatment of 2. Preece Test
Galvanizing/ 10% IS 4759 & Approved Drawing , TA Galvanizing
6.2 Electro forged 3. Mass of Zinc Coating P RW - -
Visual as per Lot coating Thickness shall be 120 Microns DFT Report Coating Thickness shall be 120 Microns
Gratings (Galvanizing) 4. Coating Thickness visual for Finish
(DFT)

7.0 FINAL CLEARANCE

1)Fitments of all components,

Finish product as per
Completeness of all Dimensions measurments. Visual/ Finish product as per approved Inspection *Match Mark Hard Punch to be Done.
7.1 100% approved Drawings and P R - -
previous Stages 2) Review of previous stage reports. Measurement Drawings and Specification Report Same should be Highlighted after Painting
Specification
3) Workmanship

Packing to be as per
7.2 Dispatch Packing Visual - - P R - -
Purchase Order/Drawing Requirement,WUHUAN Guidelines

Inspection Release
7.3 Complete Documents Review - As per the Purchase Order Terms &Specifications - P H R I
Note
Quality Original Documents to be submit prior to
dispatch to WUHUAN
7.4 Final Dossier Complete Inspection Reports Review - As per the Purchase Order Terms & Condition - P R R -

LEGEND : P- PERFORM, W - WITNESS, A - APPROVAL, R - REVIEW OF DOCUMENTS, RW - RANDOM WITNESS W - WITNESS , I- INFORMATION, MTC - MANUFACTURER TEST CERTIFICATE, BTC - BATCH TEST CERTIFICATE
NDT : NON - DESTRUCTIVE TESTING, UT : ULTRASONIC TEST, DPT: DYE PENETRANT TEST, AWS: AMERICAN WELDING SOCIETY, IS - INDIAN STANDARDS, PO - PURCHASE ORDER, DFT - DRY FILM THICKNESS

Form No : ZET-QA-F-01 REV.00 Dt.03.08.2020 Page 3 of 4

 ZETWERK MANUFACTURING BUSINESSES PVT LTD.,
Oriental Towers No.461, 1st & 2nd Floor, 4th Sector,
ZETWERK MANUFACTURING BUSINESSES PRIVATE LIMITED 17th Cross, HSR Layout Bengaluru, India - 560 102.
Website: www.zetwerk.com
CUSTOMER WUHUAN ENGINEERING CO., LTD QAP NO CN_KA-22890/23-24/QAP/106 Rev.02 DATE : 06.07.2023
CUSTOMER
CLIENT TALCHER FERTILIZERS LIMITED (TFL) 17269-ASM1801-PO DATE : 27-Mar-2023
PO.NO
PMC PROJECTS & DEVELOPMENT INDIA LTD (PDIL)

PROJECT AMMONIA UREA PLANT, TALCHER

PRODUCT / NAME FABRICATION AND SUPPLY OF STRUCTURAL STEEL AND OTHER STEEL, IRON OR METAL ITEMS
DOCUMENT REF: 1. 17269 -002000- AR01 Rev.0C - General Specification of Architecture 4. 17125/17269-PP67-001 Rev.1 - Instructions for QAP/ITP Preparation
2. 17269 - 00200- ST0504 Rev.2A - Specification for Steel Fabrication 5. 17269-PP41-001 Rev.0A - Packing and Marking Specification
3. 17269-ASM1801-PO Rev.2A Technical Appendix for Structural Steel and Other Steel, Iron or Metal Items (Material 6. 17269-PP79-01 Rev.2 - Vendor Document Handling procedure
and fabrication of Ammonia-Urea Plant)
QUALITY ASSURANCE PLAN
INSPECTION & QUANTUM RESPONSIBILITY
CHARACTERISTIC REFERENCE STANDARD/ FORMAT/
Sl. No. TESTING TYPE OF CHECK OF ACCEPTANCE CRITERIA WUH TFL/ REMARKS
TO BE VERIFIED DOCUMENT/ RECORDS MFG TPIA
DESCRIPTION CHECK UAN PMC
1 2 3 4 5 6 7 8 9 10 11 12 13
REF : Doc. No.: PC009/E/4001/P-II/Sec.15 Sheet 51 of 91 & Sheet 48 of 91 - Talcher Fertilizers Limited Vendor List

Prepared by: Zetwerk Manufacturing Businesses Pvt Ltd Reviewed By : Zetwerk Manufacturing Businesses Pvt Ltd Approved By : M/s. WUHUAN ENGINEERING CO., LTD

Name : R Shanmuganathan Name : B. Ramesh Babu Name :

Signature : Date.06.07.2023 Signature : Date : 06.07.2023 Signature : Date:

Designation : Manager - QA Designation : General Manager - QA/QC Designation

Form No : ZET-QA-F-01 REV.00 Dt.03.08.2020 Page 4 of 4