Quality Assurance Plan For Seamless U-Tubes

Tubacex Prakash India Pvt. Ltd.

131/1,Umbergaon-Sanjan Road,Umbergan.Gujarat.India-396 171 Document No. Rev. date Rev. No. Page No.
D/QCD/002 01.09.2015 0 01 of 02
ITP No. TPIPL /QAP/1549/0018 Rev- 00 Date: 26.03.2020

CUSTOMER NAME. M/s. E BACHILLER B.S.A.

PO No. 658150 DTD: 27.02.2020

SOC No. 1201549

PRODUCT SPECIFICATION: ASME SEC. II PART-A (ED.2017) SA 789 ,SA 1016.

CUSTOMER DOCUMENT: U Tube Drawing- Provided by client, Material Purchase specification_SA-789 UNS S31803
PRODUCT DETAILS: COLD FINISHED SEAMLESS AUSTINETIC-FERRITIC STAINLESS STEEL U-TUBES GRADE: UNS S31803 SIZE: 19.05 MM OD X 2.11 & 2.41 MM (MW)THK X 6096 MM LEG LENGTH, QTY - 356 +10 NOS.

QUANTUM OF FORMAT OF SCOPE OF INSPECTION

SR NO. COMPONENTS CHARACTERISTICS CLASS TYPE OF CHECK REFERANCE DOCUMENT ACCEPTANCE NORMS REMARKS
CHECK RECORD TPIPL TPI/CUSTOMER

RAW MATERIAL As per ASTM A 276 /SA 789

1.1 Identification of Raw material Major Visual 100% SA 789 RMTC P R/R
IDENTIFICATION / UNS S31803

2.0 IN PROCESS INSPECTION

Heat treatment
Solution Annealing at 1040 0C SA 789/SA 1016 / UNS SA 789/SA 1016 / UNS Heat Treatment
2.1 (IN STRAIGHT TUBES Major Heat Treatment 100% P R/R
followed by water Quenching S31803 S31803 Record & Chart
CONDITION)
Eddy Current test
(IN STRAIGHT TUBES
2.2 Internal flaws Major Visual 100% As per E 309 / SA1016 As per E 309 / SA1016 Test Record P R/R
CONDITION PRIOR TO U
BEND)
As per SA 789/ SA 1016 / As per SA 789/ SA 1016 /
a) Product Analysis Major Chem. AS PER SPEC. Test Record P R/R
UNS S31803 UNS S31803

As per SA 789/ SA 1016 / As per SA 789/ SA 1016 / A

b) Tensile Testing Major Mech. AS PER SPEC. Test Record P R/R
A 370 / UNS S31803 370 / UNS S31803
Chemical, Mechanical &
Metallurgical Test on Tubes As per SA 789/ SA 1016 / As per SA 789/ SA 1016 / A
2.3 c) Hardness Testing Major Mech. AS PER SPEC. Test Record P R/R
(In straight tubes prior to U- A 370 / UNS S31803 370 / UNS S31803
Bend)
As per SA 789/ SA 1016 / As per SA 789/ SA 1016 / A
d) Flattening Test Major Mech. AS PER SPEC. Test Record P R/R
A 370 370

As per SA 789/ SA 1016 / As per SA 789/ SA 1016 / A

e) Flaring Test Major Mech. AS PER SPEC. Test Record P R/R
A 370 370
 Quality Assurance Plan For Seamless U-Tubes
Tubacex Prakash India Pvt. Ltd. Document No. Rev. date Rev. No. Page No.
131/1,Umbergaon-Sanjan Road,Umbergan.Gujarat.India-396 171
D/QCD/002 01.09.2015 0 02 of 02
ITP No. TPIPL /QAP/1549/0018 Rev- 00 Date: 26.03.2020

QUANTUM OF FORMAT OF SCOPE OF INSPECTION

SR NO. COMPONENTS CHARACTERISTICS CLASS TYPE OF CHECK REFERANCE DOCUMENT ACCEPTANCE NORMS REMARKS
CHECK RECORD
TPIPL TPI/CUSTOMER
Mock up test for Check As per ASME SEC. VIII Div-
As per ASME SEC. VIII Div-1
Thinning, Flattening at U bend 1 / TEMA RCB 2.31 of
2.4 U-Bending Major Measurement 100% / TEMA RCB 2.31 of section - Mock up test report P W Ref .Note 1 & 2
portion for inner most 3 radius section -5 / PO MATERIAL
5 / PO MATERIAL SPEC
after stress relieving SPEC

U bend Annealing for all Stress relieving at 1020°C at U

As per TEMA RCB 2.3.1 of As per TEMA RCB 2.3.1 of
U_TUBES bend portion +300 mm Heat Treatment soaking temperature shall be
2.5 Major Stress Relieving 100% section -5 / PO MATERIAL section -5 / PO MATERIAL P R/R
(Electric Resistance Heat Straight from Tangent line Record 30-40 seconds
SPEC SPEC
Treated) followed by Forced air cooling

Pickling & Passivation Pickling & Passivation

2.6 Surface Condition Major Visual 100% As per A 380 As per A 380 P R/R
for U bend tubes. report

3.0 FINAL INSPECTION

Hydrostatic testing for U As per SA 789/SA1016 / As per SA 789/SA1016 / PO At 1000 PSI for 5 sec holding
3.1 Pressure, Time, Leakage Major Visual 100% Test Record P 10% W
tubes PO MATERIAL SPEC MATERIAL SPEC time.

OD,Thickness at straight OD & Thk tolerance as per

Visual & Dimensional
portion, Leg Length, Radius, Visual & As per SA 789/SA1016 / As per SA 789/SA1016 / PO spec ,
3.2 Inspection Major 100% Inspection Record P 10% W
Straightness, Surface condition Measurement PO MATERIAL SPEC MATERIAL SPEC Leg.LENGTH: +3 MM, - 0MM,
(U bend tubes)
& Identification mark on tubes. Bend Radius: ±1.5mm,

Liquid Penetranrt Test for all

ASME Sec-VIII Div-1 ASME Sec-VIII Div-1
radius (At U bend portion
3.3 Surface defect Major Visual 10% Appendix 8 / PO Appendix 8 / PO MATERIAL Test Record P R/R After stress relieving only.
+300 mm straight from
MATERIAL SPEC SPEC
Tangent line)

Seaworthy packed in wooden

3.4 Packing & Dispatch Major Visual 100% SA 789 / SA1016 SA 789 / SA1016 / Packing Record P -
cases with end caps

Review &
Certification & Verification of all TCs for Endorsement of
3.5 Major Visual 100% SA 1016 / PO SA 1016 / PO P R/R
Documentation completion Documents, MTC
(As per EN 10204 3.1)

Legends: P- Perform by, W- Witness, V- Verify, A- Approval, PO- Purchase Order,TDC -Technical delivery condition, R/R-Record Review, TPIPL- TUBACEX PRAKASH INDIA PVT. LTD.

NOTE:
1 one tube from inner most three radius shall be hardness tested before and after heat treatment, minimum 5 points, 3 in the external diameter of the bent part and 2 in the straight part.

2 Flattening shall be 10 % for R ≤5D i.e. for innermost 3 radiuses, for rest radius flattening shall be 6% max.

Supriya Yadav J. ENPARAJ

 Quality Engineer AGM (QA/QC)
Prepared By(TPIPL QA) Reviewed By (TPIPL QA) Approved By(Client)