QAP for MS Pipes-Revised

Name of Sub Project: Date: FOR MANUFACTURE OF SPIRALLY WELDED MS PIPES WITH INLINING & COATING PROCESSES , INSPECTION AND TESTING PLAN Sl. No. 1

Component / Material

Characteristics Check

Category

Type of Check

Quantum of Check

Reference Documents

Acceptance Norms

Format of Record

MTC

M

Agency Engineer & TPI

RAW MATERIAL CONTROL Critical

Chemical Analysis

1 per section or lot

IS 10748 Gr. 3/ IS 3589

IS 10748 Gr. 3/ IS 3589

1. Tensile

Critical

UTM

1 Samples per every 40 tonnes

IS 10748 Gr. 3/ IS 3589

IS 10748 Gr. 3/ IS 3589

2. Bend Test

Critical

UTM

One Sample per Batch

IS 10748 Gr. 3/ IS 3589

IS 10748 Gr. 3/ IS 3589

c. Dimension

Major

Measuring Instrument

100%

IS 5504-1997 & Customer Specification if any

d. Surface Defect

Major

Visual

100%

Major

Visual, Template, Measurement

a. Chemical

R

R

P

R

P

R

Manufacturer's Register/ IS 5504-1997 & Customer Specification if Report (MEIL/QAQC/F013) any

P

R

IS 3589/IS 5504

IS 3589/IS 5504

P

R

100%

IS 5504:1997

IS 5504:1997

W

R

100%

ASME Sec II part C for weld wire & flux, IS 3658:1999 & IS 814-1991 for stick electrode

W

R

WPS (MEIL/ QAQC/F024)

W

R

Repair Rectification report (MEIL/QAQC/F014)

W

R

b. Physical

1.1

2 2.1

2.2

HR Coils

PROCESS CONTROL Pipe Forming

Welding & NDT Consumables

Edge Milling & Forming

Chemical composition, Mechanical Properties and DPT Materials

Major

2.3

a) Determination of WPS for SAW welding Parameter Pipe manufacturing b) SAW pipe Process manufacturing process in length of 5.0-12.2 Mtr.

Critical

2.4

Repair welding

Repair of weld defects

2.5

DPT

End Preparation

2.6

3

Lab Report (MEIL/QAQC / F- 011)

Verification of batch TC’s

ASME Sec II part C for weld wire & flux, IS 3658 :1999 for NDT materials

-

MTC

& IS 814-1991 for stick electrode

Mechanical Test

100%

ASME Sec IX/PQR

ASME Sec IX/PQR /WPS

Critical

Visual

100%

IS 5504 :1997

IS 5504 :1997

Repaired Weld Defects

Critical

Visual

10%

ASME Sec. V Article ASME Sec. V Article 6.0 6.0

DPT report (MEIL/QAQC/F-017)

W

R

a) Bevel end Outside b) Root face. C) End Flushing : ID & OD 100mm from both weld ends

Critical

100%

IS 5504 :1997

IS 5504 :1997

Bevelling Inspection report (MEIL/QAQC/F006)

W

RW

100%

IS 5504 : 1997

IS 5504 : 1997

W

RW

Visual & Bevel gauge

FINAL INSPECTION & TESTING a. Dimension

Critical

Measuring Instrument

Inspection Report (MEIL/PR/F-010)

Remarks

Sl. No.

3.1

Component / Material

Characteristics Check

Category

M

Agency Engineer & TPI

W

RW

Ultrasonic Test Report (MEIL/QAQC/F-015)

W

W

IS 5504-1997

Inspection Report (MEIL/QAQC / F- 011 )

W

W

IS 5504 : 1997

IS 5504 : 1997

Inspection Report (MEIL/QAQC / F- 005)

W

W

Manufacturer's Register/ Report (MEIL/QAQC / F007 )

W

RW

W

RW

Critical

Ultrasonic

As per agreement specififcations IS 4260 (10% of Weld Length)

IS 4260

d. Mechanical Test

Critical

Root & Face Bend Test

Sampling as per IS 4711

IS 5504-1997

Hydraulic Pressure at manufacturer's work at 100% a)15 kg/cm2 & b) 22 kg/cm2

Format of Record

Inspection Report (MEIL/PR/F-009)

c. Soundness of Weld

INNER LINING & OUTER COATING Pipes

Cement

1. Dimension

Major

Measuring Instrument

100%

IS 3589-2001

IS 3589-2001

2. Surface Defect

Major

Visual

100%

IS 3589-2001

IS 3589-2001

a. Chemical

Critical

Chemical Analysis

One Sample IS 269 / IS 8112 / IS IS 269 / IS 8112 / IS forevery 200Bags 12330 12330

Suppliers MTC

W

R

b. Physical 1. Fineness

do

By Sieve

do

do

do

Lab Report

W

R

2. Standard Consistency do

Lab Test

do

do

do

Lab Report

W

R

do

Lab Test

do

do

do

Lab Report

W

R

do

Lab Test

do

do

do

Lab Report

W

R

5. Compressive Strength do

Lab Test

do

do

do

Lab Report

W

R

a. Delitereous Material Aggregate(Sand)

4.4

Weld Mesh for outer Coating & Inside MS Rings

4.5

Water

Lab report

W

R

b. Soundness

do

do

do

do

do

do

W

R

c. Specific Gravity

do

do

do

do

do

do

W

R

d. Grading & Size

do

do

do

do

do

do

W

R

As per customer specification IS: 1566

Wire Mesh Size: 50x50x3.0 mm, & Inside 6mm dia MS Rings 04 nos. at each end of the pipe

Suppliers MTC

W

R

W

R

W

R

Dimension

Suitability of Water for Concrete Works a. Mix Design

4.6

As per welding As per welding practise practise (IS 816 & IS (IS 816 & IS 822) 822)

Visual

3. Setting Time Initial, Final 4. Soundness

4.3

Acceptance Norms

Critical

Inspection of Welded Pipes

4.1

4.2

100%

Reference Documents

b. Welding

e. Hydraulic Pressure Test for Pressures as per Critical agreement specifications 4

Quantum of Check

Type of Check

Outer & Inner Coating Mix

Major

Minor

Major Major

Lab Test

1 per batch

Measuring Instrument

Lab Test Measurment

100%

Once in a Year 1 Per Batch

IS 3589 / IS11906

IS 456/IS 3589 IS 1916:1989

IS 3589 / IS11906

IS 456/IS 3589

Lab TC

Outer Cement Mortar ratio : 1:3, Inner Cement Manufacturer's Register/ ratio: 1:2 Report (MEIL/QAQC / F007 )

Remarks

Sl. No. 4.6

Component / Material Outer & Inner Coating Mix

Characteristics Check

b. Cube Strength

4.7

4.8 5

Outside & Inside Coating

Major

Curing

Proper curing

6.1

Type of Check

Compressive Strength

Quantum of Check

3 Per Batch

Thickness guages/ vernier caliper

Reference Documents IS 784 Purchaser's Specification & IS 3589 / 2001

100%

IS 3589: 2001

Acceptance Norms

Format of Record Manufacturer's Register/ Report (MEIL/QAQC / F007 )

IS 784 Purchaser's Specification & IS 3589 / 2001 Gunneting thickness: Manufacturer's Register/ 30mm, Inlining thickness Report (MEIL/QAQC / F: 12 mm, Cut back : 007 ) 150 mm,

Critical

1. Visual 2. Co-relating with cube strength

100%

Major

Visual

100%

IS 3589 : 2001 & IS 5504 : 1997

IS 3589 : 2001 & 5504 : 1997

IS

Major

Measuring Instrument & Gauges

100%

IS 3589 : 2001 & IS 5504 : 1997

IS 3589 : 2001 & 5504 : 1997

IS

Major

Visual

100%

IS 3589 : 2001 & IS 5504 : 1997

IS 3589 : 2001 & 5504 : 1997

IS

IS 3589 : 2001

IS 3589 : 2001

M

Agency Engineer & TPI

W

R

W

RW

W

RW

W

W

W

RW

W

W

Remarks

FINAL INSPECTION & TESTING

Fabricated , Lined & Coated Pipe b. Dimension c. Marking

6

Critical

Coating thickness

a. Surface Defects

5.1

Category

Manufacturer's Register/ Report (MEIL/QAQC / F007 )

SEALING & STAMPING Stenciling IA Stamp

Legibility of Stamp

Major

Visual

100%

-

-

Test Reports

W

W

Samples inspected by TPI are double stamped

1. Reviwed items may be randomly witnessed by the concerned if necessary. 2. All measuring instruments and testing equipmenets shall be calibrated periodically and put up for verification to Third Party Inspection Agency. 3. Legend: M: Manufacturer, TPI: Third Party Inspection, R; Review, W: Witness, RW: Random Witness (10%),V: Verify 4. MS Pipe 1540mm OD/1040mm OD x 8mm thickness, Outer Coating 30mm thk Cement Mortar (CM 1:3) with Wire Mesh 50x50x3mm, Inlining 12mm thk Cement Mortaar (CM:1:2) using 4 No. of 6mm Dia. MS Rings 5. Stenciling with the lettering - APMDP - KAKINADA is to be marked on the Finished MS Pipes Approved By Signature: Name: Designation: