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MANUFACTURER'S NAME &

QUALITY ASSURANCE PLAN

ADDRESS: M/S. ENCON, FARIDABAD

Sl. No.

COMPONENT

P.O. NO. ITEMS : TUNDISH PREHEATING STATION TUNDISH DRYING STATION SEN PREHEATING OVEN CHARACTERSTICS TYPE/METHOD EXTEN REFERENCE TO BE CHECKED CATEGOR OF CHECK T OF DOCUMENT CHECK Y

QAP NO. REV. PAGE I OF 3

NAME OF CLIENT : DANIELI INDIA LIMITED PROJECT : JINDAL STEEL & BSRM JOB POSITION AGENCY P W V REMARKS

ACCEPTANCE NORMS

FORMAT OF RECORD

RAW MATERIAL BOUGHT OUT ITEMS FOR PACKAGE UNITS. PHYSICAL & MAJOR 1 PLATE, ANGLE, CHANNEL, BEAM CHEMICAL PROPERTIES

MILL TC

APPROVED MANUFACTURIN 100% G DRG. DATA SHEET/ DAN STD.

APPROVED MANUFACTURER'S MANUFACTURING TC DRG. DATA SHEET/ DAN STD. MANUFACTURER'S TC

UT REPORT FOR 16 MM 1 & ABOBE THK TO BE SUBMITTED

2 ROUND BAR

PHYSICAL & CHEMICAL PROPERTIES

MAJOR MILL TC 100% DO DO

UT REPORT FOR 50 MM 1 & ABOBE DIAMETER TO BE SUBMITTED

3 PIPE (CU, CS & SS 4 ELECTRICALS & INSTRUMENTS

PHYSICAL & CHEMICAL PROPERTIES MANUFACTURER'S TC

MAJOR MILL TC MAJOR PERFORMANCE CERTIFICATION 100% DO DO

MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC

100% 100%

DO DO DO DO DO DO DO

DO DO DO DO DO DO DO

2 2 2 2 2 2 2

1 1 1 1 1 1 1

5 THERMOCOUPLE MANUFACTURER'S TC MANUFACTURER'S 6 VALVES TC MANUFACTURER'S 7 HOSE TC 8 PLUMMER BLOCK MANUFACTURER'S WITH BEARING TC 9 AIR/GAS/RATIO REGULATOR 10 PR. GUAGE

MAJOR MAJOR MAJOR MAJOR MATERIAL & PR. TEST MATERIAL & PR. TEST MATERIAL

100% 100% 100%

MANUFACTURER'S MAJOR TC MANUFACTURER'S MAJOR TC

PERFORMANCE REPORT CALIBRATION CERTIFICATE

100% 100%

PREPARED BY:

LEGENDS:
P-PERFORM, W-WITNESS, V-VERIFICATION

APPROVED BY :

1- TPIA/DIL/CUSTOMER/CONSULTANT, 2-MANUFACTURER

MANUFACTURER'S NAME &

QUALITY ASSURANCE PLAN


P.O. NO. ITEMS : TUNDISH PREHEATING STATION TUNDISH DRYING STATION SEN PREHEATING OVEN TYPE/METHOD OF CHECK EXTEN T OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS

ADDRESS: M/S. ENCON, FARIDABAD

QAP NO. REV. PAGE 2 OF 3

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NAME OF CLIENT : DANIELI INDIA LIMITED PROJECT : JINDAL STEEL & BSRM JOB POSITION AGENCY REMARKS P W V

COMPONENT

CHARACTERSTICS CATEGOR TO BE CHECKED Y

FORMAT OF RECORD

RAW MATERIAL BOUGHT OUT ITEMS FOR PACKAGE UNITS. MANUFACTURER'S MAJOR 11 HYDRAULIC CYLINDER TC

MATERIAL, PR. TEST & B/O DETAILS ROUTINE TEST CERTIFICATE VISUAL DIMENSION & SIMULATION MATERIAL & PERFORMANCE TEST REPORT MATERIAL & PERFORMANCE TEST REPORT MATERIAL & PHYSICAL PROPERTIES CERTIFICATION MEASUREMENT

APPROVED MANUFACTURIN 100% G DRG. DATA SHEET/ DAN STD. 100% DO

APPROVED MANUFACTURER'S MANUFACTURING TC DRG. DATA SHEET/ DAN STD. DO MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC MANUFACTURER'S TC

12 POWER PACK

MANUFACTURER'S TC

MAJOR

13 CONTROL PANEL MANUFACTURER'S TC 14 BURNER MANUFACTURER'S TC MANUFACTURER'S TC

MAJOR

100%

DO

DO

MAJOR

100%

DO

DO

15 BLOWER

MAJOR

100%

DO

DO

16 REFRACTORY & INSULATION

MANUFACTURER'S TC

MAJOR

100%

DO

DO

MANUFACTURER'S TC

IN-PROCESS INSPECTION OF PACKAGE UNITS MAJOR 16 STRUCTURAL STEEL & PIPING WPS, PQR, WPQ 17 STRUCTURAL STEEL & PIPING WELDING 18 ELECTRICAL PANEL MAJOR NDT MEGGER TEST, HV TEST MAJOR

ASME SEC-IX DAN STD CLASS-B 100%

ASME SEC-IX DAN STD CLASS-B

MANUFACTURER'S RECORD INSPECTION REPORT

2 2 2

1 1 1

MEASUREMENT

NOT LESS THAN INSPECTION REPORT IM ohm

PREPARED BY:

LEGENDS:
P-PERFORM, W-WITNESS, V-VERIFICATION

APPROVED BY :

1- TPIA/DIL/CUSTOMER/CONSULTANT, 2-MANUFACTURER

MANUFACTURER'S NAME &

QUALITY ASSURANCE PLAN

ADDRESS: M/S. ENCON, FARIDABAD

QAP NO. REV. PAGE 3 OF 3

Sl. No.

COMPONENT

CHARACTERSTICS CATEGOR TO BE CHECKED Y

TYPE/METHOD OF CHECK

EXTEN T OF CHECK

REFERENCE DOCUMENT

ACCEPTANCE NORMS

FORMAT OF RECORD

NAME OF CLIENT : DANIELI INDIA LIMITED PROJECT : JINDAL STEEL & BSRM JOB POSITION AGENCY REMARKS P W V 2 1 1 CALIBRATION CERTIFICATES OF MEASURING INSTRUMENTS ARE TO BE SUBMITTED

FINAL INSPECTION OF PACKAGE UNITS MAJOR 19 COMPLETE UNIT VISUAL, IN ASSEMBLED DIMENSIONAL, CONDITION WITH FUNCTIONAL ONBOARD TEST/ RUN TEST PIPING, (ONEUMATIC ONBOARD MOVEMENT ELECTRICALS & CHECK, COLD INTERCONNECTI TEST FOR NGS ELECTRICAL CIRCUIT, BURNER. IGNITION & REGULATION. (WITH FULL AUTOMATIC SCOPE OF TEMPERATURE SUPPLY) CONTROL IN PRESET MODE FUNCTIONAL DYNAMICS FUNCTIONAL & SAFETY INTERLOCKS) 20 ASSEMBLED UNIT MAJOR

MEASUREMENT

100% APPROVED GA DRG. DATA SHEET

APPROVED GA DRG. DATA SHEET

INSPECTION REPORT

SURFACE PREPARATION & PAINTING

DFT, ADHESSION, SHADE, VERIFICATION

100% AS PER CONTRACT AS PER CONTRACT

INSPECTION

1 1

PREPARED BY:

LEGENDS:
P-PERFORM, W-WITNESS, V-VERIFICATION

APPROVED BY :

1- TPIA/DIL/CUSTOMER/CONSULTANT, 2-MANUFACTURER

PROCEDURE QUALIFICATION RECORDS (PQR) Construction Code : (ASME Sec IX) Company Name : M/s. Encon Thermal Engineers, Palwal PQR No: ETE/PQR/004 Date : 12/09/2013 Rev. No. WPS No: ETE/WPS/004, Date : 12/09/2013 Welding Process(es)/Type: Joints (QW-402 : Groove Design of Test Coupon:

Page 1 of 2

Rev. Date: SMAW /Manual

BASE METALS (QW-403) Material specification : IS:2062 to IS:2062 Type or Grade Gr. B TO Gr. B P-No: to P-No. : Thickness of Test Coupon : 12 mm Diameter of Test Coupon: Other:. FILLER METALS (QW-404) Buttweld SFA No. : AWS CLASS: F. No.: A. No.: Size of Filler Metals Deposited Weld Metal Thickness Range
POSITIONS (QW-405) 5.1 E-7018 4 1 2.50 / 3.15

POST WELD HEAT TREATMENT (QW407) Temperature Range :... Time range:. Other GAS(QW-408 Gases Mixture Shielding .. .. Trailing None None Backing None None Fillet
ELECTRICAL CHARACTERISTICS (QW-409)

Flow rate .. None None

Current : (AC or DC): DC Polarity : (SP or RP): RP Amps. See table Volts: See table Tungsten Electrode Size and Type: NA
Other :

12mm

TECHNIQUE (QW-410) Travel speed: Refer Table


String or Weave Bead: -Root stringe,sub runs weave Bead -Max. 3 times of rod dia.

Positions of groove: 3G Welding Progression: Uphill Other PREHEAT (QW-406) Preheat Temperature, Minimum: N.A Inter pass Temperature, Maximum : 250 to 300 C Other : Filler Metal Weld Process Layer(s) F-No. A-No. SFA No. AWS No. Root 1st & 2nd Layer 3rd + n Layer Back side 1st Layer SMAW SMAW SMAW SMAW 1 1 1 1 5.1 5.1 5.1 5.1 E-7018 E-7018 E-7018 E-7018

Oscillation: Side to Side Multiple or Single Pass (per side) : Multiple Multiple or Single Electrodes : Single Method of back Gouging: Grinding Peening : NA Other : Trav. Speed Size Type Other Amp. Volt. Range Range 6-8 in./Min. 2.5mm Solid 80/100A 20/32V 3.15mm 3.15mm 3.15mm Solid Solid Solid 90/120A 90/120A 90/120A 20/35V 20/35V 20/35V 6-8 in./Min. 6-8 in./Min. 6-8 in./Min.

Page 2 of 2 PQR No: ETE/PQR/004 Date : 12/09/2013 Rev No: Rev. Date:

Tensile Test (QW - 150)

Test Report No: STH/2013/TC/I-006-2, Dt. 10/09/2013

Specimen No. UTS-1 UTS-2

Width 24.8 25.7

Thickness 12.2 mm 12.2 mm

Area 302.56 313.54

Ultimate Total Load (Kgf) 13700 14700

Ultimate Unit Stress-kg/mm2 45.28 46.88

Type of Failure and Location Broken from Parent Metal Broken from Parent Metal

Guided -Bend Test (QW-160) Specimen No. RB-1 RB-2 FB-1 FB-2 Type and Figure No. ROOT BEND TEST AT 180 DEG. ROOT BEND TEST AT 180 DEG. FACE BEND TEST AT 180 DEG. FACE BEND TEST AT 180 DEG. Toughness Tests (QW-170)

Test Report N0: STH/2013/TC/I-006-2, Dt. 10/09/2013 Result SATISFACTORY SATISFACTORY SATISFACTORY SATISFACTORY Test Report No:

Specimen Notch No. Location

Specimen Size

Test Temperature N.A.

Impact Value Impact Value % Shear Mills

Drop Weight Break (Y/N)

Comments: NDE Result : NA Result: NA Fillet Weld Tests (QW-180):-Result ----Macro - Results: NA Other Tests Visual Inspection Appearance : SATISFACTORY N.A. Test Report No.: Test Report No:--

Penetration in to Parent Metal:-----

Other Tests (Micro/Micro/Hardness)

Welder Name & Welder ID Number: Mr. Sanjay Singh - W6 Tests Conducted by: SARRC Test House, Faridabad. We certify that the statements in this record are correct and that the test welds/coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME BOILER AND PRESSURE VESSEL CODE.

Prepared By: M/s. ENCON Thermal Engineers (P) Ltd., Palwal

WELDING PROCEDURE SPECIFICATION (WPS) Construction Code : (ASME Sec IX)


Company : M/s. ENCON Thermal Engineers (P) Ltd., Faridabad WPS No: ETE/WPS/004 Supporting PQR No: ETE/PQR/006 Welding Process(es)/Type : SMAW JOINTS (QW-402) Jooint Design ( Manufacturing Drawing) BUTT WELD SINGLE V GROOVE Date : 06/08/2013 Date : 12/09/2013 PREHEAT (QW-406) Preheat temperature, Minimum: N. A. Rev No. 00 Page 1 of 1

Inter pass Temperature : 250 to 300 C

Backing: - No Backing Material(Type) : N/A BASE METALS(QW-403) P-No. 8 Group No. 1 To P-No. 8 Group No. 1 Or Spec.Type & Grade to spec: Type & Grade : A240 Gr. 304 to A240 Gr. 304 Thickness Range: Base metal 4 to 10 mm plate Fillet All Pipe Dia. (mm); Max Thick per pass(mm) Other: FILLER METALS (QW-404) Butt Weld Fillet F. No: 5 A. No: 8 SFA No: 5.4 AWS CLASS: E-308 (L) -16 Size of filler Metals 2.50 & 3.15 Deposited Weld Metal Thickness Range: 5 mm Thickness Range(Groove) Upto 10 mm Thickness Range(filler) All Electrode Flux(Class) N.A. Flux Trade Name Consumable Insert other; POSITIONS(QW-405) Positions of groove: 1G Welding Progression: Uphill Position(s) of Fillet :All Weld Layers(s) Root 1st Layer 2nd + n Layer Process SMAW SMAW SMAW F-No. A-No. 8 8 8
N.A. N.A. N.A.

Preheat maintenance: N. A. POST WELD HEAT TREATMENT (QW407) Temprature Range: N. A. Time Range: N. A. GAS(QW-408) Gases Mixture Flow rate . Shielding None None Trailing None Backing None None None ELECTRICAL CHARACTERISTCS(QW-409): Current :(AC or DC): DC Polarity:(SP or RP): RP Metal Transfer Mode for GMAW/FCAW:-N.A. Tungsten Electrode Size and Type : None Electrode Wire Feed Speed Range: N. A. TECHNIQUE(QW-410)
String or Weave Bead: -Root stringe,sub runs weave Bead -Max. 3 times of rod dia.

Filler Metal SFA NO. 5.1 5.1 5.1 AWS NO. E-308(L)- 16 E-308(L)- 16 E-308(L)- 16

Orifice or Gas Cup Size: N. A. Initial & interpass: Cleaning(Brushing, Grinding etc.): Brushing and Grinding Method of Back Gouging: Grinding Oscillation: Side to Side Contact Tube to Work Distance: N. A. Multiple or Single Pass(per side): Multiple Layer Multiple or Single Electrodes: Single Teravel Speed (range): See Table Trav. Speed Size Type Other Amp. Volt Range Range 40-50 2.5mm Solid 60/80A 17/18V mm/Min. 40-50 3.15mm Solid 60/110A 18/25V mm/Min. 40-50 3.15mm Solid 60/110A 18/25V mm/Min.

Prepared By: M/s. ENCON Thermal Engineers (P) Ltd., Faridabad.