Manufacturing Process Plan (MPP)

Doc. No. ATV/MPP/AHPL/V0322/54269 A.C. Garg P HIN EX 35 12-2 Rev .00, Issue Date: 28.12.10

Customer ANDRITZ HYDRO PVT. LTD. Supplier ATV PROJECT INDIA LTD.
Project Name XEKAMAN 1 HYDRO POWER
PROJECT
MPP No.
Project No. V0377 Component
P.O. No. Drawing No. V0377-TU-2008
Main Process Fit-up , Welding , NDT , SR , Assembly, Blasting & Primer Painting










Edition
No.
Revision details Submitted By Supplier
Date
Approved By SQE
Date
Name Signature Name Signature
00

A.C. Garg






Page no. 1of 5


Manufacturing Process Plan (MPP)

Doc. No. ATV/MPP/AHPL/V0322/54269 A.C. Garg P HIN EX 35 12-2 Rev .00, Issue Date: 28.12.10

General Applicable Documents

Example
Customer Specification (drawings, bill of material, specification)
RHY SP003/1E packing instruction
EN1002
EN10045
EN 10228-1
EN 10228-3
EN 10204
ISO 5817
R HY SP 008
ASME SEC V & SEC VIII
Q HDE 60 014
PAINTING SPEC- TKT-TU-02-0100
STRESS RELIEVING AS PER MENTIONED ON DRG.
QAP NO: - QC2-ITP-V0322-050 REV-G

General Determination

Scope of test:
If no limitations are stated in this Manufacturing process plan or in specifications referred to therein, the test of scope shall be 100%
All dimensions shall be checked. If not specified otherwise, special dimension shall be recorded with nominal- and actual values.
All required test certificates shall be in English language (unless otherwise specified in purchase order).
At least 5 working days (unless otherwise specified in the purchase order) in advance Andritz Hydro shall be informed about the readiness of the parts for
acceptance tests.

Abbreviations

-Sr. Serial No. -CTQ Critical to Quality
-PO Purchase Order -SDR Supplier Deviation Request -W Witness Point
-CA Chemical analysis -NDT Non Destructive test -BOM Bill of Material
-Pos. Position -Z Tensile test -K Impact test
-3.1 Inspection certificate (Acc. to EN 10204) -3.2 Inspection certificate (Acc. to EN 10204) -C General Test Report

Page no.2 of 5
Manufacturing Process Plan (MPP)

Doc. No. ATV/MPP/AHPL/V0322/54269 A.C. Garg P HIN EX 35 12-2 Rev .00, Issue Date: 28.12.10

Operation/
Activity No.
Operation / Activity Machine/
device/Jig/
tools used
Applicable
Documents
Verification
by AHPL
H/QA/R
Operator Brief / critical
parameter & requirement
Measuring
instrument
Supplier
signature &
date
SQE/MM
signature &
date
Draft Tube Liner
10.
CNC/Manual Cutting Of
Segments. (1A-12A) &
(1B 12B)
CNC/
Gas cutting
Drg. V0377-TU-
2008 REV-A
R
20.
Bending Line Marking of
(1A-12A) &
(1B 12B)
Measuring Tape
and Marker
Drg. V0377-TU-
2008 REV-A
R
Bending Line, Bending Radius &
Circumference.
Measuring Tape &
Scale visual

30. Edge Preparation
Gas Cutting/
Grinding M/C
Drg. V0377-TU-
2008 REV-A
R
Bevel angle, Root Gap, offset &
Circumference

Template
Measuring Tape &
Scale visual

40.
Rolling/Pressing of
Segments (1A-12A) &
(1B 12B)
Rolling MC/
Pressing M/C
Drg. V0377-TU-
2008 REV-A
R
As Per the Drawing
Template
Measuring Tape &
Scale visual

50.
Gauging (1A-12A) &
(1B 12B)
Hammer &
Cleats
Drg. V0377-TU-
2008 REV-A
R
Ovality & ID to be maintained as per
Drawing
Measuring Tape &
Scale visual


60.

LS fit up
Welding M/C
L cleats &
wedges
Drg. V0377-TU-
2008 REV-A
R
Bevel angle, Root Gap, offset &
Circumference

Measuring Tape &
Scale visual

70. L/S welding 1
ST
Side SMAW M/C

Drg. V0377-TU-
2008 REV-A
R

Temperature stick
for preheat &
interpass

80. Back chip & DPT Grinding M/C
Drg. V0377-TU-
2008 REV-A
R
Grinder man/Level II
Verification by
DPT

90. L/S welding 2
nd
Side SMAW M/C
Drg. V0377-TU-
2008 REV-A
R

Temperature stick
for preheat &
interpass





Page no.3 of 5

Manufacturing Process Plan (MPP)

Doc. No. ATV/MPP/AHPL/V0322/54269 A.C. Garg P HIN EX 35 12-2 Rev .00, Issue Date: 28.12.10

100. NDT of Welding
VT and DPT
Apparatus
Drg. V0377-TU-
2008 REV-A
R
Level II
110. Bracing Fitup & Welding
Rolling M/C
Template
Drg. V0377-TU-
2008 REV-A
R
Ovality & ID to be maintained as per
Drawing

120.
Stiffening Ribs Fitup &
Welding
SMAW M/C
Drg. V0377-TU-
2008 REV-A
R
Bevel angle, Root Gap, offset &
Circumference

Measuring Tape &
Scale visual

130. Fitup for C/S Welding.
Welding M/C
L cleats &
wedges
Drg. V0377-TU-
2008 REV-A
R
Bevel angle, Root Gap, offset &
Circumference


140. C/S welding 1
ST
Side SMAW M/C
Drg. V0377-TU-
2008 REV-A
R

Temperature stick
for preheat &
Interpass

150. Back chip & DP Grinding M/C
Drg. V0377-TU-
2008 REV-A
R
Grinder man/Level II
Verification by
DPT

160. C/S welding 2
nd
Side SMAW M/C
Drg. V0377-TU-
2008 REV-A

R

Temperature stick
for preheat &
Interpass

170. NDT of Welding
VT and DPT
Apparatus
Drg. V0377-TU-
2008 REV-A
R
Level II
180.
External Inspection of
Parts 1,2,3 and 4
VT and DPT
Apparatus
Drg. V0377-TU-
2008 REV-A
QA
Measuring Tape &
Scale visual

190.
Fitup & Welding of
Cleats

Drg. V0377-TU-
2008 REV-A
R

200.
External Inspection of
Assembly of parts
Measuring
Devices
Drg. V0377-TU-
2008 REV-A
QA
ID, Circumference & Offsetting as
per Drawing
Measuring Tape &
Scale visual






Page no.4 of 5


Manufacturing Process Plan (MPP)

Doc. No. ATV/MPP/AHPL/V0322/54269 A.C. Garg P HIN EX 35 12-2 Rev .00, Issue Date: 28.12.10





210. Fitup & Welding of feet SMAW M/C
Drg. V0377-TU-
2008 REV-A
R
Bevel angle, Root Gap, Offset
220.
Opening Marking &
Cutting
Gas Cutting/
Grinding m/c
Drg. V0377-TU-
2008 REV-A
R

230.
Fitup & Welding of
Dewatering Box
SMAW M/C
Drg. V0377-TU-
2008 REV-A
R
Bevel angle, Root Gap, Offset
240.
Fitup & Welding of
Relief Pipe
SMAW M/C
Drg. V0377-TU-
2008 REV-A
R
Bevel angle, Root Gap, Offset
250. Final Inspection
Measuring
Devices
Drg. V0377-TU-
2008 REV-A
QA

Measuring Tape &
Scale visual

260.
Shot Blasting of
Assembly
Blasting M/C
Drg. V0377-TU-
2008 REV-A
R

270. Painting of Assembly SMAW M/C
Drg. V0377-TU-
2008 REV-A
R
Q EWR 43 001,
V0377-TU-01-8950


280. Painting Inspection DFT Meter
Drg. V0377-TU-
2008 REV-A
QA
Q EWR 43 001,
V0377-TU-01-8950

290. Loading & Dispatch
Drg. V0377-TU-
2008 REV-A
R



H- Hold Point
QA- Witness by AHPL
R- Review by AHPL.




Page no.5 of 5