IDS for Internal Quality co

General Fabricated items: This is a process of manufacturing activities where

components or parts through welding and or fastening through bolts & nuts
components, the stages may be more or less.

Inspection
Sl No Properities to check
stage

1 Drawing Study of drawing with respect to Quality

requirement
Material of construction
Detailing of constructions with Weld details

Dimensional, Orientation & elevation

matching
NDT requiremets: RT, DPT, MPT, UT,
Testing requirements - Hydro & Pneumatic
Painting: - Surface finish, Paint: procedure,
Tests
PWHT & production test coupon
Any special requirements
Fasteners & Gaskets

All process incorporaion

All stages covered as per the relevant codes
and specifications
Incorporation of all PO terms
1 QAP/ITP
 Requirements as per Approved drawings
1 QAP/ITP incorporation
Incorporation of requirements as per
technical datasheets.
All test requirements
Scope of individual agencies
Materials involved ( P No, Group No, material
specification etc)
Welding process,
Weld details:
Welding Parameters(Position, Joint preparation,
2 Current details etc)
procedure
specifacation Mandatory variables
Non-mandatory variables.
Qualification range
Preparation of test coupan as per joint
configuration
Welding machine details
Current measuring instruments
Parent metal details
Welding consumable details
Certificates of all materials and
Welding Consumeables being used.
3 Procedure
Qualification Welder's identification No, name.
record Safety equipments
Weld position
Root gap
Root landing
Joint / Vee preparation
 Calibration certificates of all machine &
instruments which are being used
Welder All requiremets as above applicable in WPQR
Performane
Qualification
4

Bolting & Calculations of bolting & riveting parameters

Rivetting and torques.
5

Test Applicable tests like NDTs, DTs, Pressure tests

procedures etc.
Visual test / check
Dye penetrant test

Magnatic particle test

Pneumatic test
Ultrasonic test
Radiography
6
Hardness test
Chemical composition test
Physical properties test

Hydro test, pneumatic test

 Dimensions Measurement

Process, loading Temperature, rate of

heating, soaking temperature, soaking
period,cooling rate, unloading temperature,
recording details, hardness.

Applicable Heat treatment process.

Heat
7 Lot qty(Either weight or quantity as per
treatment
furnace capacity)
Loading temperature
Unloading temperature
Soaking time as per section thickness
Heattreatment chart
Surface preparation requirements,
Paint specification
Painting Dry film thickness
8 procedure
Finish
Paint Shade
Material Requirements as per approved drawings &
identification respective manufacturing codes

Materials specification
Drawing
Size
9 Quantity
Marking on materials
MTC verification
 Surface
Dimensions
Quantity
Marking of Transfer of identification details, size &
10 components quantity.

Size
Offset
Diagonal in case of rectangular or square
shape,
Long seam set Roundness in case of circular shape
11 up for welding Root gap
of parts Landing
Condition of tack-weld
Joint configuration
vee angle
Straightness
Removal of unsound metal
Application of DP as per procedure
Back chip & Look for any discontinuty in weld metal or in
12 parent metal
DP
Lack of fusion
Lack of penetration left over
Size
Offset
Allignment
Roundness in case of circular shape
Circumferenti Root gap
13 al seam set up
 Circumferenti
13 al seam set up Landing
Condition of tack-weld
Joint configuration
vee angle
Straightness
Final assembly fit up of each components
of all
14 componens

inspection of joints
orientation
elevation
level
welding / fastenning
finishing

Recommende
d NDTs before
15 PWHT DPT
MPT

Balance Radiography
pneumatic test
Hardness
UT
15 PWHT Applicable Heattreatment process.
Lot qty(Either weight or quantity as per
furnace capacity)
 Loading temperature
Unloading temperature
Soaking time as per section thickness
Heat treatment chart

Testing of the
16 test coupon Physical properties test
17 Final
dimensions Over all dimensions
checking of all components dimensions
orientation
elevation
nozzle face level
all test records
all documents
surface condition
Final
18 pneumatic / holding of pressure for recommended time
Hydro test period.
complete surface and all joints checking for
any leakage or shippage

Final stamping Hard stamping on the equipment as per

and quality norms.
documentatio
19 n
A set of final docs signed by inspection
authority.
 Surface
preparation &
20 painting Surface finish
paint shed
Dry paint thickness
Proper packing as per the packing drawing
21 Despatch and procedure

Raw Materials inspectio

Raw materials: This may be Plates, pipes, forgings or any other items to b

Stage of
Sl No Properities to check
inspection
Surface condition
Shape
Dimensions
Final Quantity
1
inspection MTCs
Physical & chemical Properties
PO conditions.
Identification marking wrt MTC
Surface, shape
PO conditions
Shape
Dimensions
2 Pre-despatch
Quantity
Identification marking wrt MTC
2 Pre-despatch

Chemical & physical Properties

MTCs
Discontinuty
Surface defects
Cracks
Pittings
3 Surface Surface un-eveness
Laminations,
Straightness
waviness
Surface finish
Length, width and thickness, and other
dimensions as the case may be.
ID, OD
4 Dimensions RF dia
Bolt hole dia & qty
RF dia, height of RF and finish
and so on
Details of plates, pipes or any other items.
5 Mill markings
Dimensions of the item
Material properities
Test records
6 MTCs
PO conditions.
Identification details with quality stamp
details
Chemical properities
Mechanical properities

7 Check test
 Heat treatment requirements,
NDT RT, UT, DPT,MPT
7 Check test Macro
Micro
IGC
Hardness
Impact
To establish the design parameters
8 Burst test

Identification markings and stamping

9 Final stamping
 ernal Quality control
g activities wherein, cutting, giving a shape and joining the
ough bolts & nuts or riveting. Depending upon the equipment and its

Extent Remarks
of check

While studing the drawing , take care of latest

approved drawings are only followed. Any deviation
noticed in dimention or requirements which is
Thoroug contradicting shall be taken up with concern
hly department. Identify the critical stages if any and note
in the QAP. Inform Design & Production in advance. A
Job note to be prepared which must include the said
points.

There shall be two documents. One QAP for internal

purpose & ITP for client & Inspection authority. It
involves the welding process, bolting details, revitting
details, fabrication stages, heat treatments, test
100% procedures (both Dt & NDT), painting procedures,
recording of all details,Tollerences & allowance,
responsibilities of each authorities.
 There shall be two documents. One QAP for internal
purpose & ITP for client & Inspection authority. It
involves the welding process, bolting details, revitting
details, fabrication stages, heat treatments, test
100% procedures (both Dt & NDT), painting procedures,
recording of all details,Tollerences & allowance,
responsibilities of each authorities.

If proper documents and records are not available

100% then new WPS shall be prepared and requalifications
shall be carried out for the welders and welding
procedures as per the job reqirements.

Welding procedure can be qualified by any one

welder of the company. The test coupon shall be
tested as per the respective code and specification.
Special tests to be carried out as per the job
requirements including heat-treatment if job calls for.
100% The test records and the welding parameters shall be
recorded during the welding & in the specified
formats as per code after testing. If require, then a
revised WPS shall be prepared after the WPQ is done.
All supporting test certificates with the weld datas
shall be attached with the PQR for record purpose.
 All supporting test certificates with the weld datas
shall be attached with the PQR for record purpose.

Any number of welders can be qualified using the

established PQR. Only the welder shall follow the
weld parameters as per the PQR and the test coupon
100% shall be tested as per the respective code of
qualification.

Torque calculations shall be given to support the

confirmation of torque requirements for each bolt
100% joints & rivet joints. Testing shall be carried out as per
the respective specification.

The tests are check tests, DPt, MPT, VT, RT,

Pneumatic, Hydro tests etc.
surface condition, surface finish, shape, quantity
surface discontinuties / defects, cracks open to
surface, porosity, undercut, lack of penetration.
For sub-surface defects in magnetic materials
For leakage through the joints
For inner surface defects
for innersurface/ subsurface/ on surface defects
100%
Weight method / Spectro meter
Tensile strength, yeild strength, impact strength,
compressive strength, drop test, bend test, Micro,
macro, corrosive test.
For leakage through the joints, Holding the pressure
 For dimensions to see for any permanent deformation
during the hydro test.
Depending upon the design requirements and
materials of construction, heat treatment is
applicable. The lot is decided on the basis of quantity
specified in the respective code and the raw material
heat numberwise quantity. Some times, the
manufacturer may have online heattreatment
100% process. Or the forging operation may have been
completed within the critical temperature, hence the
requirement of criterias will change.

media to be used for surface preparation,

intermidiate time lapse allowed between surface
preparation and 1st coat paint, drying time of the
100% paint are very important

For critical parts 100% to identify& for non-critical

items depends upon the inspecton agency and their
policy.
Respective codes
Approved for the product
Part size & overall all size wrt quantity
100% No of components
Mill mrking and stamp transfer on each part
wrt the code and all requirements of approved
drawings
 As per the drawing / product specifications
As per the specification & drawing
As per part list/ MTC
For critical parts 100% to identify& for non-critical
100% items depends upon the inspectoin agency and their
policy.

Requirements of joint/ VEE preparation shall be

100% fulfilled as per the thickness of parent metals and the
qualified weld procedures.

The method os applying the DP is very important to

identify the discontinuty or defects.

100%

Ovality, Allignment and straightness are most

important. Before closing seam circumferential seam,
100% one shall ensure that all intrnal activities are
completed in access after the closing seam is
restricted.
 Ovality, Allignment and straightness are most
important. Before closing seam circumferential seam,
100% one shall ensure that all intrnal activities are
completed in access after the closing seam is
restricted.

This is to ensure that all the fabrication activities are

100% completed.

100%
100% These tests shall be carried out as per thhe
requirements of the job, related approved QAP.
100% /
10%
100%
10%
100%

Depending upon the material of construction, the

heat treatment cycle is decided and a procedure is
100% approved by client. Also the test coupon plate to be
heat treated alongwith the equipment if the technical
specification of the equipment is asked for.
 Depending upon the material of construction, the
heat treatment cycle is decided and a procedure is
100% approved by client. Also the test coupon plate to be
heat treated alongwith the equipment if the technical
specification of the equipment is asked for.

100%
If the job calls for it.

Even if all the dimensions are checked earlier

individually, but a complete dimensional and visual
check is warranted at this stage with respect to the
100% latest approved drawings.

all records shall be checked to ensure that all

technical requirements are fulfilled and necessary
records are complete.
Two pressure guages shall be used. Ensure the
pressure inlet shall be from bottommost position,
outlet shell be topmost position. All the top nozzles
100% shall be tighten by torque wrench after the water over
flow. The total surface and soroundings shall be kept
dry.
 The 1st coat of painting shall be done within one hour
100% of surface preparation. Then subsequent coats shall
be done as per the procrdure.

Depending upon the size, weight and route , packing

100% shall be done.

Materials inspection
y other items to be used by the company for its product or project..

Extent Remarks
of check

This is a pre-despatch inspection stage. Items can be

100% 0r given for check test depends upon the items and PO
10% conditions.

Both the(100%) surfces shall be checked visually after

proper cleaning.

100% 0r
10%
100% 0r
10%

The 100% surface is to be checked visually. In any

doubt of defects, use proper method to detect the
defect. They may be: Dye-Penetrant test, Magnetic
particle test, Ultrasonic test, Radiography Test, surface
finish measurment.
100%

Thickness shall be checked with Screw guage, pointed

srew guage(pipes), Electronic digital meter at various
points. The dimensional checks shall be done as per
100% 0r the item is being checked wrt PO, technical
10% specification, respective codes and drawings if any.

Shall meet the requirements of specification and

100% match with the MTC.

MTC shall have the records of all requirements as per

the respective specificatios and PO.
100%

Some additional tests may be carried out, like, Macro

As per test for seamless pipes, micro test for Stainless
the materials, impact test for some steel materials,
respecti Hardness. These check tests shall be carried out on
ve test pieces which may have been taken separate test
specifica piece or may be from integrated test pieces. These
 Some additional tests may be carried out, like, Macro
As per test for seamless pipes, micro test for Stainless
the materials, impact test for some steel materials,
respecti Hardness. These check tests shall be carried out on
ve test pieces which may have been taken separate test
specifica piece or may be from integrated test pieces. These
tion or tests shall be done in a designated test laboratories.
as per
PO
terms.

Type This is the test of establishing the design parameters

test with respect to establish the validity of manufacturing
once process.
To be stamped or method to be used to identify that
100% the same inspected materials are being despatched
and received.