QUALITY ASSURANCE PLAN

A) DESIGN FEATURES

DESIGN CODE : ASME SEC VIII DIV 1 ED 2001 & TEMA Class 'C'
RADIOGRAPHY : SHELL : SPOT, DISH : FULL | EXPANSION BELLOW- FULL

HYDRO TEST PRESSURE : AS PER ORDER

REFERENCE HOLD POINTS
SR. COMPONENTS & CHARACTERISTICS DOCUMENT FORMAT OF
No. OPERATION CHECKS ACCEPTANCE RECORD EDES CLIENT
NORMS
B) DOCUMENT CONTROL
As per Clients P.O. and
1 Drg. Approval Drg. P W
requirements. Specification.
As per Welding
ASME sec VIII
2. Review of WPS / PQR details in Drgs. Records P R
Div 1 & Sec IX

C) INPROCESS CONTROL
Dimension ,Surface As per
Pressure part.
Defects, Physical respective
Material Identification Test
and Chemical material Specn
3. for shell. dished ends, Certificates - W/R
properties, ICG, UT & approved
tubes , tubesheet of Lab.
for thk above 25 Drgs.& Lab T.C.
mm etc.
Non Pressure Parts. As per
Materials Identification respective
Dimensions, Inspection
4. for skirt support, baffles Materials W -
Surface Defects Report
spacer tubes, tie rod, specn. &
gussets etc. Approved Drgs.
Weld soundness,
Test
5 PQR physical test. ASME sec IX P -
Reports

Material stamp transfer As per respect.

for shell, channel shell Dimensions, Materials Inspection
6 W R
tube sheet, dished end, Material grade. Specn. & Report
tubes etc. Approved Drgs.
Set up of long seams Weld geometry
of main shell courses , offset. Profile W.R.T ASME Sec VIII Internal
7 W R
skirt shell, channel shell Template ID, Div I Inspection
and fabricated pipes etc ovality. Etc. Report

Back chip of long seam Internal

8 Welding defects. ASME Sec V W R
welding & D. P. test Inspection
Report
Profile as per the
template and
Dimensions ASME Sec VIII
Dished ends Internal
9 Including thinning Div I & W R
forming Inspection
DP Test on knuckle Approved Drg.
Report
portion at KR, SF,
and edge etc.
 REFERENCE HOLD POINTS
SR. COMPONENTS & CHARACTERISTICS DOCUMENT FORMAT OF
No. OPERATION CHECKS ACCEPTANCE RECORD EDES CLIENT
NORMS
Dimension as per
approved drg, No. ASME Sec VIII
Tube sheet inspection Internal
10 of holes, pitch, Div I ,TEMA & W R
after reaming Inspection
Tube holes finish Approved Drg.
Report
grooving details
Circ Seams set up of
Weld geometry ASME Sec VIII
main shell courses, and Internal
11 offset, Alignment & Div I & W R
channel shell to Inspection
Dimensions. Approved Drg.
dishend Report

D.P. test of Back chip of

Internal
12 Circ Seam welding of Welding defects ASME Sec V W R
Inspection
Shells.
Report

Weld Geometry,
Set up of nozzle pipes Internal
13 Gasket Seat facing Approved Drg. W R
to Nozzle Flanges. Inspection
tell/tale hole.
Report

Set up of Nozzles on Weld geometry, ASME sec VIII

Internal
14 main shell and channel orientations, height, Div I & W R
Inspection
shells bolt hole Straddling Approved Drg.
Report

DP test of back chip of

Internal
15 nozzles on main shell Welding Defects ASME sec V W R
Inspection
& channel shell
Report
welding

Weld geometry, ASME sec VIII

Set up of body flanges Internal
16 orientations, bolt Div I & W R
to channel shell Inspection
hole Straddling Approved Drg.
Report

Corners to be
Flush grinding of all
rounded off to a ASME sec VIII Inspection
17 nozzles from inside and W R
minimum of div 1 Report
rounding off of corners
3-mm radius.

Test Pressure : 1.25

Pneumatic test of RF kg/cm2g
ASME sec VIII Inspection
18 pads of all concerned Medium : air,to be W R
Div 1 Report.
nozzles checked with soap
solution
No.of baffles, baffle
Inspection of tube ASME Sec VIII Internal
orientation, spacing
19 bundle before insertion Div I ,TEMA & Inspection W R
tightness of
in shell Approved Drg. Report.
spacers,
 REFERENCE HOLD POINTS
SR. COMPONENTS & CHARACTERISTICS DOCUMENT FORMAT OF
No. OPERATION CHECKS ACCEPTANCE RECORD SKF CLIENT
NORMS
Orientation, tube
sheet to tube sheet
distance, weld
ASME Sec VIII Internal
Fit up of tube sheets to geometry,
20 Div I ,TEMA & Inspection W R
shell squareness of tube
Approved Drg. Report.
sheets w.r.t shell
bolt hole
straddling.
Test pressure 2.0
Hydro test of shell side ASME sec VIII Inspection
21 kg/cm2 g H W
after tubes expansion Div - 1 Report.

Under cuts, tacks,

Visual and Final
ensure that all ASME Sec VIII
dimensional inspection Inspection
22 welding is Div I & H W
prior to hydro test of Report.
completed, Approved Drg.
shell and channel shells.
dimensions, etc
Test press : 7.222
ASME Sec VIII
Hydrostatic testing of Kg/cm2 g Inspection
23 Div I & H W
shell side Medium : Water Report.
Approved Drg.
Period :30 min
Test press : 7.53
ASME Sec VIII
Hydrostatic testing of Kg/cm2 g Inspection
24 Div I & H W
tube side Medium : Water Report.
Approved Drg.
Period :30 min
Internal
25 Polishing Surface finish 180 GRID Inspection - W
Report.
Cleaning and painting SKF Std Inspection
26 Surface finish - W
of cs part Procedure Report.
Review of
documents like
Material Heat
Pre- dispatch & Issue of Chart, Test Inspection
27 - R R
Release note. Certificates Report
Inspection Reports
for previous stages
etc