QUALITY ASSURANCE PLAN

FOR MANUFACTURE OF M.S. PIPES, INSPECTION AND TESTING PLAN

Agency
Sl. Characteristics Type of Quantum of Format of
Component / Material Category Reference Documents Acceptance Norms Remarks
No. Check Check Check Record
M TPI B
1.0 RAW MATERIAL CONTROL

1.1 Steel Pipes/Coils a. Chemical Critical Chemical 1/section / lot IS 3589 - 2001 IS 3589-2001 MTC R R R
Analysis
b. Physical
1. Tensile Critical UTM One sample IS 3589 - 2001 IS 3589-2001 Lab report W R R
for every 40 T
2. Bend Test Critical UTM One Sample IS 3589 - 2001 IS 3589-2001 Lab report W R R
per Batch

c. Dimension Major Measuring 100% IS 3589 - 2001and customer IS 3589 - 2001and Manufacturer's W R R
Instrument specification, if any customer specification, if Register /
any Report

d. Surface Defect Major Visual 100% IS 3589 - 2001 IS 3589 - 2001 Manufacturer's W R R
Register /
Report
2.0 PROCESS CONTROL
2.1 Cutting the plate to size Dimension Minor Measuring 100% Manufacturer's Drawing Manufacturer's Drawing - W R R
Instrument
2.2 Edge preparation to size Dimension Minor Measuring 100% Manufacturer's Drawing Manufacturer's Drawing - W R R
Instrument
2.3 Rolling and bending to Dimension Minor Measuring 100% Manufacturer's Drawing Manufacturer's Drawing - W R R
cylindrical shape Instrument

2.4 Tack welding for welding Alignment, root gap Major Gauges 50% Manufacturer's Drawing Manufacturer's Drawing - W R R
etc.,
2.5 Welding Procedure Current, Voltage & Critical Indicating 50% Manufacturer's welding Manufacturer's welding - W R R
Speed Instruments procedure procedure

CONTRACTOR EMPLOYER / ENGINEER

 Agency
Sl. Characteristics Type of Quantum of Format of
Component / Material Category Reference Documents Acceptance Norms Remarks
No. Check Check Check Record
M TPI B
3.0 FINAL INSPECTION & TESTING
3.1 Inspection of welded Pipes a. Dimension Critical Measuring 100% Manufacturers Drawing / Manufacturers Drawing / Inspection W W R
Instrument Purchaser's Specification Purchaser's Specification Report

b. Welding Critical Visual 100% As per standard welding As per standard welding Inspection W W R
practice (IS 816 & IS 822) practice (IS 816 & IS 822) Report

c. Soundness of Weld Critical Ultrasonic 5% IS 4258 IS 4258 Ultrasonic Test W W R

Report
d. Mechanical Test Critical Root & Face Sampling as IS 3589 IS 3589 Inspection W W R
Bend test per IS 4711 Report

e. Hydraulic Pressure Critical Hydraulic 100% IS 3589 IS 3589 Inspection W W R

Test Pressure at Report
manufacturer's
works

4.0 INNER LINING & OUTER COATING

4.1 1. Dimension Major Measuring 100% IS 3589/2001 IS 3589/2001 Manufacturer's W R R
Instrument Register/
Report

2. Surface Defect Major Visual 100% IS 3589/2001 IS 3589/2001 Manufacturer's W R R

Register/
Report

4.2 Cement a. Chemical Critical Chemical One sample IS 269 / IS 8112/ IS 12330 IS 269 / IS 8112/ IS Suppliers TC W R R
Analysis for every 200 12330
bags
b. Physical
1. Fineness -do- By Sieve -do- -do- -do- Lab report W R R

2. Standard -do- Lab test -do- -do- -do- Lab report W R R

Consistency
3. Setting time -do- Lab test -do- -do- -do- Lab report W R R
Initial, Final

CONTRACTOR EMPLOYER / ENGINEER

 Agency
Sl. Characteristics Type of Quantum of Format of
Component / Material Category Reference Documents Acceptance Norms Remarks
No. Check Check Check Record
M TPI B
4. Soundness -do- Lab test -do- -do- -do- Lab report W R R

5. Compressive -do- Lab test -do- -do- -do- Lab report W R R

Strength
4.3 Aggregate a. Deleterious Major Lab test 1/lot IS 383 IS 383 1. Supplier's W R R
Material TC
2. Lab report.
b. Soundness -do- -do- -do- -do- -do- -do- W R R
c. Specific Gravity -do- -do- -do- -do- -do- -do- W R R
d. Grading & Size -do- -do- -do- -do- -do- -do- W R R
4.4 Weld Mesh for outer Coating Dimension Minor Measuring AQL 4.0 I.L.II As per customer Manufacturer's Register/ Manufacturer/ W R R
Instrument D.S.P of IS specification Inspection/ Record IA
2500
4.5 Water Suitability of water Major Lab test Once in a year IS 456 IS 456 Lab TC W R R
for concrete works
4.6 Outer Coating Mix a. Mix design Major Measurement 1/Batch Manufacturer's own Manufacturer's own -do- W W R
standard standard

b. Cube Strength Critical Compressive 3/Batch IS 784 and purchaser's IS 784 and purchaser's Manufacturer's W R R
strength specification specification Register
4.7 Outside Coating Coating thickness Major Spike gauges 5% Purchaser's specification Purchaser's specification -do- W W R

4.80 Curing Proper curing Critical 1. Visual 100% Purchaser's specification Purchaser's specification -do- W W R
2.
Co-relating
with cube
strength
5.0 FINAL INSPECTION AND TESTING
5.1 Fabricated, lined and coated a. Surface defects Major Visual 100% Purchaser's specification/ Purchaser's specification/ Test Reports W W R
pipe IS 1916 IS 1916

b. Dimension Major Measuring 100% Purchaser's specification/ Purchaser's specification/ -do- W W R

Instrument and IS 1916
Gauges IS 1916

CONTRACTOR EMPLOYER / ENGINEER

 Agency
Sl. Characteristics Type of Quantum of Format of
Component / Material Category Reference Documents Acceptance Norms Remarks
No. Check Check Check Record
M TPI B
c. Marking Major Visual 100% Purchaser's specification/ Purchaser's specification/ -do- W W R
IS 1916 IS 1916

6.0 SEALING AND STAMPING

6.1 Stenciling IA stamp Legibility of Stamp Major Visual 100% --- --- Test Reports W W R Samples
inspected by
TPI are double
stamped

7.0 PACKING AND DESPATCH

Each pipes is handled only by flat canvas belt to avoid damages during handling and properly stacked to avoid damages during transport and unloading.

Note :- No Negetive tolerence in respect of thickness is permissible

R = Review
W = Witness
M = Manufacturer
B = Board
TPI = Third Party Inspection agency

Reviewed items may be randamly witnessed by the concerned if necessary. All measuring instruments and testing equipments shall be calibrated periodically
and put up for verification to Third Party Inspection agency.

CONTRACTOR EMPLOYER / ENGINEER