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QUALITY ASSURANCE PLAN FOR UNITANK

QAP REF

: QAP/AAV/MFG/00107/UT

CLIENT

CROWN BEERS INDIA LTD

DRG REF / REV /


DATE

: AAVI-GA-003,R0, 210507

PROJECT REF

00107

CONTACT

: ANURAG BHATNAGAR

EQUIPMENT TAG
NO

UT 12 to UT 21

No

DESCRIPTION

CHARACTERISTICS CHECK

WELDER
QUALIFICATION

Review of WPS & PQR


Review of WPQ

MATERIAL
IDENTIFICATION - MAIN
COMPONENTS
(viz. Shell, Cone, Jacket,
Dish end, Pipes and
Flanges)

Co-relation of TC with Material


Marking
Verification of material TC with
Specification.
Check Testing of Material in
absence of above
Check testing TC Verification as
per Specification

EXTENT
OF CHECK

ACCEPTENCE
STANDARD

FACT

INSP. BY
QA

100%

ASME Section IX

100%

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

Shall be
available
Material
specification
Material
specification
Material
specification
Material
specification

CL/ TPI

Page 1 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

Drawing
Layout
Layout
Drawing

Weld defects

Free from
Defects

DISHED END INSPECTION


AFTER FORMING

Inside Diameter
OD Circumference
Inside Height
Straight Face
Ovality
DP Test of Knuckle Radius
Surface & L seam

Drawing
Drawing
Drawing
Drawing
Drawing
Free from
defects

CONE BLANK L-SEAM SET-


UP

Weld geometry
Blank diameter
No of joints
Thickness

Drawing
Layout
Layout
Drawing

Free from
defects

DISH END BLANK


L-SEAM SET-UP

BACK CHIP D.P. TEST


OF LONG SEAM
4

BACK CHIP D.P. TEST


OF LONG SEAM

Weld geometry
Blank diameter
No of joints
Thickness

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

Weld defects

100%

100 %

100%

100%

100 %

Page 2 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

CONE INSPECTION
AFTER FORMING

SHELL L- SEAM SET UP

Inside Diameter
OD Circumference
Height
Straight Face
Ovality
DP Test of Knuckle Radius
Surface & L - seam

Weld geometry ( Root Gap,


Groove Angle, Root Face )
OD circumference

SHELL C- SEAM SET UP

CONE C- SEAM SET UP

10

INSPECTION OF L SEAMS/
C SEAMS OF

SHELL/CONE/DISH

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

Weld geometry (Root Gap,


Groove Angle, Root Face )
Height
Staggering of weld joints
No of shells
Total height
Alignment / profile matching

100%

100%

100%

Weld geometry (Root Gap,


Groove Angle, Root Face )
Height
Staggering of weld joints
Alignment / profile matching

100%

Visual inspection weld Joint


Radiography

100%
Spot

Drawing
Drawing
Drawing
Drawing
Drawing
Free from
defects

Drawing

Drawing

Drawing
Drawing
Drawing
Drawing/ Layout
Drawing
3mm/mtr
Template

Drawing
Drawing
Drawing
Drawing/ Layout
Template

Free from
defects

Page 3 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

11

CONE JACKET
INSPECTION BEFORE
FITMENT

Profile ( inside height ,pitch )


No of Dimples
Hole ( size , pitch ,shape)
Removal of Burr

12

CONE JACKET SET UP

Shell Surface Pickling &


Passivation ( Under Jacket )
Orientation
Cone gauging
Jacket elevation
Weld geometry(Root Gap,
Groove Angle, Root Face )

DISHEND / CONE TO
SHELL C-SEAM
SET-UP

Weld geometry (Root Gap,


Groove Angle, Root Face )
Degree matching
Water level
Plumb
Alignment

14

INSPECTION OF ABOVE
WELD SEAMS

Visual inspection weld Joint


D.P.test
Radiography

15

SHELL JACKET
INSPECTION BEFORE
FITMENT

Profile ( inside height ,pitch )


No of channels
Hole ( size , pitch ,shape)
Removal of Burr

13

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

100%

100%

100%

100%

100%

Drawing
Drawing
Drawing
Free from Burr

Free from Oil &


Grease
Drawing
Template
Drawing
Drawing

Drawing
Drawing
Drawing
2 mm.
4 mm.
2 mm/mtr.

Free from
defects

Drawing
Drawing
Drawing
Free from Burr

Page 4 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

16

SHELL JACKET SET UP

Cleaning Of Jacket

Shell Surface Pickling &


Pssivation ( Under Jacket )
Orientation
Shell gauging
Jacket elevation
Weld geometry (Root Gap,
Groove Angle, Root Face )

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

100%

Free from Oil &


grease

Free from Oil &


Grease
Drawing
Template
Drawing
Drawing

Page 5 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

17

CONE DIMPLE JACKET


WELD JOINT DP TEST

Weld Defects

18

HEADER SET-UP ON
SHELL

Nozzle elevation
Center distance of header
Partition plate fitment
Weld geometry
Straightness (would be carried
out at site)

19

SKIRT SET UP

Degree matching
Water level
Plumb
Elevation from Tan line
Hole Dia & PCD

Orientation
Elevation
Opening size

Orientation
Elevation
Stand out / Projection
Size
Bolt hole straddling

20

21

NOZZLE MARKING

NOZZLE SET-UP /
PIPING

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

100%

100%

100%

100%

100%

Free from weld


defects

Drawing
Drawing
Drawing
Drawing
+/- 2 mm

Drawing
2mm.
4mm.
Drawing
Drawing

Drawing
Drawing
Drawing

Drawing
Drawing
Drawing
Drawing
Drawing

Page 6 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

TANK TOP FLANGE /


MAN HOLE FLANGE
FITMENT

Concentricity with vessel


Water level & Plumb
Elevation
Weld geometry (Root Gap,
Groove Angle, Root Face )

23

PLAT FORM SUPPORT


FITMENT

Orientation
Elevation
PCD
Water level / plumb

24

TOP DOME

Height
Shell ID
Flange OD/PCD/No of holes size
Visual inspection

22

25

MARKING & SET-UP OF


EXTERNAL ATTACHMENT
( Pipe cleats, lifting lugs,
earhting boss,shroud,top
dome etc. )

Orientation
Elevation
Stand-out

26

INSPECTION BEFORE
PRESSURE TEST OF
JACKETS

Visual inspection

Dimensions & Nozzle


orientation and Elevation

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

100 %

100%

100%

100%

100%

2 mm
3 mm
Drawing
Drawing
Drawing

Drawing
Drawing
Drawing
3 mm

Drawing
Drawing
Drawing
Distortion weld
Uniform Finish

Drawing
Drawing
Drawing

Free from
Defects
Drawing

Page 7 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

27

28

29

PNEUMATIC TEST OF

JACKETS

(As per Procedure No.

MFG/P/221) (Ref note no.5 )

Test Pressure
Medium
Leakage
Duration
Calibration of Pr. gauge

PNEUMATIC TEST OF
REINFORCEMENT PAD
( As applicable )
(As per Procedure No.
MFG/P/221) (Ref note no. 5)

Test pressure
Medium
Leakage
Duration

INTERNAL SURFACE
FINISH

Visual inspection
Surface finish reading - Ref
W.I.No. 201.
Degreasing of polished surface

30

CIP PIPE FITMENT ON


SHELL ( connection
between TTP and VESSEL )

Size / orientation / Position


Assembly with TTP or Dummy

31

FINAL INSPECTION
BEFORE PR.TESTING

Overall dimensions
Visual inspection
Document Review

100%

100%

100%

100%

100%

Drawing
Inert gases / Air
No leakage
Min.45 minutes
Calibrated

Drawing
Inert gases / Air
No leakage
Minimum 5 Min

Drawing
Drawing
Free from oil and

Drawing
To match

Drawing
Free from
surface
Defects
Status Chart

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

Page 8 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

PRESSURE TESTING
OF EQUIPMENT/PIPING
(As per Procedure No.
MFG-P-221/ MFG-P-220)

Test Pressure
Medium
Leakage
Duration
Calibration of Pr. gauge

33

CONE PICKLING AND


PASSIVATION FROM
OUTSIDE

34

INSULATION & CLADDING


(IN-PROCESS INSP.)

35

CONE CLADDING
WELDING INSP

36

FINAL INSPECTION

32

a
b

Drawing
Air/water/gas
No leakage's
Min. 45 minutes
Calibrated

100%

Visual Inspection (Ref


procedure No MFG-P-219)

100%

Uniform cleaning
- Aesthetically
good

Supports for cladding.


Type of cladding.

100%

Drawing
Drawing

Visual Insp.

100 %

Free from weld


defects

PICKLING & PASSIVATION


OF SS PARTS FROM
OUTSIDE

Visual Inspection of Cleaned


Surface

100 %

No Acid Stains &


MS ontamination
H

PAINTING OF MS PARTS

Visual inspection of Painting

100 %

Uniform thk,
shade & no paint
Spills .

SHIPPING INSPECTION

Stenciling (Eqpt. Code & 0 )


Blanking of Nozzles

100%

Drawing
Blanked

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

Page 9 of 10

QUALITY ASSURANCE PLAN FOR UNITANK

Scope of Supply
Damage of components

Loading & Supporting

Drawing
Free from
damages
Proper Loading &
Supporting

NOTES
1. P-Perform, H- Hold for Inspection, R- Review of Documents & Inspection.
QA AAV QA Engineer, FACT- AAV Shop Engineer, CL-Client. TPI-Third Party Inspection Agency
2. Stages marked "H" in QA column shall be offered to QA.
3. MFG Supervisor shall record all his hold point inspection in Inspection status chart.
4. QA Engineer shall record inspection in standard format for their HOLD stage as applicable.
5. All Butt joint & Nozzle to shell /Dish joint shall be back chipped and welded from both side or Full penetration weld.
6. Material Identification on 6 mm thick plate and above shall be done by hard punching. Use 4 to 6 mm size punches.
7. Identification below 6 mm thickness can be done by Engraving or Permanent Marker.
8. Welding consumable is to be used as per the Aavishkar approved list.
9. AAV WPS or Vendor WPS is reviewed and accepted by AAV QA shall be used for welding
10. Inspection cum status chart, Material chart including test certificates for shell, cone, dish end and jackets, Final dimensional inspection
report, Pressure test report and inside polish inspection reports shall be submitted to customer.
DISTRIBUTION:
1. Engineer, Factory
2. Engineer,QA
3. Client

RECORD OF REVISION:
Rev
No.

DATE OF
REVISION

PREP
BY

CHKD
BY

APPRD
BY

DETAILS OF REVISION

12.05.2007

MNS

BA

ANU

First Issue For Execution

Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB

Page 10 of 10