QUALITY ASSURANCE PLAN FOR CS SEAMLESS PIPES

Client : NPCIL ITEM : Carbon Steel Seamless Pipes

Spec : PC-M-288 REV.0

PROJECT NAME KAKRAPAR ATOMIC POWER PROJECT
CLIENT NPCIL
SUPPLIER/MANUFACTURER
ITEM NAME & TAG NO. Carbon Steel Seamless Pipes
REF. DOCUMENT / SPEC
Material Specification

Component and Quantum Format of Agency

Sr No Characteristic Type of Check Reference Document Acceptance Norms Remarks
Operation of check Record P W R H
Raw Material Verification of Mechanical & Raw Material Inspecion
1 100% ASME SA 333/SA 53 ASME SA 333/SA 53 Mill test certificate 2 1 1 1 Ref note 1
( Mother Pipes) Chemical Properties Report Review with MTC
As per Material Spec
Chemical Chemical Analysis ASME SA 333/SA 53 ASME SA 333/SA 53
SA 288

2/a - Heat treatment ASME SA 333, SA53 ASME SA 333, SA53

Soaking Time & Temperature 100% 2 - 1 - Ref note 8
( As Applicable ) Approved Procedure Approved Procedure H.T Report/ Chart

ASTM A380, Approved ASTM A380, Approved

2/b - Pickling Visual Each Pipe 2 - 1 -
Procedure Procedure Inspection report

ASME SA 333,
Refer Table 1 of PC-M- ASME SA 333, SA53 Ref note 1 and Random
2/c - Product Analysis Chemical Analysis PC-M-288, Table-1 Spectro Test Report 2 - 1 -
288,SA 312 TP304L witness by 1.
TP304L
Mechanical Properties
As per Material Spec Ref note 1 and Random
2/d - Mechanical Test (Tensile,transeverse tension, ASME SA 288, A 370 ASME SA 288 & Tech Spec Mechanical Test 2 1 1 -
SA 288 witness by 1.
%EL, Uts, Flattening) Report

2/e Fracture toughness As per Material Spec As per Material Spec As per Material Spec Applicable for SA 333 GR 6
2 In Process Inspection requirement SA 288 SA 288 SA 288 CL NB

As per Material Spec Applicable for SA 333 GR 6

2/f Impact test CVNDTT ASME SA 370 ASME SA 288 & Tech Spec Impact test report
SA 288 CL NB

One sample from each size Grain size evaluation

2/g - grain size ASME-E-112 ASME SA 288 & Tech Spec Grain size shall be 5 or finer
per lot . report

2/h Metal macro One sample from each size Applicable for SA 333 GR 6
ASME-E-381 ASME SA 288 & Tech Spec Macro etching report
structure/etching test per lot . CL NB

One sample per Heat per

2/i - Seamless Checking Macro Etch Test ASTM E 381/ E340 Visual Examination Lab Test Report 2 1 1 - Ref note 1
Size
 QUALITY ASSURANCE PLAN FOR CS SEAMLESS PIPES

Client : NPCIL ITEM : Carbon Steel Seamless Pipes

Spec : PC-M-288 REV.0

3/a - Liquid Penetrant 25% Witness by '1' and
PC-M-308, E-165 &
Examination on Reworked NDE 100% repaired area Approved Procedure Inspection report 2 1 1 - Repair by Welding not
Approved Procedure
area permitted

Leak tightness and Pressure ASME SA 312/ SA999 &

3/b - Hydrostatic test Each Pipe Approved Procedure Inspection report 2 1 1 - 25% online witness by '1'
integrity Approved Procedure
3 NDT
3/c - Ultrasonic Examination Each Pipe in both transverse ASME Sec III NB-2552 &
NDE Approved Procedure Inspection report 2 1 1 - 25% online witness by '1'
(For Class 1 NB UTE pipes only) and longitudinal directions Approved Procedure

ASTM A380, Approved ASTM A380, Approved

3/d - Passivation Visual Each Pipe Inspection report 2 - 1 -
Procedure Procedure

Measurements of outer Dia,

4/a - Dimensional ASME SA 333/SA53/ 25% Witness by '1'
thickness, end finish, ovality Each Pipe ASME SA 333/SA 53 Inspection report 2 1 1 -
Examination SA530 Ref. Note - 6, 7 & 9
and wrinkles
4 Final Inspection

ASME SA 333/SA 53/

4/b - Surface Quality Surface Visual Examination 100% ASME SA 333/SA 53 Inspection report 2 1 1 - 25% Witness by '1'
SA530

Marking On Pipes :
Name of the manufacturer),
NPS X SCH X RANDOM
SA 333/SA 33 Colour Code
5 Identification Marking , Colour coding Visual & Verification Each Pipe LENGTH, SA-333,SA53 Report 2 1 1 -
PC-M-288 White Stripe
SEAMLESS, gr, HEAT NO.
CLASS-1 OR CLASS-2 &
ITEM CODE.

Documents Verification/ Test reports & Test As per SA 333, Product Test
6 Verification All test certificates SA 333,SA53 PC-M-288 2 - 1 -
Test certificate Verification Certificates PC-M-288 Certificate

All pipes to be suitably PC-M-288 PC-M-288

7 Packing of Pipes Packing & End Protection Visual Report 2 1 1 - Random Witness By "1"
packed and Ends protected Approved Procedure Approved Procedure

Issue of TPI Certificate and

8 Documentation Shipping instruction Review & Clearance PC-M-288 & P.O. PC-M-288 & P.O. Release Note 2 - - 1
shipping Release Note
 QUALITY ASSURANCE PLAN FOR CS SEAMLESS PIPES

Client : NPCIL ITEM : Carbon Steel Seamless Pipes

Spec : PC-M-288 REV.0

Notes
Co-related original material test certificate is acceptable. In absence of co-related original material test certificate, sample per lot (lot means, all material having same heat mark / material specification
1 requirements) for chemical and physical test shall be drawn and witnessed by NPCIL QS or his Authorized Representative ( Purchaser). Manufacturer shall submit all material verification reports as per
material specification to NPCIL-QS or his Authorized Representative ( Purchaser) for checking / verification and clearance. 100% by Manufacturer, Random witness for co relation by NPCIL

2 All Test reports, Test Certificates and Inspection reports shall be reviewed by Manufacturer before submitting the same for verification by NPCIL.

3 Chemical and mechanical tests on the material shall be performed in suppliers laboratory which shall be approved laboratory by NPCIL orany otherNPCIL approved Labs..

4 Calibrated instruments shall be used during inspection, examination and testing.

5 Non-destructive examinations shall be carried out by personnel qualified to Level – I and evaluated by Level II of ISNT or ASNT.

6 Quantity tolerance shall be +1/- 0 Random Length shall be allowed .

7 Dimension measurement will done at both Ends only. Wall Thickness measurment at repaired areas shall be checked by Ultrasonic Meter.

8 Heat treatment furnace shall be in good condition and shall have temperature recorder and checked for calibration by NPCIL. The validity of calibration shall not be more than 6 months.

ABBREVIATIONS :
1 NPCIL QS or his Authorized Representative ( Purchaser) LPE Liquid Penetrant Examination
2 Supplier/Manufacturer UTE Ultrasonic Examination
Hold Point : 'Witness is mandatory before proceeding to further activities . This activity shall be kept under hold till inspection clearance or written waiver is obtained from the agency responsible for this
H
stage [ NPCIL QS / its Authorized Representative ( Purchaser) ]

Witness Point : Witness points are critical steps in manufacturing and examination / inspection / testing . Where the supplier is obliged to notify in sufficient advance of the start of the operation / test so
W
that it may be witnessed . The Supplier may proceed with the work past a witness point , if the NPCIL-QS or its authorized representative is not available at the appointed time .

R Document Review : Review / Verification of documents carried out by agency for compliance and acceptance
P Performed and Witnessed by