QUALITY ASSURANCE PLAN

A . DESIGN FEATURES

DESIGN CODE : ASME SEC VIII DIV 1 ED 2001 & TEMA Class 'C'

RADIOGRAPHY : SHELL & DISH : FULL

HYDRO TEST PRESSURE : SHELL SIDE ; 6 Kg/cm²g TUBE SIDE ; 17.58 Kg/cm²g

REFERENCE HOLD POINTS

SR. COMPONENTS & CHARACTERISTICS DOCUMENT FORMAT OF
# OPERATION CHECKS ACCEPTANCE RECORD SKF CLIENT
NORMS
B. DOCUMENT CONTROL
As per Clients P.O. and
1 Drg. Approval Drg. P
requirements. Specification.
As per Welding
ASME sec VIII
2. Review of WPS / PQR details in Drgs. Records P
Div 1 & Sec IX
C. INPROCESS CONTROL
As per
Dimension ,Surface respective
Pressure part.
Defects, Physical material Specn Test
Material Identification
and Chemical & Mfgr's Test Certificates
3. for shell. Dished ends, -
properties , UT for Certificates and of Mfgr's &
tubes , tubesheet
thk above 25 mm approved Lab.
etc. Drgs.& Lab T.C.

Non Pressure Parts. As per

Materials Identification respective
Dimensions Inspection
4. for saddle support, Materials W
,Surface Defects Report
baffles spacer tubes, specn. &
tie rod, gussets etc. Approved Drgs.
Weld soundness,
Test
5 PQR physical test. ASME sec IX P
Reports
Material stamp
As per respect.
transfer for shell,
Dimensions, Materials pecn. Inspection
6 channel shell tube W
Material grade. & Approved Report
sheet, dished end,
Drgs.
tubes etc.
Set up of long seams Weld geometry
of main shell courses offset. Profile ASME Sec VIII Internal
7 W
channel shell and W.R.T Template ID, Div I Inspection
fabricated pipes etc ovality. etc. Report

Back chip of long seam Internal

8 Welding defects. ASME Sec V W
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
Forming Inspection
DP Test on knuckle Approved Drg.
Report
portion at KR, SF,
and edge etc.
Dimension as per
approved drg, No. ASME Sec VIII
Tube sheet inspection Internal
10 of holes, pitch, Div I ,TEMA & W
after reaming Inspection
Tube holes finish Approved Drg.
Report
grooving details
Circ Seams set up of
Weld geometry ASME Sec VIII
main shell courses, Internal
11 offset, Alignment & Div I & W
and 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
Inspection
Shells.
Report
Weld Geometry,
Set up of nozzle pipes Internal
13 Gasket Seat facing Approved Drg. W
to Nozzle Flanges. Inspection
tell/tale hole.
Report
Weld geometry,
Set up of Nozzles on ASME sec VIII
orientations, Internal
14 main shell and channel Div I & W
height, bolt hole Inspection
shells Approved Drg.
Straddling Report

DP test of back chip of

Internal
15 nozzles on main shell Welding Defects ASME sec V W
Inspection
& channel shell
Report
welding
Weld geometry, ASME sec VIII
Set up of body flanges Internal
16 orientations, bolt Div I & W
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
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
Div 1 Report.
nozzles checked with soap
solution
No.of baffles,
Inspection of tube ASME Sec VIII Internal
baffle orientation,
19 bundle before insertion Div I ,TEMA & Inspection W
spacing tightness
in shell Approved Drg. Report.
of spacers,
 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
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
after tubes expansion Div - 1 Report.
Visual and Final Under cuts, tacks,
dimensional inspection ensure that all ASME Sec VIII
Inspection
22 prior to hydro test of welding is Div I & H
Report.
shell and channel completed, Approved Drg.
shells. dimensions, etc
Test press : 7.222
ASME Sec VIII
Hydrostatic testing of Kg/cm2 g Inspection
23 Div I & H
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
tube side Medium : Water Report.
Approved Drg.
Period :30 min
Internal
25 Polishing Surface finish 180 GRID Inspection -
Report.
Cleaning and painting SKF Std Inspection
26 Surface finish -
of cs part Procedure Report.
Review of
documents like
Material Heat
Pre- dispatch & Issue of Chart, Test Inspection
27 - R
Release note. Certificates Report
Inspection Reports
for previous stages
etc