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Quality Assurance Plan For Unitank:: QAP/AAV/MFG/00107/UT Crown Beers India LTD: AAVI-GA-003, R0, 210507 00107
Quality Assurance Plan For Unitank:: QAP/AAV/MFG/00107/UT Crown Beers India LTD: AAVI-GA-003, R0, 210507 00107
Quality Assurance Plan For Unitank:: QAP/AAV/MFG/00107/UT Crown Beers India LTD: AAVI-GA-003, R0, 210507 00107
QAP REF
: QAP/AAV/MFG/00107/UT
CLIENT
: 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
MATERIAL
IDENTIFICATION - MAIN
COMPONENTS
(viz. Shell, Cone, Jacket,
Dish end, Pipes and
Flanges)
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
Drawing
Layout
Layout
Drawing
Weld defects
Free from
Defects
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
Weld geometry
Blank diameter
No of joints
Thickness
Drawing
Layout
Layout
Drawing
Free from
defects
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
CONE INSPECTION
AFTER FORMING
Inside Diameter
OD Circumference
Height
Straight Face
Ovality
DP Test of Knuckle Radius
Surface & L - seam
10
INSPECTION OF L SEAMS/
C SEAMS OF
SHELL/CONE/DISH
Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB
100%
100%
100%
100%
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
11
CONE JACKET
INSPECTION BEFORE
FITMENT
12
DISHEND / CONE TO
SHELL C-SEAM
SET-UP
14
INSPECTION OF ABOVE
WELD SEAMS
15
SHELL JACKET
INSPECTION BEFORE
FITMENT
13
Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB
100%
100%
100%
100%
100%
Drawing
Drawing
Drawing
Free from Burr
Drawing
Drawing
Drawing
2 mm.
4 mm.
2 mm/mtr.
Free from
defects
Drawing
Drawing
Drawing
Free from Burr
Page 4 of 10
16
Cleaning Of Jacket
Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB
100%
Page 5 of 10
17
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%
Drawing
Drawing
Drawing
Drawing
+/- 2 mm
Drawing
2mm.
4mm.
Drawing
Drawing
Drawing
Drawing
Drawing
Drawing
Drawing
Drawing
Drawing
Drawing
Page 6 of 10
23
Orientation
Elevation
PCD
Water level / plumb
24
TOP DOME
Height
Shell ID
Flange OD/PCD/No of holes size
Visual inspection
22
25
Orientation
Elevation
Stand-out
26
INSPECTION BEFORE
PRESSURE TEST OF
JACKETS
Visual inspection
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
27
28
29
PNEUMATIC TEST OF
JACKETS
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
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
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
34
35
CONE CLADDING
WELDING INSP
36
FINAL INSPECTION
32
a
b
Drawing
Air/water/gas
No leakage's
Min. 45 minutes
Calibrated
100%
100%
Uniform cleaning
- Aesthetically
good
100%
Drawing
Drawing
Visual Insp.
100 %
100 %
PAINTING OF MS PARTS
100 %
Uniform thk,
shade & no paint
Spills .
SHIPPING INSPECTION
100%
Drawing
Blanked
Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB
Page 9 of 10
Scope of Supply
Damage of components
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
Ref : QAP/STSPL/MFG/00107/UT/R0
Proj Ref :XXXXXX /BREWPUB
Page 10 of 10