MANUFACTURER’S KORBA MANUFACTURING QUALITY PLAN PROJECT: NTPC LIMITED,

NAME & ADDRESS: ITEM: ECO COILS QP NO: ITP/ 900000236/P13 PROJECT No: 900000236
THERMAX BABCOCK & REV NO: 0 PACKAGE: ECO COILS
WILCOX ENERGY P. O. NO: 4000229767-M46-1019
DATE: 26/12/2019
SOLUTIONS PRIVATE
MFGR’s LOGO LIMITED PAGE 1 OF 4

Quantum Of Accepta
Component/ Reference Format Of Agency
Sl No Characteristics Class Type Of Check Check nce Remark
Operations Document Record
M N Norms M C
1 2 3 4 5 6 7 8 9 ** 10 11
1.0 Raw Material
TS, YS % of TC from manufacturer’s
lab/NTPC approved lab &
Mechanical & elongation & 1 sample per NTPC PO / Drawing /
1.1 Major MTC √ H V same shall be verified during
Chemical Analysis chemical lot Material Specs PDI. Tubes from well known
properties tube maker.
Eco coil tubes Vendor
1.2 Dimension Major Measurement 100% NTPC PO / Drawing √ H V -
(CDS tubes) log
UT to be done as per ASTM E-
NTPC PO / Drawing
1.3 NDT Major UT 100% ---- IR √ H V 213. Longitudinal notch of 5%
& ASTM E-213 or 8% on tube wall thickness
NTPC PO / Drawing /
1.4 Hydro test Major Hydro test 100% MTC √ H V
Material Specs
TS, YS % of TC from manufacturer’s
Mechanical & elongation & 1 sample per lab/NTPC approved lab &
1.5 Attachment Major NTPC PO / Drawing MTC √ H V same shall be verified during
Chemical Analysis chemical lot
Material(Strap PDI.
properties
Support Saddle
Assly) NTPC PO / Drawing / Vendor
1.6 Dimension Major Measurement 100% √ H V -
Vendor log log

2.0 In Process Inspection

2.1 Bending
Heating & Heat Time Temp Review of IBR / NTPC PO / All instruments shall be duly
2.1.1 Major 100% Report √ H V calibrated & thickness ensured
Treatment Control charts/log Specs.

LEGEND: RECORDS INDICATED WITH “TICK” ( √ ) MARK DOC NO: REV: CAT
TBWES TBWES SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA
MANUFACTURER / MAIN SUPPLIER DOCUMENTATION CHP: Customer Hold Point
SUB SUPPLIER ** M:TBWES C: Client(NTPC)
H: hold W: WITNESS RW: Random Witness R: Review
SIGNATURE NOTE: IBR will carry their inspection as per their norms. FOR NTPC USE REVIEWED BY APPROVED BY
Also, IBR TC’s shall be submitted for customer review.
 MANUFACTURER’S KORBA MANUFACTURING QUALITY PLAN PROJECT: NTPC LIMITED,
NAME & ADDRESS: ITEM: ECO COILS QP NO: ITP/ 900000236/P13 PROJECT No: 900000236
THERMAX BABCOCK & REV NO: 0 PACKAGE: ECO COILS
WILCOX ENERGY P. O. NO: 4000229767-M46-1019
DATE: 26/12/2019
SOLUTIONS PRIVATE
MFGR’s LOGO LIMITED PAGE 2 OF 4

Quantum Of Accepta
Component/ Reference Format Of Agency
Sl No Characteristics Class Type Of Check Check nce Remark
Operations Document Record
M N Norms M C
1 2 3 4 5 6 7 8 9 ** 10 11
Ovality, Flow area, First using D-meter.
Bends first off Measurement, 100 NTPC PO / Specs /
2.1.2 Thinning, Surface Major off Report √ H V
inspection Visual % Drawing & IBR
quality trails
Dimensions,
Coils/Bends Ovality, Minimum Measurement, NTPC PO / Specs /
2.1.3 Major 10% Report √ H V
Manufacturing Thickness, Visual Drawing
Surface quality
2.2 Welding
Procedure &
Welding Document WPS/ WPS/PQR shall be reviewed
2.2.1 personal Major 100% IBR & ASME-IX √ H V by NTPC inspector during PDI.
qualification review PQR
qualification
Preproduction In case of overlap of 2 shifts,
NTPC PO / Spec /
of IPW Butt Cold impact 2 samples final samples of first shift & first
2.2.2 Weld soundness Major Manufacturer Report √ H V sample of 2nd shift shall be
welds (if bend test per shift
standard same. Refer Note 8
applicable)
NTPC PO / Specs / 10% IPW butt weld UT witness
2.2.3 IPW butt welds Weld soundness Critical UT 100% 10% Report √ H W by NTPC.
ASME-I, V
NTPC PO / Spec /
2.2.4 Fillet Welds Weld soundness Minor LPI / MPI 10% Manufacturer Report √ H V -
standard
RT During PDI 5% RT films
Butt weld by randomly selected including
Review of RT / 100 NTPC PO / Specs / films &
2.2.5 TIG/MIG & Weld soundness Major 5% √ H V check shots for review by
Fluoroscopy % ASME-I, V vendor NTPC. For fluoroscopy refer
SMAW
log note:5

LEGEND: RECORDS INDICATED WITH “TICK” ( √ ) MARK DOC NO: REV: CAT
TBWES TBWES SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA
MANUFACTURER / MAIN SUPPLIER DOCUMENTATION CHP: Customer Hold Point
SUB SUPPLIER ** M:TBWES C: Client(NTPC)
H: hold W: WITNESS RW: Random Witness R: Review
SIGNATURE NOTE: IBR will carry their inspection as per their norms. FOR NTPC USE REVIEWED BY APPROVED BY
Also, IBR TC’s shall be submitted for customer review.
 MANUFACTURER’S KORBA MANUFACTURING QUALITY PLAN PROJECT: NTPC LIMITED,
NAME & ADDRESS: ITEM: ECO COILS QP NO: ITP/ 900000236/P13 PROJECT No: 900000236
THERMAX BABCOCK & REV NO: 0 PACKAGE: ECO COILS
WILCOX ENERGY P. O. NO: 4000229767-M46-1019
DATE: 26/12/2019
SOLUTIONS PRIVATE
MFGR’s LOGO LIMITED PAGE 3 OF 4

Quantum Of Accepta
Component/ Reference Format Of Agency
Sl No Characteristics Class Type Of Check Check nce Remark
Operations Document Record
M N Norms M C
1 2 3 4 5 6 7 8 9 ** 10 11
In case of mismatch with
RT of TIG/MIG original film, all butt welds in
Check One joint per NTPC PO / Specs / RT
2.2.6 Weld soundness Critical & SMAW weld √ H W concern pair shall be
Radiography assembly ASME-I, V films reradiographed & it also attract
joints.
penalty as per NTPC PO spec.
To be carried out at more than
Hydraulic test Strength & leak Visual(hydro 100 NTPC PO / Specs. / 311.1 ksc pressure in
2.3 Critical 20% Report √ H W presence of IBR authority.
(270 kg/cm2) tightness test) % IBR
Refer note 6.
Steel & Sponge NTPC PO / Specs /
2.4 Free passage Major Visual 100% Report √ H V -
ball test Manufacturer’s STD
3.0 Final Inspection
Overall Records
NTPC PO / Specs. /
Verification of dimensions, verification, 100
3.1 Critical 10% Drawing / in process Report √ H W -
completion Review of visual & %
records
previous records measurement
Visual for color
NTPC PO / Specs /
Material & grade code, Material Vendor
3.2.1 Major 100% Drawing / √ H V Refer note 1&2.
Eco Coil identification Grade & job log
Manufacturer’s STD
Assembly details
Painting & DFT, VCI & end NTPC approved Vendor
3.2.2 Major 100% √ H V -
Preservation Capping painting scheme log

LEGEND: RECORDS INDICATED WITH “TICK” ( √ ) MARK DOC NO: REV: CAT
TBWES TBWES SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA
MANUFACTURER / MAIN SUPPLIER DOCUMENTATION CHP: Customer Hold Point
SUB SUPPLIER ** M:TBWES C: Client(NTPC)
H: hold W: WITNESS RW: Random Witness R: Review
SIGNATURE NOTE: IBR will carry their inspection as per their norms. FOR NTPC USE REVIEWED BY APPROVED BY
Also, IBR TC’s shall be submitted for customer review.
 MANUFACTURER’S KORBA MANUFACTURING QUALITY PLAN PROJECT: NTPC LIMITED,
NAME & ADDRESS: ITEM: ECO COILS QP NO: ITP/ 900000236/P13 PROJECT No: 900000236
THERMAX BABCOCK & REV NO: 0 PACKAGE: ECO COILS
WILCOX ENERGY P. O. NO: 4000229767-M46-1019
DATE: 26/12/2019
SOLUTIONS PRIVATE
MFGR’s LOGO LIMITED PAGE 4 OF 4

Quantum Of Accepta
Component/ Reference Format Of Agency
Sl No Characteristics Class Type Of Check Check nce Remark
Operations Document Record
M N Norms M C
1 2 3 4 5 6 7 8 9 ** 10 11
Compilation of
Certificates &
NTPC PO / Specs. /
3.2.3 Code compliance Major final CHP 100% TC √ H V -
Drawing & IBR
Clearance
reports
NOTE:
1. Material grade/composition of alloy material shall be verified with the help of material analyzer by NTPC inspection engineer during PDI.
2. Agency shall ensure availability of calibrated metal analyzer for grade verification of material by NTPC inspection engineer at the time of PDI.
3. In case vendor do not have testing facility, NTPC inspection engineer identified sample to be sent to NTPC approved test laboratories for testing & TC shall be
reviewed by NTPC inspection engineer.
4. For indigenous items where manufacturer & contractor are not same, contractor needs to be performing the test which has already been done by manufacturer.
However verification of co-relation for TC/MTC is required to be done by contractor.
5. In case of manufacturing plants, where NTPC inspection office already exists to witness fluoroscopy tests of welds on-line, then the radiography and check
radiography shall not be applicable. However, the record of tests and its witness shall be maintained by such vendor.
6. Hydro test to be conducted at pressure 270 kg/cm2 for 15 min. in presence of IBR authority. Witnessing records of same shall be reviewed by NTPC inspector.
However, 20% coils randomly selected are to be witnessed by NTPC, on Hydro test.
7. Handling & transport arrangement: Manufacturer to arrange- A) Plugging of all tubes parts at ends with proper end caps, B) Packing for transportation in suitable
steel crates with wooden packing, C) Suitable lifting/handling hooks are to be provided for all coil assemblies, for the purpose of handling lifting, erection etc., at
site.
8. For pre production IPW butt welds, destructive testing of samples shall be done at the beginning and at the end of each shift. In case of continuation of shift, the
sample at the end of one shift and at the beginning of the next shift may be the same. In case of failure of the sample in test, all the butt welds done during the
shift shall be rejected.

LEGEND: RECORDS INDICATED WITH “TICK” ( √ ) MARK DOC NO: REV: CAT
TBWES TBWES SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA
MANUFACTURER / MAIN SUPPLIER DOCUMENTATION CHP: Customer Hold Point
SUB SUPPLIER ** M:TBWES C: Client(NTPC)
H: hold W: WITNESS RW: Random Witness R: Review
SIGNATURE NOTE: IBR will carry their inspection as per their norms. FOR NTPC USE REVIEWED BY APPROVED BY
Also, IBR TC’s shall be submitted for customer review.