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SQPOF01 - 14 - FBV, SSV, Tree Equipment
SQPOF01 - 14 - FBV, SSV, Tree Equipment
SQPOF01 - 14 - FBV, SSV, Tree Equipment
RECORD OF REVISIONS
1.0 MATERIALS Material as per BHEL approved drawings. Procured from BHEL.
approved Vendors
1.1 Pressure Containing Part: Chemical & Mechanical A Review of 100% Specification/ TC QC Refer Note-1
Castings, Forgings/ Properties, Hardness & documents as TDC:0:411
Barstock: Body, bonnet, Soundness as applicable per TDC TDC:0:410
stem, Flanges
1.2 Pressure Controlling Part Chemical & Mechanical A Review of 100% Specification/ TDC:0:409 TC QC Refer Note-1
Forgings/ Barstock: Properties, Hardness & documents as
FBV: Gate & Seat ring Soundness as applicable per TDC
Choke: Seat
1.3 RJ gasket Compliance to purchase A Review of 100% Purchase Spec.& Drawing TC QC Procured with relevant
order documents TC
1.4 Actuators: Sub delivery Compliance to purchase A Review of 100% Purchase Spec.& Drawing TC QC Procured with relevant
order documents TC
1.5 Fasteners Compliance to PO A Review of 100% Drawing, TDC 5:164 * QC *Compliance Certificate
documents
1.6 Elastomers Shelf life (Elastomers) A Review of 100% Drawing & TDC 5:151 * QC *Compliance Certificate
documents
1.7 Flow bean Compliance to purchase A Review of 100% Drawing & TDC 5:201 * QC *Compliance Certificate
order documents
2.1 Personnel Qualification Visual Examination A Review of 100% QMI 21 / ASNT SNT-TC-1A QR QC QR-Qualification Record
records
Non Destructive A Review of 100% ASNT SNT-TC-1A QR ND
Examination records
Inspection A Review of 100% QMI 21 / Documented QR QC
records procedure
2.2 Machining of components Critical dimensions B Measurement 100% Drawing & QCP:003 DR QC Refer Note-2
Other features B Measurement Note 2b Drawing DR QC
Gauging B Measurement 100% Drawing & SIP:VS:24 DR QC DR-Dimension Report/
Logbook
Check SQP: OF: 01/14
Reference Doc. / Acceptance Type of
SL. No. Component / Operations Characteristics Cl Type Quantum Agency Page 4 of 10
Norms $ Record
REMARKS
2.3 Welding Procedure & Performance B Review of 100% ASME Sec IX PQR WTC
Qualification WPS/PQR/ API 6A WQR /QC
WQR
2.4 Hardfacing /Weld overlay Soundness-NDE B MPI/ 100% BHE:NDT:VV:OFE:MT:04 / NDE ND Refer Note-3
/ Welding LPI/ BHE:NDT:VV:OFE:PT:03 / Report
RT/ BHE:NDT:VV: RT:07 /
UT BHE:NDT:VV:UT:18
Hardness (except weld B Measurement 100% Drawing/ASTM E10 or E18 or HR/ QC HR- Hardness Report
overlay& Hard facing) E110; Note: 1, 5e Log
2.5 Nitriding, Molybdenum Hardness & B Review of 100% Drawing & SIP:VS:04 DR QC Refer Note-4
disulphide coating Minimum thickness documents
2.6 Machined Parts: Hardness$ B Measurement Note 5 Drawing/ASTM E10 or E18 or HR/ QC $ Except Seat(Choke)
Body, Bonnet, E110 Note:1,5e Log and Gate & seat ring of
Stem, Flanges, PSL 1 & 2 of Material
Gate & Seat ring (FBV& Class AA, BB & CC.
SSV),Seat (choke) Soundness-NDE* B MPI or LPI Note 5 MPI for ferromagnetic NDE ND MPI: prod method
material: Report prohibited.
BHE:NDT:VV.OFE:MT:04- * PSL 1 to 4 – Body,
PSL 1 & 2:Dry method Bonnet, Stem & Flanges
-PSL3, 3G & 4 Wet florescent PSL 3 to 4 – Gate & Seat
Method ring (FBV, SSV), Seat
LPI for ferromagnetic & non- (Choke)
ferromagnetic materials: Refer Note-5f
BHE:NDT:VV.OFE:PT:03
- PSL 1 to 4
2.7 Assembly of full bore Completeness B visual 100% Drawing & OPS HC QC HC- History Card
valve Refer Note-5
2.9 SSV and Actuator Strength,Leak Tightness, A visual 100% Drawing & SIP:VS:01 HC QC
Bore passage &
Functional Test
Gas test for PSL 3G & 4 A visual 100% Drawing & SIP:VS:12 HC QC
2.10 Tree Assembly Completeness B visual 100% Drawing. & OPS HC QC Refer Note-5
2.11 Testing:
2.11.1 Shell test* Strength A visual 100% Drawing, SIP:VS:08 HC QC *Both as FBV & tree
assembly (Note-5)
2.11.2 Seat test# Leak tightness A visual 100% Drawing, SIP:VS:08 HC QC # Both FBV & Back
Pressure Valve
2.11.4 Gas test (for PSL 3G & 4) Performance A visual 100% Drawing, SIP:VS:12 HC QC For FBV only
3.1 Assemblies Marking & Stamping B visual 100% SIP:VS:10 - QC Refer Note-5
3.2 Painting, preservation & Appearance & protection B visual 100% SIP:PP:22 FR QC FR- Final Inspection
protection DFT B Measurement random SIP:PP:22 FR QC Report
3.3 Certification Preparation of History B Compilation 100% Drawing * QC Refer Note- 5 & 6
Card/Certificate of *History Card/Certificate
Conformance of Conformance
Legends: Cl: Class (A: Critical; B: Major) R: Review; TC: Test Certificate; DFT: Dry Film Thickness; OPS: Operations Process Sheet; RT: Radiographic Test;
UT: Ultrasonic test; MT: Magnetic Particle Test; PT: Penetrant Test; ND: NDTL; QC: Quality Control; WTC: Welding Technology Centre;
TC: Test Certificate; PQR: Procedure Qualification Record; WPS: Welding Procedure Specification; WQR: Welder Qualification Record;
QP No.: SQP: OF:01
BHEL NOTES REV.: 14 Page: 6 of 10
whichever is less; For PSL 3, 3G & 4: if weld repair is greater than 20%
of wall thickness or 25 mm (1 inch) whichever is less, or if the extent of
Note-3: Weld NDE: the cavity exceeds approximately 65 cm 2 (10 in2)
Weld Type Stages PSL 1 PSL 2 PSL 3/ PSL 3G PSL 4 h - Liquid Penetrant Method or Magnetic Particle Method as applicable for
Pressure- Preparation* -- -- a a material (base or weld) defects only.
containing Completion** -- a, b & a, b, e & a, b, e & i - Measurement of overlay thickness & Ultrasonic Testing on Weld metal
(c/d) (c/d) (c/d) overlay
Non-Pressure Preparation* -- -- a a Preparation* = Surface preparation, joint preparation, fit up & preheat.
containing Completion** -- a a&e a&e Completion** = After all welding, post weld heat treat and machining, except for
volumetric NDE which shall be done prior to machining that would
Pressure- Preparation* -- h h h
limit effective interpretation of results.
containing Completion** -- a, b & a, b, e & a, b, e &
repairs (f/g) (f/g) (f/g)
Weld metal Preparation* -- -- b b
overlay-partial Completion** -- b b&i b&i Note -4:
overlay(other 1) Requirement for Nitriding (Wherever specified in the drawing.):
than ring Material Grade Case depth mm
grooves) AISI 410 22 HRC MAX. 0.08 - 0.15
Weld metal Preparation* -- -- b b ASTM A 564 Type 630 33 HRC max. 0.05 - 0.10
overlay-partial Completion** -- b b b Austenitic SS 22 HRC max. 0.05 - 0.10
overlay( on ring Austenitic Precipitation 0.05 - 0.10
grooves) hardened SS 35 HRC max.
Weld metal Preparation* a a a, b a, b AISI 41XX Steels 22 HRC max. 0.08 - 0.15
overlay-full Completion** a, b a, b a, b & i a, b & i AISI 5012 22 HRC max. 0.10 - 0.15
overlay
Weld metal Preparation* -- -- b b Surface case hardness:
overlay(Hard Completion** -- b b b AISI 41XX:450 HV (45 HRC) min.
facing)-Gate, Seat Other steels: 600 HV (55 HRC) min.
ring & Choke Seat
a - Visual examination 2) Wherever specified in the drawing, the following coating shall be used for
b – Liquid Penetrant Method (PT for all ferro magnetic material or non-ferro stainless and K-monel components to provide resistance against galling
magnetic material) or Magnetic Particle Method (MT for all ferro at temperature. upto 148.8 deg.C.
magnetic material)
c - Radiation (radiography or imaging) examination a) Coating material: Molybdenum disulphide, Multi-Polymer binder
d - Ultrasonic examination
e - Hardness test (weld) b) Process of application:
f - Ultrasonic examination: For PSL 1 & 2: if weld repair is greater than 25% i) Vapour degrease-trichlorethylene or perchlorethylene.
of wall thickness or 25 mm (1 inch) whichever is less; For PSL 3,3G & 4: if ii) For light roughening of surface to be coated
weld repair is greater than 20% of wall thickness or 25 mm (1 inch) use dry bead of 120 grit size.
whichever is less, or if the extent of the cavity exceeds approximately 65 iii) Apply Multi-Polymer coating.
cm2 (10 in2) iv) Apply Molybdenum Disulphide coating.
g - Radiation (radiography or imaging) examination: For PSL 1 & 2: if v) Bake at 176.7 - 190.6 deg.c for one-hour min.
weld repair is greater than 25% of wall thickness or 25 mm (1 inch) vi) Minimum thickness shall be 0.01 mm per side.
QP No.: SQP: OF:01
BHEL NOTES REV.: 14 Page: 9 of 10
Note-5: Following shall be recorded in the history card. iv. PSL 3 &4: When the WPS requires PWHT, hardness testing shall be
performed after all heat treatment on the weld metal and the base metal
a. Traceability: For PSL 2 to 4: within 13 mm (0.5 in.) from the weld to conform to above i to ii. When the
The Traceability to Test Certificates of Body, Bonnet and Stem & Flanges. WPS does not require PWHT, the weld metal at a minimum shall be
hardness tested to conform to above i to ii.
For PSL 3, 3G & 4:
In addition to the above components the Traceability to Test Certificates of Gate v. The hardness shall be recorded in the Hardness Test report & History
and Seat rings. card/Logbook, as applicable, and the same shall be punched on the
components.
The serial numbers of Body, Bonnet, Stem, Flanges, Gate, Seat rings and Seat of
all assemblies. f. Surface NDE:
i. Surface NDE report reference shall be recorded
b. Hydraulic Testing for PSL 3, 3G & 4: Identification of the recorder used. ii. PSL 1: one casting from each heat on all accessible wetted & sealing
surfaces. If the casting fails, Surface NDE shall be performed on all
c. Gas Testing for PSL-3G & 4: Castings from that heat on all accessible wetted & sealing surfaces.
Actual Test pressure & actual holding period duration iii. PSL 2 to 4: Each finished component (refer Cl.2.6) shall be examined on
all accessible wetted & sealing surfaces.
d. Heat Treatment Records: iv. PSL 3 to 4: In addition to iii, additionally all accessible surfaces of each
For PSL-3, 3G: HT Records of actual temperature and actual time at soaking finished part shall be examined
temperature.
For PSL-4: HT charts showing temperature and time. Note-6: The following records shall be furnished to the customer.
Note-7: Some of the machining, Welding, Heat treatment, Coating and Plating
activities are outsourced at the sub-contractor’s facility by OP&C. In such cases, the
requirements specified in this Quality Plan are applicable for the activities performed at
sub-contractor’s facility also.
Note-8: Packing