SAMPLE QUALITY ASSURANCE PLAN FOR CS FLANGES

PROJECT NAME KAKRAPAR ATOMIC POWER PROJECT

CLIENT NPCIL
SUPPLIER/MANUFACTURER
ITEM NAME & TAG NO. CS flanges
REF. DOCUMENT / SPEC ANSI B16.5, PC-M-599, PC-M-288, ASME SEC III NB, NC
Material Specification AS SPECIFIED IN SOR, SA 105, SA350 GR LF2
Component / Activity Quantum of Reference Acceptance Agency
Sl. No. Characteristics Class Type of check Format/ Record Remarks
Description check Document Standard P W R H
1 RAW MATERIAL

Round bars / billets/ Chemical, Verification of original SA 105, SA 350 SA 105, SA 350 Test Certificate,
1.1 Major 100% 2 1 1 1 Ref. general Note
ingots for flanges Mechianical MTC, visual GR LF2 GR LF2 MTC

PC-M-288, PC-M-288, Applicable for class I fittings

Voumetric only. Shall be carried out
UT on bars NDE Major 100% Approved Approved Test Certificate 2 1 1 wherever UT on final
examination
procedure procedure product is not possible.

2 In process Inspection & final inspection

Keep forging margin,
2.1 Forging as per PO Forging Major Measurement 100% As per spec As per spec Internal report 2 - - -
indicate forging ratio
Monitoring of
Heat Treatment of Heat Treatment Approved HT Approved HT HT chart & Witness of first charge only
2.2 Major Temperature & 100% 2 1 1 and furnace calibration
forging (normalizing) procedure procedure vendor record
Time
One sample for
each heat/ each SA 105, SA 350 SA 105, SA 350
2.3 Test piece marking Mechanical Major 100% Internal report 2 1 - 1
heat treatment GR LF2 GR LF2
batch
 Component / Activity Quantum of Reference Acceptance Agency
Sl. No. Characteristics Class Type of check Format/ Record Remarks
Description check Document Standard P W R H
One sample per SA 105, SA 350 SA 105, SA 350 Lab Test
Major Chemical analysis 2 - 1 -
heat GR LF2 GR LF2 certificate
UTS, YS, % One sample per
SA 105, SA 350 SA 105, SA 350 Lab Test
Major elongation, heat treatment 2 1 1 -
GR LF2 GR LF2 certificate
hardness batch
One sample per Lab Test
Major Impact SA 350 gr LF2 SA 350 gr LF2 2 1 1 -
heat certificate
product analysis of
2.4 Product analysis Approved Approved Inspection
flanges Major UT examination 100% 2 1 1
procedure procedure report
Approved Approved Inspection
Major LP examination 100% 2 1 1
procedure procedure report
One representative
Sample per Size per
Major Grain size PC-M-288 Five or finer Inspection report 2 1 1
Heat treatment
batch
AS per NPCIL AS per NPCIL
LPE on machined Free from surface
2.5 Non destrutive testing Major 100% approved approved Test report 2 1 1 - 25% by 1
part defect
procedure procedure
AS per NPCIL AS per NPCIL
Pickling and Inspeciton
2.6 Surface cleaning Major Visual 100% approved approved 2 1 1
passivation Report
procedure procedure
Diameter, thickness,
Dimension & visual Inspeciton
2.7 VDI Major length, ends & 100% ANSI B 16.48 ANSI B 16.48 2 1 1 25% by 1
examination Report
visual
Stencling by As per
Marking, color Electro etching Inspeciton
2.8 Major manufacturer/NPCI 100% manufacturer 2 1 1 10% by 1
coding and stamping or vibro tool Report
L/stamp standard
As per As per Wrapping foil will be
Inspeciton
2.9 End protection Major Visual 100% manufacturer manufacturer 2 1 1 provided by
Report
standard standard manufacturer
Compilation of Test certificate and
3 Major Review 100% As per QAP As per QAP Record 2 1 1
documentation release note
1- NPCIL QS or his authorised representative (Purchaser) 2- Supplier
Legend
W- Witness Point H- Hold Point R- Review/Verification P- Performing Agency

Note: Refer NPCIL general notes attached

Approved by NPCIL