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SAMPLE QUALITY ASSURANCE PLAN FOR SHELL AND TUBE TYPE HEAT EXCHANGERS
S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
1. TUBE SHEET

1.1 Verification of Chemical Major TC Verification Sample/heat Approved As per Approved Test 2 - 1 Ref. Note-1
Documents Specification Specification Certificate
Mechanical Major TC Verification Sample/heat Approved As per Approved Test 2 - 1 Ref. Note-1
Specification Specification Certificate
NDE Major TC Verification 100% Approved As per Approved Test 2 - 1 Ref. Note-1
Specification Specification Certificate
Dimension Major Measurement 100% Approved As per Approved Test 2 1
Drawing Drawing Certificate
1.2 Cleaning & Cleaning & Major Measurement 100% Approved As per Approved Test 2 1
Preservatives Preservatives Specification Specification Certificate
1.3 Machining of Tube Dimension Major Measurement 100% Approved As per Approved Test Report 2 1
Sheet for Cladding Drawing Drawing
1.4 MPE/LPE before Surface Quality Major NDE 100% Approved As per Approved Test Report 2 1
Cladding Procedure Procedure
1.5 Review of WPS/PQR Essential Variables Major Verification 100% Approved As per Approved Test Report 2 1
before cladding and Parameters. Specification Specification
1.6 Release Welding Conformance to Major TC Verification 100% Approved As per Approved Test 2 1
Consumables for Spec. Specification Specification Certificate
Automatic/ Manual
Cladding.
1.7 Deposit Automatic/ Parameters Major Measurement 100% Approved Data As per Approved Procedure 2 1
Manual Cladding by Sheet Data Sheet Qualification
Control of No. of Layers Record
through Data Sheet.
1.8 Control of Welding Parameters Major Measurement 100% Approved Data As per Approved Procedure 2 1
technique for the Sheet Data Sheet Qualification
merging portion of strip Record
auto and spacer also
cladding of Test
Coupon.
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S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
1.9 Rough Machining for Dimension Major Measurement Random Approved As per Approved Test Report 2 1
NDE and check for Clad check Drawing Drawing
thickness
1.10 LPE of Cladding Surface Quality Major NDE 100% Approved As per Approved Test Report 2 1 Ref. Note-3
Procedure Procedure
1.11 UT of Cladding and Cladding Quality Major NDE 100% Approved As per Approved Test Report 2 - 1
repair, if any and repeat Procedure Procedure
of UT/LPE
1.12 Attest Support lugs Material and Size Major Verification of TC 100% Approved As per Approved Inspection 2 1
materials . and Cutting Plan Drawing Drawing Report
1.13 Welding through WPS Welding Parameters Major Measurement Random Approved WPS As per Approved Inspection 2 1 Ref. Note-2
Specification Report
1.14 RT, UT of support lug Weld Quality Major NDE 100% Approved As per Approved Inspection 2 - 1
Welding Procedure Procedure Report
1.15 Set up and machining
(i) Set up check for Dimensions Major Measurement 100% Approved As per Approved Test Report 2 1
coplanarity Drawing Drawing

(ii) Position and Dimensions Major Measurement 100% Approved As per Approved Test Report 2 1
thickness Drawing Drawing

1.16 ISHT of Tube Sheet and Control of ROH, ROC Major HT Chart Review. 100% Approved As per Approved HT Chart + 2 1
Test coupon after and soaking Procedure Procedure Test Report
cladding and support
lug welding.
1.17 UT & LPE of Cladding Cladding Quality Major NDE 100% Approved As per Approved Test Report 2 - 1 UT is NPCIL
Procedure Procedure Hold Point,
Ref. Note-3
1.18 UT / RT of lug welding Weld quality Major NDE 100% -DO- -DO- Test Report 2 - 1 -do-
1.19 Final machining of Dimensions and Major Measurement 2 or 3 Approved As per Drawing/ Test Report 2 1
Cladding and Chemical composition and Chemical locations Drawing/ Approved
verification of Weld Analysis. Specification Specification
Chemistry
1.20 Mechanical Test result Mechanical Major Mechanical Tests One/heat Approved As per Approved Test Report 2 - 1
of Test Coupon Properties Specification Specification
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S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
1.21 Tie Rod hole secondary Axis matching Major Visual 100% Approved As per Approved Test Report 2 1
side drilling after set up Drawing Drawing
verification by jig plate.

1.22 Thread checking by Threads Major Gauge Check. 100% Approved As per Approved Test Report 2 1
gauge Specification Specification

1.23 Setting for Tube Sheet (i) Axes Verification Major Measurement 100% Approved As per Approved Test Report 2 1
Drilling. Drawing Drawing
(ii) Clamping Sequence Major Measurement 100% Approved As per Approved Test Report 2 1
Drawing Drawing
1.24 Trial Drilling in Control (i) Hole Dia, Drift, Major Measurement 100% Approved As per Approved Test Report 2 1
Block and Verification. Surface finish, Procedure Procedure
Posiitional Accuracy
and Ligament
Check.
1.25 Tube Sheet Drilling as i) Hole Dia, Drift, Major Measurement 100% of Approved As per Approved Test Report 2 - 1
per Approved Surface finish, Control Procedure Procedure
Procedure and Posiitional Accuracy, Holes.
Inspection. Ligament Check and
Boroscopic
Examination
2. BAFFLE
2.1 Material Verification Identification (Chem., Major Verification 100% Approved As per Approved Test Report 2 - 1 Ref. Note-1
Mech., Impact, NDE, Specification Specification
Dimension etc.)
2.2 Baffle hole drilling Dimension Major Measurement 100% Approved As per approved Test Report 2 1
Drawing drawing
2.3 Checking of full set of Hole Alignment Major Bar Gauge 10% of holes. Approved As per approved Test Report 2 1
Baffles. Check. Drawing drawing
2.4 Trepanning of Baffles. Radius Major Measurement 100% Approved As per approved Test Report 2 1
Drawing drawing
3. TIE RODS
3.1 Material Verification Identification (Chem., Major Verification 100% Approved As per Approved Inspection 2 - 1 Ref. Note-1
Mech., Impact, NDE, Specification Specification Report
Dimension etc.)
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S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
3.2 Thread machining and Threads Major Gauge Checking 100% Approved As per Approved Inspection 2 1
Inspection. Specification Specification Report
4. SHELL & DISH
4.1 Materail verification for Identification (Chem., Major Verification 100% Approved As per Approved Inspection 2 - 1 Ref. Note-1
shell Mech., Impact, NDE, Specification Specification Report
Dimension etc.)
4.2 Edge Preparation LPE Major NDE 100% Approved As per Approved Inspection 2 1
Procedure Procedure Report
4.3 Seam welding of shell
course as per WPS
(i) Root and Root Major NDE 100% Approved As per Approved Inspection 2,1 1
Back chip LPE Procedure Procedure Report

(ii) Final Weld MPE/ Major NDE 100% Approved As per Approved Inspection 2,1 1 1 Hold for RT/
LPE/ RT/ UT Procedure Procedure Report UT only
4.4 Fit up of Nozzle with Dimensions Major Measurement 100% Approved As per Approved Inspection 2,1 1
Shell. Drawing. Drawing. Report
4.5 Welding of Nozzle Welding Major Measurement Random/ Approved As per Approved Inspection 2 1
and shell as per WPS Parameters shift WPS WPS Report
4.6 NDE of Nozzle Weld
(i) MPE/LPE Weld Quality Major NDE 100% Approved As per Approved Inspection 2 1
Procedure Procedure Report
(ii) RT/UT Weld Quality Major NDE 100% Approved As per Approved Inspection 2 1 1
Procedure Procedure Report
4.7 ID Exam of Shell Circularity Major Measurement Ten Approved As per Approved Inspection 2,1 1
Course for radii Locations Drawing Drawing Report
4.8 Material verification Identification Major Verification 100% Approved As per approved Test 2 - 1 Ref.Note-1
for dished ends (Chem., Mech., drawing drawing Report
Impact, NDE,
Dimension etc.)
4.9 Dished End
Formation
Dimensions Major Measurement 100% Approved As per approved Test 2 1
drawing drawing Report
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S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
Heat treatment Major Control of 100% Approved As per approved Test 2 1
ROH/ROC Procedure Procedure Report
soaking
LPE Major NDE 100% Approved As per approved Test 2,1 1 Random
Procedure Procedure Report check by
NPCIL, QS
4.10 Dish and Shell
Assembly
1. Fit-up Dimensions Major Measurement 100% Approved As per approved Test 2,1 1
drawing drawing Report
2. Root & final Weld quality Major LPE/ RTE 100% Approved As per approved Test 2,1 1 1 Hold for RT
welding Procedure Procedure Report Ref. Note-3
5. CHANNEL COVER
5.1 Material Verification Identification (Chem., Major Verification 100% Approved As per Approved Test Report 2 - 1 Ref. Note-1
Mech., Impact, NDE, Specification Specification
Dimension etc.)
5.2 Primary head machining Dimensions Major Measurement 100% Approved As per approved Inspection 2 1
and bolt hole drilling & drawing drawing Report
vent hole, drain hole & LPE Major NDE 100% Approved As per Approved Inspection 2,1 1
intergasket hole drilling Procedure Procedure Report
5.3 Welding of Nozzle with
Channel Cover
(i) Fit up Dimension Major Measurement 100% Approved As per approved Inspection 2,1 1
drawing drawing Report
(ii) Root Weld LPE/MPE Major NDE 100% Approved As per Approved Inspection 2,1 1
Procedure Procedure Report
(iii) Final Weld LPE/MPE Major NDE 100% Approved As per Approved Inspection 2,1 1 Ref. Note-3
Procedure Procedure Report
5.4 Partition plate welding MPE/LPE Major NDE 100% Approved As per Approved Inspection 2,1 1
Procedure Procedure Report
6. FINAL ASSEMBLY
6.1 BAFFLE BUNDLE
ASSEMBLY
(i) Insertion of Baffle Smooth Insertion Major Physical 100% Approved As per Approved Inspection 2,1 1
Bundle. Verification Drawing Drawing Report
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S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
(ii) Optical Check. Alignment Major Measurement Specified Approved As per Approved Inspection 2,1 1
Locations Procedure Procedure Report
(iii) Pretensioning of Tie Elongation Major Measurement 10% Approved As per Approved Inspection 2,1 1
Rod. Procedure Procedure Report
(iv) Trial Tubing Smooth Insertion Major Hand Feeling 10% of holes Approved As per approved Inspection 2 - 1
Procedure Procedure Report

6.2 TUBING:
(i) Material Verification Identification (Chem., Major Verification 100% Approved As per Approved Inspection 2 - 1 Ref. Note-1
Mech., Impact, NDE, Specification Specification Report
Dimension etc.)
(ii) Visual Examination Surface Quality/ Major Visual 100% Approved As per Approved Inspection 2 1
of Tubes. Scratches Specification Specification Report
(iii) Tubing Freeness in the entry Major Feeding 100% Approved As per Approved Inspection 1,2 1
Procedure Procedure Report
(iv) Cone rolling of Length of Contact Major Visual One Approved As per Approved Inspection 1,2 1
Tube ends after Surface. Tube/shift/ Procedure Procedure Report
Verification of operator
Cone rolling
Qualification.
(v) Edge Preparation of Tool Profile Major Shadowgraph 100% Approved As per Approved Inspection 1,2 1
Free end tubes . Drawing Drawing Report
(vi) Inspection of Edge Concentricity and Major Visual 100% Approved As per Approved Inspection 1,2 1
Preparation. Chattering mark. Drawing Drawing Report
6.3 TUBE-TO-TUBE
SHEET WELDING:
(i) Welding Qualification Welding Parameter Major NDE, Mech. & 100% Approved WPS Applicable Procedure 2 - 1
Chem. specification Qualification
Record
(ii) Welding of Visual, Gauge Check, Major Visual and 100% Approved As per Approved Inspection 2,1 1
Production QC Size of Weld. measurement Procedure Procedure Report
Block.
(iii) Checking of QC MLP Major Measurement 100% Approved As per Approved Inspection 2,1 1
Block weld for Procedure Procedure Report
MLP
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S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
(iv) Production Parameter Major Measurement One/shift/ Approved As per Approved Chart 2,1 1
Welding Operator Procedure Procedure
of Tube-to-Tube
Sheet Welding
(v) Inspection of Visual, Plug Gauge Major Measurement 100% Approved As per Approved Inspection 2 - 1
Production and LPE and NDE Procedure Procedure Report
Welding
of Tube-to-Tube
Sheet Welding
(vi) Helium Leak Test Leak Tightness Critical NDE 100% Approved As per Approved Inspection 2 - 1
Procedure Procedure Report
6.4 TUBE EXPANSION :

(i) Tube Expansion Percentage of Major Measurement One Approved As per Approved Inspection 2 - 1
after verification thinning and length of Tube/shift/ Procedure Procedure Report
of Expansion expansion of Tube in Operator.
Qualification. QC Block.

(ii) Inspection of (a) Diameter and Major Measurement 100% Approved As per Approved Inspection 2,1 1
Production Tube Length Procedure Procedure Report
Expansion. of Expansion.
(b) Percentage of Major Control holes. 100% Approved As per Approved Inspection 2,1 1 Random
thinning. Procedure Procedure Report check by
NPCIL, QS
(c) Boroscopic Major Optical 100% Approved As per Approved Inspection 2,1 - 1
Examination. Procedure Procedure Report
6.5 BUNDLE INSERTION Visual Major Visual 100% Approved As per Approved Inspection 2 - 1
Procedure Procedure Report
6.6 SHELL & TUBE SHEET
FINAL WELD
(i) Fit-up Dimensions Major Measurement 100% Approved As per Approved Inspection 2 1
Drawing Drawing Report
(ii) Welding MPE/LPE/RTE Major NDE 100% Approved As per Approved Inspection 2 - 1 Hold for RT
Procedure Procedure Report Ref. Note-3
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S. COMPONENT AND CHARACTER- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF
CLASS AGENCY REMARKS
NO. OPERATION ISTICS CHECK OF CHECK DOCUMENT NORM RECORDS
P W R H
6.7 ASSEMBLY OF Torque Checking Major Measurement 100% Approved As per Approved Inspection 2,1 1
PRIMARY HEAD WITH Procedure Procedure Report
TUBESHEET FLANGE
7. BOUGHT OUT ITEMS :
Spacer Tube, Bolts, Material Identification Major Verification Sampling Approved Spec. As per Approved Inspection 2 1
Nuts, Gaskets etc. (Chem,Mech, NDE, & Drawing Spec. & Drawing Report
Dimen. Etc.)
8. FINAL TEST:
8.1 Hydro Test Leak Tightness and Critical Proof Test 100% Approved As per Approved Inspection 2 - 1
Shell Side Pressure Drop. Procedure Procedure Report
8.2 Hydro Test Leak Tightness and Critical Proof Test 100% Approved As per Approved Inspection 2 - 1
Channel Side Pressure Drop. Procedure Procedure Report
8.3 Final Helium Leak Leak Tightness Critical Vacuum Method. 100% Approved As per Approved Inspection 2 - 1
Testing: Procedure Procedure Report
8.4 Final Dimensions Terminal Dimensions Major Measurement 100% Approved As per Inspection 1,2 1
Drawing Approved Drawing. Report
8.5 Shot Blasting & Painting Preservative Major Visual 100% Approved As per Approved Inspection 2,1 1
Procedure Procedure Report
8.6 Nitrogen Filling Positive Pressure Major Verification Few Approved As per Approved Inspection 2,1 1
Locations Specification Specification Report

8.7 Packing Rigidity Major Visual 100% Approved As per approved Inspection 2,1 1
Procedure procedure Report
9. FINAL Compilation of Major Verification 100% Tender As per Tender History 1,2 1 1
DOCUMENTATION Documents Document Document Docket
AND RELEASE

File : D:\users\ucm\files\QAP with hold\Heat EX.doc