Fabrication Division QMD

Compendium
of
Inspection Checklists for Fabrication Division Quality
Management Department
00
29/06/2005
Rev.
No.
Date
Issued for Reference

Description
FABRICATION DIVISION
RELIANCE INDUSTRIES LIMITED, JAMNAGAR
Job Number
0
SNS
SNS
AJV
By
Chkd.
Appd.
Department/
Division
Quality Management
Location:
Jamnagar
Document No
0
Hard copy of this document shall be treated as uncontrolled if not signed by approver
Total pages - 11
Fabrication Division
CONTENTS
1. PIPE SPOOL FABRICATION
2. STRUCTURAL STEEL FABRICATION
3. WRAPPING & COATING OF PIPE/PIPE SPOOLS
Inspection checklists for Fabrication Division Quality

Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005
Page 2 of 11
Quality Management
Jamnagar
1.
CHECK LIST FOR PIPE SPOOL INSPECTION AT

Sr. no.
Activity
Method
Verify and ensure the storage condition/stock

No mix-up between SS & CS materials
status of the material.
Whether identification of the pipe classes are

shown in the isometric & format
Verify the NDT % & PWHT requirement

written on the spool sheet w.r.t. form 167A
Spool Sheet to be cross checked with

form 167A
Whether the required WPSs are available in

line with form 167 A?
WPS apllication chart
Whether qualified welders only performing

welding / tacking?
PMI check carried out on alloy steel material

prior to welding
10
11
Project specification 22960-3PSGAW004 & Form 167A

Problem faced. Be
careful.
Verify WPQ / ID
100 % on all pipe cut pieces and on
fittings
IBR material TC verified or not?
Verification of IBR material summery

list
Heat numbers are transferred on IBR pipe cut

lengths or not?
Verification on pipes for hard punch
Remarks
LTCS pipes are identified with colour strip

(orange) or not
Verification.
Prior to induction bend positive thickness
Prior to Induction bend, the pipe thickness is
of the pipes shall be ensured. The
checked or not ? Transfer of heat number /
identfication marks i.e. Matcode / Heat
matcode number to inside the pipe is done or numbers shall be transferred to inside the
not?
pipe.
Induction bend ovality. hardness & thinning
of CS and AS checked or not ?
Induction bend ovality & thinning of SS
The bend dimensions and parameters
shall conforms to the induction bend
checked or not ?
procedure 2 PF JEP GE 001
NDT of Induction bend done or not?
12
Electrode baking
Verifying the oven record, randomly
13
Correct usage of electrode
Cross checking the electrode while

welding the job
14
Correct usage of WPS
15
Purging of the pipe
16
Preheating

Welding Engineer is
ensuring the baking of the
electrode on daily basis.
Cross checking the electrode while

welding the job
Cross checking the purging while
welding the job
Cross checking the preheating while
welding the job
Page 3 of 11
Quality Management
Jamnagar
Sr. no.
Activity
Method
Remarks
Pipe Spool contd

Cross checking the post heating while
welding the job
17
Post heating
18
Cross check and sign on the PWHT

PWHT, number of thermocouples attachment time - temperature chart during PWHT.
19
No of runs on socket joints
20
Interpass Temperature
21
During Spool weld visual inspection the

followings are verified or not?:
Cross check while welding socket joints.

Cross check while welding the joint.
Line no
Verify the punching on spool as well as

on Aluminium tag
on Aluminium tag
FCO no

on Aluminium tag
Joint no
Verify the punching on spool weld joint
Welder no
Verify the punching on spool weld joint
STS no
Spool verification with ISO for no. of

joints and Spec break
Verify the punching on spool weld

joint
Verify the WPS number mentioned in
spool clearance report.
Weld process with WPS

Physical condition of the spool, especially
for pitting on ERW pipes.
Physical verification
Flange serration
Reinforcement of weld joint is within code

limit and not less than the thickness.
Complaints
Received
from site on this point
For dissimilar thickness or external

overlap, the weld shall be tapered to
suit the step.
Orifice flange internal grinding
Power brushing on joint internal wherever

accessible
Internal cleaning by air blowing
Aluminum tag verification

Ensuring proper gauge of GI wire is used for
tag and wooden blanks
Ensuring SS wire is used for tag n the case of

SS spools.
Flagging of the spools for the status:
Orange colour ribbon for readiness of the
spool for inspection
Green colour ribbon for NDE cleared spools
Red colour ribbon for repair spools
Complaints
Received
from site on this point
All spools are to be rotated to 360 and

inspected. All weld joints shall be inspected
from inside if open joints.
Page 4 of 11
Quality Management
Jamnagar
Sr. no.
Activity
Method
Remarks
Pipe Spool contd

22
Radiography testing
23
Whether the approved NDT procedures are

available or not?
Site approval from BARC is available or
not?
Document verification with NDE agency
24
Record of present strength of the camera is

available or not?
25
26
Calibration for safe light, densitometer,

survey meter, IQI are available or not?
27
Radiography camera operating system is in

good condition or not?
28
Qualified site incharge is in site or not?
29
Qualified personnel operating the camera or

not?
30
Availability of the procedures
Physical verification during testing
31
NDT Darkroom condition verified or not?

Work instruction of film processing
procedure is displayed in the dark room or
not?
32
Log book for humidity, room temperature ,

film process and chemical replenishing are
maintained or not?
33
Magnetic particle testing
34
Magnetic particle testing procedure and

qualified procedures are available with NDE
contractor or not?
35
Yoke calibrated, and Lifting capacity

verified or not?
36
Magnetic particle bath concentration is

verified with centrifuge or not? Log book for
the same is maintained or not?
37
Field indicator is being used during the test

or not?
38
Sprayer is in working condition or not?
39
During test surface contrast enhancement

properly being done or not?
40
NDT marking for random NDT pipe

classes
41
identification of lot (per day offering or as

per production manager)
42
minimum % of joints as per form 167A to be

covered
43
At least one joint per welder per lot shall be

marked for NDT

2QA WIN ME 009
Page 5 of 11
Quality Management
Jamnagar
Sr. no.
Activity
Method
Remarks
Pipe Spool contd
45
Spec wise minimum % as per form 167A per

welder shall be covered.
In case of repair, penalty shall be selected
from the same lot and shall not be carried
over to other lot.
46
Evaluation of welder performance are being

done on daily basis or not?
Daily welder performance reports

Issue repair memo and follow up
48
Status of repair joints are being moinitored or

not?
After RT interpretation, for repair joints
repair memo are issued to the contractor or
not?
Penalty joints offered on same group of
joints or not?
49
44
47
For Other Jobs like PP,

ASME B 31.3 table 341.3.2
the applicable
Project specification 22960-3PS-GAWspecification to be
004
followed
50
Whether the copies of acceptance criteria are

available or not?
51
Whether the fit-up is as per the requirement

or not?
Root gap, off-set if any
52
In case of Impact requirements, whether the

electrode weaving are controlled or not?
Applicable WPS
53
Whether DPT material is in stock or not?

The set is from single manufacturer or
not? DPT is carried out as required in
Form 167A or not?
54
The required weld fillet size of supports, RF

pads, branch connections are verified or not?
55
The PWHT procedure is available or not?.

PWHT procedure - 2QM 00 JEP ME 006
All the PWHT recorders and the
The chart is to be
WPS, Calibration records
thermocouples alongwith compensating leads
certified at 300 deg and
again at soaking temp.
are calibrated or not?
As per procedure required nos/locations of
thermocouples are installed or not?
56
The heating band width is maintained as per

the PWHT procedure or not?
57
58
After PWHT the butt weld joints Hardness is

checked or not as per specification?

Coordination with stores
All
Temporary
attachment
including
thermocouple
attachment
shall
be
DP/MP tested
Project specification 22960-3PSGAW004 & Form 167A
Page 6 of 11
Quality Management
Jamnagar
Sr. no.
Activity
Method
Remarks
Pipe Spool contd

Hydrotest
59
Verify the offer report with the spool

numbers and maximum permissible
pressure.
60
Physical verification of spools for any

damage etc.
61
Verification of the dressing of temporary

attachment, fill-up & NDT.
62
For alloy steel temp. joints, verify preheat,

postheat & PWHT as per WPS.
63
Verify the dummy used are rated as per the

pressure rating
Verify with the pipe class wise

maximum permissible pressure list.
Combination of SS to CS & LAS not
permitted.
Verify with the hard punch.

For Carbon Steel 300 ppm and for SS 30
ppm
64
Chloride content of hydrotest water is

verified or not?
65
The used pressure gauges for the hydrotest

are calibrated on daily basis with date
marking
66
Two gauges used or not?
Calibration record
67
Test pressure is within 1.5 to 4 times of the

gauge pressure or not?
68
Carry out inspection after min 30 min

holding time.
69
Verify whether pressure gauges are returning

to 0 after pressure test.
71
All NCR / MDR / FOR / SER are being

maintained or not?
Whether all stagewise inspection records are
prepared and signed by the concerned
persons.
72
The safety practices at work area being

maintained or not?.
70

Problem faced. Be
careful.
Verify all flange for any leaks and all

joints & Long Seam Welds.
As per QAP: 2 QA QAP GE 001
Page 7 of 11
Quality Management
Jamnagar
2.
CHECK LIST FOR STRUCTURAL STEEL INSPECTION AT

Method
Sr. no.
Activity
Verify and ensure the storage condition/stock status of

the customer supplied material.
Remarks
Stock register and propoer
storage methodology.
Applicable ITPs
2
Whether the approved copy of the ITP available?
3
Whether the copy of project / job specification is

available?
Whether applicable WPS is used?
4
5
Whether welders performing welding / tacking are

qualified? Are they do weld with in the qualified
ranges?
Whether the electrodes being used are approved
brands or not?
3PS SS 001 / applicable spec.

Availability of applicable
WPS
WPQ Certificate / Welder ID
card
List of approved brand,
Physical verification along
with batch test certificates
Reviewed batch test
certificates
Whether the batch test certificates are reviewed before

start use of the electrodes?
Whether all the low hydrogen electrodes are properly daily baking record
baked or not?
Whether the materials other than IS 2062 are verified

along with MTC?
PMI check on alloy steel / stainless steel material

prior to start use?
10
Whether the copies of acceptance criteria are

available?
11
Whether DPT material is of from single

manufacturer?
12
13
14
If welding electrodes are in

contractors scope
If welding electrodes are in
contractors scope
Document review and

physical verification
IS 7215, BS 5135, IS 3658,

Physical verification before
start of job
BS 5135 acceptance level for

Whether the surface defects on weldment is visually butt and fillet welds.
verified for 100% ?
Whether the required weld fillet size is verified for
Physical verification during
structural being inspected?
weld visual inspection along
with drawing
Whether the distortion occurred in the fabricated
structural is with in the acceptable limit?
IS 7215 / Applicable std or

code
IS 7215 / Applicable std or
code
15
Whether the camber/sweep in column or beam of the

fabricated structural is with in the acceptable limit ?
16
Whether the weld access holes are properly dressed /

shaped?
17
Verify the structural is have the correct identification

by hard punch.

As per drawing / AWS D 1.1

physycal verification
Page 8 of 11
Quality Management
Jamnagar
Sr. no.
Activity
Method
Remarks
Structural Steel contd ..

18
Confirm whether the structural are tied with duly hard

punched aluminium tag by 16 swg. GI wire.
22
23
Verify the correctness of the description punched

in the tag including revision no
Whether any NDT requirement is shown in drawing? Arrange to perform require
NDE
24
Whether the specified NDE on the structural is carried Perform NDE and confirm its
out?
acceptance
25
Whether the relevant NDE reports are attached with

the Structural steel fabn. Report?
26
All NCR / MDR / FOR / SER are being maintained or

not?
3.
Mandatory Verification. Few

complaints received from site
on wrong punching.
Random NDT shall be carried

out on daily lot as per the %
given
Verify and confirm during

NDE clearence
CHECK LIST FOR WRAPPING & COATING INSPECTION

AT FABRICATION DIVISION
Sr. no.
Activity
Method
Whether the Project specification 22960-3PSGAW008 - latest revision available with contractor
Verify the inspection doc

file .
Whether Contractor is having the Thermometer,

coating thickness gauges and Holiday tester (2 nos)
with valid calibration certificates.
Correlate and Verify the

Equipment & Certificates.
Check whether ITP No. 2QAITPME013 is available.
Verify the inspection doc

file .
Consumables supplied in Steel Drum are properly

sealed & marked
Visual inspection
Co-relate the Material TC with the wrapping & coating

materials :
Verify with TC document
and batch number
1. Primer synthetic enamel paint
2. Coal tar enamel.
Check Coal tar enamel & Primer are of same

manufacturer.
Verify with TC document
Physical characteristics of wrapping & coating

materials to be verified.
Verify with TC document/as

per specification

Page 9 of 11
Remarks
All tests as per 22960-3PSGAW008 - latest revision

shall be reported
Quality Management
Jamnagar
Sr. no.
Activity
Method
Remarks
Wrapping & Coating contd ..
Check whether the Wrapping & reinforcing materials

are stored in dry place.
As per manufacturers
recommendation / as per
specification.
Check the outer surface of pipe is free from all lose

materials,dirt, grease or moisture etc before sand
blasting.
Surveillance
10
Check the sand blasting of external surface of pipe is

SA2-1/2. Finish
11
Check the primer is applied within 4hrs after sand

blasting is carried out.
Surveillance
12
Check while handling of prime coated & wrapped

pipes, Sling belts are used or not, to prevent damage to Surveillance
outer area of pipe.
13
Verify the temperature

Check whether the enamel heated in the appliance is
frequently during heating by
not exceeding the permissible temperature limit of 260 means of calibrated
deg C
temperature measuring
instrument
14
Visual examination of Wrapping for wrinkles, pockets,

tears & for thorough bonding to surface.
15
Whether the enamel applied have overall thickness

of 4 mm on the pipe body & 2.4 mm when
measured from top of the weldment.
Check frequently the

thickness by using
calibrated coat thickness
measurement instrument.
16
Whether the spot thickness test is being performed.
Sample shall be taken 25mm

x 25mm square for checking
the thickness and
adhesiveness.
17
Whether Coating & wrapping shall be trimmed off

150 mm from end of each pipe.
18
Whether all repairs identified in the coating during

visual inspection are rectified.
Visual inspection of the

repaired surface.
19
Whether the coated pipes are examined for holidays

(at 14KV) and the identified holidays are repaired and
reexamined.
Check by calibrated holiday

detector.
20
Whether Tag identification is marked on inner surface

As per Tag Identification as
of pipe before Wrapping & coating by Permanent
tied on spool.
marker.
21
Whether adhesion test has been conducted on the day's Adhesion test as per AWWA
lot (1 nos in 50 pipes with minimum 1 no)
C203

Page 10 of 11
Visual Inspection shall be

carried out after the coating
is hard.
Check carefully,
complained received from
site for less thickness
Quality Management
Jamnagar
Sr. no.
Activity
Method
Remarks
Wrapping & Coating contd ..
22
Whether all inspection data are filled properly in the

Review of the reports before
latest revision format and signed by relevant personnel. final sign.
23
Whether the inspection reports are submitted to

planning department in time

Surveillance
Page 11 of 11
Verify once in a week
Quality Management
Jamnagar

Fabrication Division QMD

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fabrication Division QMD

Uploaded by

Copyright:

Available Formats

Compendium

Issued for Reference

2. STRUCTURAL STEEL FABRICATION

3. WRAPPING & COATING OF PIPE/PIPE SPOOLS

Inspection checklists for Fabrication Division Quality

CHECK LIST FOR PIPE SPOOL INSPECTION AT

Verify and ensure the storage condition/stock

Whether identification of the pipe classes are

Verify the NDT % & PWHT requirement

Spool Sheet to be cross checked with

Whether the required WPSs are available in

WPS apllication chart

Whether qualified welders only performing

PMI check carried out on alloy steel material

Project specification 22960-3PSGAW004 & Form 167A

IBR material TC verified or not?

Verification of IBR material summery

Heat numbers are transferred on IBR pipe cut

Verification on pipes for hard punch

LTCS pipes are identified with colour strip

Verifying the oven record, randomly

Correct usage of electrode

Cross checking the electrode while

Correct usage of WPS

Purging of the pipe

Inspection checklists for Fabrication Division Quality

Cross checking the electrode while

Pipe Spool contd

Cross check and sign on the PWHT

No of runs on socket joints

During Spool weld visual inspection the

Cross check while welding socket joints.

Verify the punching on spool as well as

Verify the punching on spool as well as

Verify the punching on spool weld joint

Verify the punching on spool weld joint

Spool verification with ISO for no. of

Verify the punching on spool weld

Weld process with WPS

Reinforcement of weld joint is within code

For dissimilar thickness or external

Orifice flange internal grinding

Power brushing on joint internal wherever

Internal cleaning by air blowing

Aluminum tag verification

Ensuring SS wire is used for tag n the case of

All spools are to be rotated to 360 and

Pipe Spool contd

Whether the approved NDT procedures are

Document verification with NDE agency

Record of present strength of the camera is

Document verification with NDE agency

Calibration for safe light, densitometer,

Document verification with NDE agency

Radiography camera operating system is in

Qualified site incharge is in site or not?

Qualified personnel operating the camera or

Availability of the procedures

Physical verification during testing

NDT Darkroom condition verified or not?

Log book for humidity, room temperature ,

Magnetic particle testing

Magnetic particle testing procedure and

Yoke calibrated, and Lifting capacity