1PQR-format1 (2)

ESSAR CONSTRUCTIONS LTD.HAZIRA.

LIST OF FORMATS

SL NO. DESCRIPTION FORMAT NO.

1 Procedure Qualification Records ECL/QA/QC/F-001

2 Welding Procedure Specifications ECL/QA/QC/F-002

3 Welder Qualification Certificate ECL/QA/QC/F-003

4 Approved Electrode List ECL/QA/QC/F-004

5 Release Note for Fabrication ECL/QA/QC/F-005

6 Release Note for Blasting ECL/QA/QC/F-006

7 Request for Inspection Works ECL/QA/QC/F-007

8 Non Destructive Test Offering ECL/QA/QC/F-008

9 Welder Qualification Test Request ECL/QA/QC/F-009

10 Welder Qualification Test Records ECL/QA/QC/F-010

11 Final Inpsection Report for Structurals - Client ECL/QA/QC/F-011

12 Final Inpsection Report for Structurals - Contractor ECL/QA/QC/F-012

13 Electrode Approval Test ECL/QA/QC/F-013

14 Debit Recovery ECL/QA/QC/F-014

15 X- Ray Details ECL/QA/QC/F-015

16 WPS & PQR Status ECL/QA/QC/F-016

17 List of Files ECL/QA/QC/F-017

18 Details of Approval ECL/QA/QC/F-018

19 Thickness Measurement Report ECL/QA/QC/F-019

20 DP Test Report ECL/QA/QC/F-020

21 List of Release Notes ECL/QA/QC/F-021

22 List of Instruments at QA/QC, ECL ECL/QA/QC/F-022

23 Blasting / Painting Status Report ECL/QA/QC/F-023

24 Inspection Report ECL/QA/QC/F-024

25 Detailed Inspection Report ECL/QA/QC/F-025

26 Ultrasonic Inspection Report ECL/QA/QC/F-026

27 Radiographic Inspection Report ECL/QA/QC/F-027

28 Daily Paint Inspection Report ECL/QA/QC/F-028

29 Material Inspection Report ECL/QA/QC/F-029

30 Protocol for Erection ECL/QA/QC/F-030

31 Inspection & Test Plan ECL/QA/QC/F-031

32 Document Control Procedure ECL/QA/QC/F-032

33 Pipe Line Specification ECL/QA/QC/F-033

34 Monthly Progress Report ECL/QA/QC/F-034

35 Camber Inspection report ECL/QA/QC/F-035

36 Non-Confirmity Report (NCR) ECL/QA/QC/F-036

37 Field Technical Queries (FTQ) ECL/QA/QC/F-037

38 Field Observation Report (FOR) ECL/QA/QC/F-038

39 Inspection Report for Column ECL/QA/QC/F-039

40 Inspection Report for Crane Girder ECL/QA/QC/F-040

41 Inspection Report for Pipe/Duct ECL/QA/QC/F-041

42 Welder's ID Card ECL/QA/QC/F-042


Format No: ECL/QA/QC/F-001

PROCEDURE QUALIFICATION RECORD (PQR)

PROJECT: JOB REF :NAME OF THE CONTRACTOR:PQR NO. :WPS NO.: REV: DATE:SUPPORTING PQR NO. : DATE:WELDING PROCESS : TYPE :

JOINTS*sketch to be attached hereGROOVE DESIGN OF TEST COUPON

(For combination qualification the deposited metal thickness shall be recorded for each filler metal of the process weld)

BASE METAL POST WELD HEAT TREATMENTMATERIAL SPECIFICATION : TEMPERATURE :TYPE OF GRADE : TIME :P NO. : TO P NO. : OTHERS :THICKNESS OF TEST COUPON :DIAMETER OF TEST COUPON :OTHERS

FILLER METALS GASWELD METAL ANALYSIS A NO. :SIZE OF FILLER METAL : TYPER OF GAS :FILLER METAL F NO. : COMPOSITION OF GAS :SFA SPECIFICATION : MIXTURE AWS CLASSIFICATION : OTHERS :OTHERS :

POSITION ELECTRICAL CHARECTERISITCSPOSITION OF GROOVE :WELD PROGRESSION : CURRENT :OTHERS : POLARITY :

PREHEAT AMPS :PREHEAT TEMPERATURE : VOLTS :INTERPASS TEMPERATURE :OTHERS : OTHERS :

TECHNIQUETRAVEL SPEED :STRING OR WEAVE BEAD :OSCILLATION :MULTIPASS OF SINGLE PASS :SINGLE OR MULTIPLE ELECTRODES :

TESTS TENSILE TEST

SPECIMEN WIDTH THICKNESS AREA ULTIMATE ULTIMATE TYPE OF FAILURENO. mm mm mm2 LOAD Kg. STRESS

GUIDED BEND TEST TYPE AND FIGURE NO. RESULT

FACE BEND FB1FACE BEND FB2ROOT BEND RB1ROOT BEND RB2

TOUGHNESS TESTS SPEC. NO. NOTCH NOTCH TEST IMPACT LATERAL REQUIRED

LOCATION TEST TEMP. VALUE EXP. VALUES

FILLET WELD TEST

RESULTPENETRATION INTO METAL MACRO RESULTS :

OTHER TESTS

TYPE OF TEST :DEPOSIT ANALYSIS :OTHERS :

WELDERS NAME :BLOCK NO. :STAMP NO. :TEST CONDUCTED BY: DATE :LAB TEST REPORT NO. : DATE :

We certify that statement in this Record are correct and the Test Welds were prepared welded and tested in accordance with requirements of Sec IX of the ASME code.

DATE : FOR ESSAR CONST. LTD.


Format No: ECL/QA/QC/F-002

WELDING PROCEDURE SPECIFICATION (WPS)

PROJECT: JOB REF :NAME OF THE CONTRACTOR:WPS NO.: REV: DATE:SUPPORTING PQR NO. : DATE:WELDING PROCESS : TYPE :

QW-402JOINTS JOINT DETAILSTYPE OF JOINT :PRODUCT FORM :BACKING :BACKING MATERIAL :OTHER :

QW-403BASE METALSP. NO. : GROUP NO. : TO P. NO.: GROUP NO. : SPECIFICATION : TO SPECIFICATION : TYPE & GRADE: TYPE & GRADE:THICKNESS RANGE : FILLET :PIPE DIA. : FILLET :OTHERS :

QW-404FILLER METALSSFA : PROCESS(ES) :AWS NO. : TRADE NAME :F NO. : A NO. :SIZE OF FILLER METAL :WELD METAL THICKNESS :THICKNESS RANGE :ELECTRODE FLUX (CLASS) : FLUX TRADE NAME:CONSUMABLE INSERT :OTHERS :

QW-405POSITIONPOSITION(S) OF GROOVE : POSITION(S) OF FILLET :WELD PROGRESSION :

QW-406PRE HEATPRE HEAT TEMP. (MIN) : INTERPASS TEMP.(MAX) :PREHEAT MAINTENANCE : TEMP. MEASUREMENT:METHOD OF PREHEATING :

QW-407POSTWELD HEAT TREATMENTTEMP. RANGE : HOLDING TIME :

QW-408GASSHIELDING GAS(ES) :PERCENTAGE COMPOSITION : FLOW RATE :(MIXTURE)GAS BACKING : PURGING RATE :TRAILING SHIELDING GAS :

QW-409ELECTRICAL CURRENT / POLARITY :

WELD DETAILSFILLER METAL CURRENT VOLT

OTHERSWELD LAYER PROCESS CLASS DIA MM TYPE AMP RANGEPOLARITY RANGE

ROOT SUBSEQUENT FINAL

TRAVEL SPEED RANGE

QW-410TECHNIQUE METHOD OF BACKGOUGING :BEAD TYPE : CONTACT TUBE TO WORK DISTANCE :PASSES PER SIDE : PEENING :ORIFICE OR GAS CUP SIZE : OTHER :INITIAL AND INTERPASS CLEANING :

NOTES :1. Tack weld ends are to be ground taper to merge with final weld.2. Minimum number of tack weld shall be as per approved procedure.3. Storage and backing of low hydrogen electrode will be done as per approved procedure.

SKETCH


FORMAT NO: ECL/QA/QC/F-003

WELDER / WELDING OPERATOR QUALIFICATION TESTS

WELDERS PHOTODate of Test : _______________________________Stamp No.: Old :___________________ New : _____________________Welders's Name : ____________________________________________________Welding Process(es) used : _________________________ Type : _________________Identification of WPS followed by welder during welding the test coupon : ______________________________________Base material(s) welded : ____________________________ Thickness : ______________________________________

MANUAL OR SEMI-AUTOMATIC VARIABLES FOR EACH PROCESS Actual Variables Range QualifiedBacking ( metal, weld metal welded from both sides, flux etc.) _________________ _________________ASME P - No. : __________ to ASME P - No. : __________________ _________________ _________________( ) Plate ( ) Pipe (enter diameter, if pipe) _________________ _________________Filler material specification (SFA) : ___________ Classification : __________ _________________ _________________Filler metal F No. : _______________ _________________ _________________Consumable insert for GTAW or PAW _________________ _________________Weld deposit / Base metal thickness _________________ _________________Process : ___________ 3 layers minimum Yes _________________ _________________Welding position (1G, 5G, etc.) _________________ _________________Progression (uphill / downhill) _________________ _________________Backing gas for GTAW, PAW or GMAW ; Fuel Gas for OFW _________________ _________________GMAW transfer mode _________________ _________________Welding Current type / polarity (GTAW only) _________________ _________________

MACHINE WELDING VARIABLES FOR PROCESS USEDDirect / Remote visual control _________________ _________________Automatic voltage control (GTAW) _________________ _________________Automatic joint tracking _________________ _________________Welding position (1G, 5G, etc.) _________________ _________________Cosumable Insert _________________ _________________Backing (metal, weld metal, welded from both sides, flux, etc.) _________________ _________________

GUIDED BEND TEST RESULTS TEST RESULTS TEST RESULTS

Visual examination results : __________________________________________________Radiographic test results : ______________ Report No. / Date : ________________________Fillet Weld - Fracture test : ____________ Report No. / Date : _____________ Length and % of defects : ________ mmMacro test Fusion : _____________ Fillet leg size : _________ mm x _________ mm Concavity/Convexity : ______ mm

We clarify that the statements in this record are correct and that the test coupons were prepared, welded and tested in accordance with requirements of Section IX of ASME Code.

ECL Insp. Contractor

Signature : Signature :

Date : Date :

ESSAR CONSTRUCTIONS LTD.

HAZIRA.FORMAT NO: ECL/QA/QC/F-004 R7

Approved Electrode ListDate : 16/09//06

A. SMAW

SL. No. CompanyBrand Name

RemarksE 6010 E 6013 E 70181 ADOR Nil a. Superbond - S Supabase A 5.1

Welding b. Superbond - SS A 5.12 ESAB Citoflex a. ESAB - 28 a. OK 48.2 A 5.1

Pipeweld - 6010R b. Ferrospeed plus b. ESAB - 36H A 5.13 General Nil a. Gri - Pink Gri - Green A 5.1

Electrodes b. Gri - Blue A 5.14 Dwekam Nil DK - 13S DK - 18 A 5.1

Electrodes A 5.15 D & H Nil a. Medio Supratherme A 5.1

b. Exobel A 5.16 Honavar Cellumate Regular - S Ultimate A 5.17 Lincon Fleetweld 5P Nil Nil A 5.18 Royal Arc Nil Royal - S Royal-therm A 5.1

Electrodes 9 Anand Arc Nil Anand SS Anandtherme A 5.1

10 Rajratna Nil a. Ratna 6013 X Ratna 7018 A 5.1 b. Ratna 6013 XX A 5.1

11 Adison Nil Steel craft - H Dynacraft - 18 A 5.1

B. SAW Wire & Fluxes


RemarksWire EL-8 Flux F7AZ1 ESAB OK Autorod 12.08L OK Flux 10.71L A 5.172 Anand - Arc Anand SAW - 1 Anand Melt - 1 A 5.173 Dwekam Mergearc Grade - A Mergearc SAF - 2 A 5.17

Electrodes Ltd.

C. GTAW Wires


RemarksBare Wire - ER 70 S21 Honavar HW70S2 A 5.182 ESAB OK Tigrod S2 A 5.18

Approved by Willy Boekhoff 16.09.06 7

G.Baskar 16.09.06 7

Prepared by S. Manisundar 16.09.06 7

Reviewed by

Name Signature Date Rev no. Remarks

ESSAR CONSTRUCTIONS LTD.HAZIRA

Format No. : ECL/QA/QC/F-005 R1

RELEASE NOTE

Date :From: QA/QC (Mech) Report no.: ECL, Hazira. Sheet no.:

Please arrange to shift the following materials from Fabrication yard to blasting yard which areinspected & cleared today in all respects :

SL DESCRIPTION OF ITEMS / QTY. AGENCY DRAWING NO. REMARKS

No. IDENTIFICATION MARK

ESSAR CONSTRUCTIONS LTD.HAZIRA

Format No. : ECL/QA/QC/F-006 R0

BLASTING RELEASE NOTE

Date :From: QA/QC (Mech) Report no.: ECL, Hazira. Sheet no.:

Please arrange to shift the following materials from Blasting yard to erection site which areinspected & cleared today in all respects :

SL DESCRIPTION OF ITEMS / QTY. AGENCY DRAWING NO. REMARKSNo. IDENTIFICATION MARK


FORMAT NO: ECL/QA/QC/F-007 R0

To, Date :QA/QC Dept. Report No.:Hazira, Surat.

Request for Inspection

Please arrange to conduct stage inspection / final inspection of the following items as on ___________________.

Description Location Time Remarks

For ESSAR Constructions Ltd.

SL. No




NDT Offering

Dear Sir,

Drg. No. Mark No. Joint No. Thickness Length Remarks

Contractor QA/QC ECL QA/QC

Kindly arrange to conduct UT / RT / DPT of the following joints as detailed below :

SL. No

Welder No.




Welder Qualification Test Request

Dear Sir,

Kindly arange for the inspection witness of the following welders qualification test

Name of the welder Process Material Dia. (in) Position RemarksSL. No

Thk . (mm)

Contractor QA \ QC ECIL QA \ QC



WELDER QUALIFICATION TEST RECORDS

Welder Name Process Type Material PositionElectrode

Polarity RemarksClass Size

123456789

10111213141516171819202122232425

Sl. No

Thk . (mm)

Dia. (in)

Root Gap mm

Current Amp.

Voltage V.

Start Time

End Time



FINAL INSPECTION REPORT - STRUCTURALSSITE : Date : ______________

CLIENT: Report No. : ______________

INSPECTION AUTHORITY : Sheet No. : ______________

WORK DESCRIPTION :JOB / DRG NO. : MKD NO. :

DESCRIPTION

FIT UP WELD VISUAL UT REPORT RADIOGRAPHY

REMARKSDate

ACCEPTANCE

DATE

ACCEPTANCE

RESULT DATE RESULT DATEUBEL UBEL

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

CLIENT

SL. No Joint

No.Type of

jointWELDER

NO.REPORT

NO.REPORT

NO.ECL( EXC. )

ECL(QA\QC)

ECL( EXC. )

ECL(QA\QC)

UBEL( QA \ QC )

ECL( EXECUTION )

ECL ( QA \ QC )



FINAL INSPECTION REPORT STRUCTURALS

CLIENT / SITE : REPORT NO. :PROJECT / DRG. NO. & REV. : DATE :PART NO. / MKD. NO. :TOTAL WEIGHT :QUANTITY :

SL. NO. DESCRITPIONACCEPTANCE

REMARKSECL INSPN CLIENT

1

2 STRAIGHTNESS

3 WELD VISUAL INSPECTION

4

5 CONFIRMITY TO DRAWING

NOTE : THE ABOVE ITEM / PART IS RELEASED FOR SURFACE PREPERATION

________________ ____________________ ___________________ECL INSPECTION CLIENT

DIMENSIONAL CHECKING (SKETCH TO BE ATTACHED)

NDT (APPLICABLE / NOT

APPLICABLE)


Format No: ECL/QA/QC/F-013 R0

ELECTRODE APPROVAL TEST

BRAND NAME : Report No. :COMPANY : Date :BATCH NO. :MFG. DATE :

SL WELDER WELDER WELDING MATERIAL ELECTRODE GROOVE FILLET CURRENT VOLTAGE START END REMARKSNO. NAME NO. PROCESS SIZE CLASS Position Thk. mm Angle Position Thk mm Size A V TIME TIME

Agency Inspection Authority Client


DEBIT NOTE FOR RECOVERY OF THE PENALTY AMOUNT OF RT REPAIR AND / OR PENALTY SHOTS

AGENCY :LOCATION :DURATION :

TOTAL DEBIT IN RS.: 0

3" width - Rs.8.50/inch 4" width - Rs.9.50/inch

SL NO.

FIRST SHOOT REPAIR SHOTS (A) PENALTY / EXTRA SHOTS (B)

REMR. NO. DATE DATE R. NO. DATE

1 0.00

2 0.00

3 0.00

4 0.00

5 0.00

6 0.00

7 0.00

8 0.00

9 0.00

10 0.00

GRAND TOTAL 0

DESCRIPTION / MKD NO.

JOINT NO.

FILM SECTION

PENALTY AMOUNT IN RS.(A+B)

REP . NO.

FILM SIZE(LXW)

FILM SIZE(LXW)


FORMAT NO: ECL/QA/QC/F-015 R0Sheet No. :

X - RAY DETAILS

IDENTIFICATIONSEGMENT

RESULT R1 RESULT R2 RESULT R3REMARKS

LINE NO. JOINT NO. STATUS REP . NO. DATE STATUS REP . NO. DATE STATUS REP . NO. DATE

SL NO.

WELDER NO.

X - RAY NO.


WPS & PQR STATUSFORMAT NO: ECL/QA/QC/F-016 R7 Date : 26/07/06

ELECTRODEMATERIAL SPECIFICATION

WPS NO. PQR NO. LIMITSTYPE & GRADE TO TYPE & GRADE

1 SMAW E 6013 IS 2062 GR. A / B IS 2062 GR. A / B ECL/NSC/CS/ WPS- 01 R0 ECL/NSC/CS/PQR -01 4.76 mm TO 24 mm

2 SMAW E6010 / E6013 A 106 GR. B A 106 GR. B ECL/SCPL/CS/ WPS- 02 ECL/SCPL/CS/PQR -02

3 SMAW E 7018 SA 515 Gr.70 SA 515 Gr.70 ECL/NSC/CS/ WPS- 03 R0 ECL/NSC/CS/PQR -03 4.8 mm TO 32 mm

4 SMAW E 7018 IS 2062 GR. A / B IS 2062 GR. A / B ECL/NSC/CS/ WPS- 04 R0 ECL/NSC/CS/PQR -04 4.8 mm TO 203 mm

5 SMAW + SAW E-7018 & EL8/F7AZ IS 2062 GR. A / B IS 2062 GR. A / B ECL/NSC/SS/ WPS- 05 ECL/NSC/SS/PQR -05 4.8 mm TO 60 mm

6 GTAW & SMAW ER-347 & E-347-5/16 A 312 GR. TYP.321 A 312 GR. TYP.321 ECL/NSC/SS/ WPS- 06 ECL/NSC/SS/PQR -06 1.6mm TO 14.22mm. DIA. 2 7/8 ” & ABOVE

7 GTAW & SMAW ER-70 S2 & E 7018 A 106 GR. B A 106 GR. B ECL/NAS/CS/ WPS- 07 ECL/NAS/CS/ PQR- 07 4.8mm TO 32 mm. DIA.2 7/8 “ AND ABOVE

8 SMAW E 8018 W2 IS IRSM 5147 IS IRSM 5147 ECL/NSC/CS/ WPS- 08 ECL/NSC/CS/PQR -08 4.8 mm TO 24 mm

9 GTAW ER 347 SA 213 TYP.321 SA 213 TYP.321 ECL/PT/SS/ WPS- 09 ECL/PT/SS/ PQR- 09 R0 1.6mm TO 17.12mm. DIA. 2 7/8 ” & ABOVE

10 SAW EL8 / F7AZ IS 2062 GR. A / B IS 2062 GR. A / B ECL/PT/CS/ WPS- 10 R0 ECL/PT/CS/PQR -10 UPTO AND INCLUDING 40 mm.

11 SMAW E 6010 & E 7018 A 106 GR. B A 106 GR. B ECL/RDS/CS/ WPS- 11 R2 ECL/RDE/CS/PQR -11 R1

12 GTAW ER 5183 SB-241 GR 5083 SB-241 GR 5083 ECL/NSC/ALU/ WPS- 12 ECL/NSC/ALU/ PQR- 12 UPTO & INCLUDING 6.4mm.DIA. 4” & ABOVE.

13 SMAW E 6010 & E 7010 G API 5L Gr.65 API 5L Gr.65 ECL/AC/CS/ WPS- 13 ECL/AC/CS/ PQR- 13 Thk. - 4.8 mm to 19.1 mm. Dia - 12.75" & above

14 GTAW & SMAW ER-70 S2 & E 7018 IS 1239 IS 1239 ECL/AS/CS/ WPS- 14 ECL/NAS/CS/ PQR- 14 1.6 mm TO 10.98 mm. DIA.2 7/8 “ AND ABOVE

Created By : GB

SL NO.

WELDING PROCESS

UPTO AND INCL. 12 mm. DIA. 2 7/8” & ABOVE - Our copy avalibale at NFY

1.6mm TO 14.22 mm. DIA. 2 7/8 “ AND ABOVE Our copy avalibale at NFY


FORMAT NO: ECL/QA/QC/F-017 R1 Date : 30/09/06

LIST OF FILES

SL NO. DESCRIPTION FILE NO.

1 APPROVED WPS & PQR ECL/QA/QC/0012 CORRESPONDENCE ECL/QA/QC/0023 NCR FILE ECL/QA/QC/0034 WELDERPERFRMANCE REPORT& WELDER LIST ECL/QA/QC/0045 WQT & WELDERS ID CARD RECORD ECL/QA/QC/0056 BUILT-UP-INSPECTION REPORTS - RMH (MATERIAL HANDLING) ECL/QA/QC/0067 BUILT-UP-INSPECTION REPORTS - RMISC ( MISC ITEMS) ECL/QA/QC/0078 BUILT-UP-INSPECTION REPORTS - RLIME ( LIME PLANT) ECL/QA/QC/0089 BUILT-UP-INSPECTION REPORTS - RPMIL (PLATE MILL) ECL/QA/QC/009

10 BUILT-UP-INSPECTION REPORTS - RPOW (POWER PLANT) ECL/QA/QC/01011 BUILT-UP-INSPECTION REPORTS - RQM2 (MOD-V) ECL/QA/QC/01112 BUILT-UP-INSPECTION REPORTS - RSMP ( CASTER/EAF-4) ECL/QA/QC/01213 BUILT-UP-INSPECTION REPORTS - RWRP ECL/QA/QC/01314 INSPECTION REPORTS - ROLLED SECTIONS ECL/QA/QC/01415 FINAL INSPECTION REPORTS - S/B & PAINTING ECL/QA/QC/01516 RELEASE NOTE - S/B & PAINTING ECL/QA/QC/01617 ULTRASONIC TEST REPORTS ECL/QA/QC/01718 RADIOGRAPHY TEST REPORTS ECL/QA/QC/01819 R.I.W FILE - FAB ECL/QA/QC/01920 R.I.W FILE - S/B & PAINTING ECL/QA/QC/02021 ELECTRODE TEST CERTIFICATE ECL/QA/QC/02122 INSTRUMENTS DETAILS ECL/QA/QC/02223 BUILT-UP-INSPECTION REPORTS - RCRX ( COREX ) ECL/QA/QC/02324 CONTRACTORS BILL ECL/QA/QC/02425 MATERIAL TEST CERTIFICATES ECL/QA/QC/02526 WORK ORDER ECL/QA/QC/02627 QUOTATION FOR INSPECTION KITS ECL/QA/QC/02728 MATERIAL INSPECTION REPORTS ECL/QA/QC/02829 MASTER LIST OF FORMATS ECL/QA/QC/02930 CALIBERATION REPORTS ECL/QA/QC/03031 INSPECTION AND TEST PLAN ECL/QA/QC/03132 MINUTES OF MEETING ECL/QA/QC/03233 SPECIFICATIONS AND JOB PROCEDURE ECL/QA/QC/033


FORMAT NO: ECL/QA/QC/F018 R0

DETAILS OF APPROVAL

Brand Name : Date of Test :Company Name : Batch No. :Size(DXL)mm : Welder No. :Material Specification : Method of Testing :

CHEMICAL ANALYSIS OF WELD METAL (%)C Mn Si S P Cr Ni

Mo Cb Cu Ti V Fe C.E

MECHANICAL PROPERTIES OF ALL WELD METALAs Welded / After Heat Treatment : As welded

ALL WELD METAL TENSION TEST C.V.N IMPACT TESTYield Stress U.T.S Elongation Temp. Energy Absorbed

ksi Mpa ksi Mpa (%) deg. C Joules

RADIOGRAPHY TEST DETAILS OF HEAT TREATMENT

DATE RESULT Type Soaking Peroid (hrs)

SPECIAL PROPERTIES IF ANY :

REMARKS

AJIT RAO G BASKARDATE REMARKSWITNESSED BY APPROVED BY

Soaking Temperature (deg. C)

DIFFUSIBLE H2 PER 100gm OF WELD METAL :



Thickness Measurement Report

Client ___________________________ Equipment ____________________ Date of Inspection :Project _________________________ Technique _____________________ Report No. :Component ______________________ Surface Condition _______________Material ________________________ Couplant _______________________

Transducer 0 45 60 70 IdentificationFrequencyCrystal SizeTwin/Single

Calibration Sensitivity Calibration StandardCompression Wave : Transducer Rel dB Loss dB Actual dBCalibrated to ___________mm Screen width sensitivity set at _________ back wall Echo to _________ full screen heightplus dB values as indicated in Table.Shear Wave :Calibrated to ___________mm Screen width sensitivity set at

_________ full screen height from the ______mm hole in __________ Calibration BlockScanning and transfer loss dB values are as indicated in Table.Specification Acceptance Standard

Sl No. Job Identification Spot No. Dimension Thickness Observations Result

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

Operator Inspection Authority Client

Signature Signature Signature

ESSAR CONSTRUCTIONS ( INDIA ) LTD.HAZIRA.


Dye Penetrant Test Report

Client : Report No.:Object : Date :Material Specification : Test Site Method : Solvent RemovableType : Manual

Accessories Cleaner : PC120B Batch No. : Date of Mfg. : Date of Expiry :Penetrant : PP110B Batch No. : Date of Mfg. : Date of Expiry :Developer : PD130B Batch No. : Date of Mfg. : Date of Expiry :

Standard Specification : ASME E - 709Acceptance Criteria : ASME Section VIII Div. I Appendix 6

Drg. No. :

Dimensions & Results :

Observations

Remarks

Notes

Witnessed By Inspection Authority Client

Signature Signature Signature

ESSAR CONSTRUCTIONS LTD.

HAZIRA.FORMAT NO: ECL/QA/QC/F-021 R3 Date : 29.09.06

LIST OF RELEASE NOTES

PROJECTS

OLD FABRICATION YARD

1 RGL BGL

2 EAF - CCP, Caster - III RSMP BSMP

3 Galvanizing Furnace - II RGF BGF

4 RPOW BPOW

5 Quick Melt Plant RQM2 BQM2

6 Waste Recovery Plant RWRP BWRP

7 Material Handling, Bogie RMH BMH

8 Oxygen Plant ROP BOP

9 RLIME BLIME

10 Acid Regeneration Plant RAP BAP

11 Plate Mill RPMIL BPMIL

12 Miscallaneous RMISC BMISC

13 Iran Project RI-01 BI-01

14 Corex RCRX BCRX

NEW FABRICATION YARD

1 Quick Melt Plant NY/RQM2 NY/BQM3

2 Oxygen Plant NY/ROP NY/BOP

SL No.

RELEASE NOTE

BLASTING RELEASE NOTE

CRM COMPLEX, Hydrogen Plant, BAF, EOT, Shearing Line (U-V), Packaging Line, Tank & Looper Structure, Continuous Tandem Mill, Boiler House Structure, ETP, Chiller Plant & Utility Miter Bends

Power Plant, CWC Pump House Structure, Busbar Support

LIME KILN - #3 - Dololime, Flexowell, Process Air System, Support Platform, Kiln Shell Structure & Hopper.


FORMAT NO: ECL/QA/QC/F-022 R1 Date : 29.09.06

LIST OF INSTRUMENTS IN QA/QC, DEPT. ECL.

SL# DESCRIPTION MAKE STICKER# RANGE LEAST COUNT DUE ON REMARKS

1 Ultrasonic Flaw detector Modsonic 001 10mm-5M nil yes 16/12/042 Profile guage Ferroderm 002 0-1 mm 0.002 yes 25/11/043 WFT Guage caltech 003 25-600mic. 25 mic. yes 27/12/044 WFT Guage caltech 004 25-600mic. 25 mic. yes 27/12/045 WFT Guage caltech 005 25-600mic. 25 mic. yes 27/12/046 Boroscope HEINE 006 1mm&more nil no7 Welding gauge-1 GIC 007 fillet 1"max. angle 0-60 1 mm, 5 deg.8 Welding gauge-2 GIC 008 fillet 1"max. angle 0-60 1 mm, 5 deg.9 Welding gauge-3 GIC 009 fillet 1"max. angle 0-60 1 mm, 5 deg.10 Vernier Caliper Mitutoyo 010 0-300 mm 0.02 mm yes11 Inside / Outside Caliper 011 10-320 mm no12 Autolevel #1 Sokkia 012 upto 3 ft. yes 2/12/200413 Autolevel #2 Sokkia 013 upto 3 ft. yes 2/12/200414 ISO Comparator International Standard 014

15 Thermohygro clock #1 Eurotemp 015 0.1 deg C

16 Thermohygro clock #2 Eurotemp 016 0.1 deg C

17 Binacular Russia 017 120m/1000m18 Portable Hardness Tester TIME Model -TH-130 018 0-50 deg C yes 14/5/0419 Luminux High Int'ty Illum., 019 1/8" - 1"20 Film Density comparator AGFA 020 0-4 (15 STEP INTRVL) 0.3 OPTICAL D yes 03/04/0521 V-Wac guage G.A.L. GAGE CO. 021 POROSITY-1/8"MAX no22 Universal Bevel Protractor Mitutoyo 022 5 min. no23 Elcometer Yuyutsu 023 0-1250microns 1micron no24 Ultrasonic Thickness gauge - 1 Pulse tech echo system 024 0.60 mm to 300 mm25 RT Survey meter Minirad 025 0-500 Mr 0.5 Mr N.A26 RT Film Viewer Eastern Engg elec. Co.ltd. 02627 Densitometer Optel 027 0-4 d N.A

28 Ultrasonic Thickness gauge - 2 Pulse tech echo system 028 0.60 mm to 300 mm

CAL. STATUS

DATE OF.CAL.

from - 50 to +70 deg C, 20 - 90 % RH

from - 50 to +70 deg C, 20 - 90 % RH



Blasting / Painting Status Report

Sl. No. Description Drg. No. Mkd. No. Item No. Received Blasting / Painting Status Blasting RemarksDate D. C. No. Blasting Primer MIO F1 Release N

Qty.(set/nos.)

Unloaded Area

Inspection Report


ULTRASONIC REPORT

Report No : _______Tower No. Sr. No of Section Date : Contractor

Inspection : Material Ref. Block : ECL -10,16Equipment : Einstein Probe : Equipment Sr. no : Probe Sr. no : Couplant : Surface Preparation :

Applicable code : ASME V, art.- 4&5.Welding technique : Acceptance standard : ASME VIII, App-12.

SR Item Joint No Welder Observation Status LOCATIONNO. No.

Operator by FOR ECL, FOR CLIENT,NAME: NAME : NAME:DATE : DATE : DATE :SIGN : SIGN: SIGN:

UT Technique : Pulse-echo- contact.

Trac


Radiography ReportReport No.___________

Tower No. Sr. No of Section Date : Contractor

NDT Agency : Intensifying screen : Material : Source type : Density : Source strength : Sensitivity : Source size : SFD : RT Technique : Applicable code : ASME V ,art 2&3Type of Film : Acceptance std : ASME VIII ,DIV-1Welding technique : SR JOINT ID SEGM THICK SIZE OF OBSERVATION STATUSNO. ENT NESS FILM

FOR NDT AGENCY. FOR ECL, FOR CLIENTNAME NAME : NAME:

IQI : DIN-6 ISO 12/10 ISO 16

REMARKS

DATE : DATE : DATE :SIGN : SIGN: SIGN:


FORMAT NO: ECL/QA/QC/F-029 R0 Date :

MATERIAL INSPECTION REPORT

Purchase Order / Invoice No : Date:Consigners Name & Address: Date:

MRS No. :Issed to Agency :

DETAILS OF MATERIAL

SI NO. Pack No. Material Description Remarks

DETAILS OF INSPECTION

SI NO. Dimensions Remarks

OBSERVATIONS:

QA/QC

Heat No. / Batch No.

Total Quantity (in nos.)

Total Weight (in MT)

Punch No.

Deviations from the Actual

Quantity Inspected

ECL



PROTOCOL FOR STRUCTURAL ERECTION

PROJECT NAME : REPORT NO. :

STRUCTURE / EQUIP. NAME : DATE :

DRG. NO. :

ITEM / MKD. NO. :

SL. NO. DESCRIPTION AS PER DRAWING OBSERVATION REMARKS

1 DIAGONAL

2 ELEVATION

3 VERTICALITY

4 NOZZLE ORIENTATION & ELEVATION

5 FIT UP AND WELD VISUAL

6 NDT (RT, UT, DPT)

7 BOLT TIGHTENING

8 GROUTING

9 OTHERS

RESULT:

ERECTION AGENCY ECL EXECUTION ECL QA/QC CLIENT

SIGN

NAME

DATE



INSPECTION TEST PLAN

PROJECT NAME ITP NO. :

JOB DESCRIPTION DATE :

Sl. No. Activity Description ResponsibilityInspection

Inspection Grade Format RemarksContractor ECL

LEGENDS : INSPECTION GRADESA - APPROVE A : Inspection & Approval from ECL is mandatory for further activities.H - HOLD B : ECL reserves the right to perform inspection as deemed necessary.DR - DOCUMENT REVIEWRW - RANDOM WITNESSM - MONITORW - WITNESS

Signature

Name

Agency Approved By ECL

Acceptance Standard / Specification

Freuency of

Inspection

Sl. No Description Acceptance Standard/Specification Inspection Format Remarks.

1.0 Prior to Fabrication1.1 Verification of Material Test Certific IS:2062-1999 P P B1.2 Identification of Welding Consumble Project specifications P A B1.3 Review of Consumable TC's ASME Section II Part C P DR B1.4 Establishing WPS/PQR ASME Sec IX P DR/A B1.5 Welder Qualification ASME Sec IX P W A2.0 During Fabrication2.1 Marking and Cutting Approved Dwg. & Spec' P M C2.2 Fit-up Inspection Approved Dwg. & Spec' P RW B2.3 Inspection of Groove Weld Joints Approved Dwg. & Spec' P RW B2.4 Pre-heating as applicable WPS & Proj. Spec. P M C2.5 NDT as applicable NDT/Proj. specifications P W/A A2.6 Final Visual and Dimensional Inspection Approved Dwgs. P W A3.0 Sand Blasting and Painting3.1 Verification of Batch TC's of Paint Paintaing/Proj. specifications P P B3.2 Inspection of Sand Blasted Surface Sa 2½ & Project specification P RW B3.3 DFT Checking of Primer Coat Paintaing/Proj. specifications P W B3.4 DFT Checking of Subsequent Coats Paintaing/Proj. specifications P RW B3.5 Final Clearance/Release Note specifications P W A4.0 Erection4.1 Checking of Foundation Elevation Approved Drawings P M C Protocols4.2 Checking of Foundation Bolts Approved Drawings P M C4.3 Final Inspection of Erected Structure Approved Drawings P W A Protocols4.4 Fit-up Inspection Approved Dwg. & Proj.Spec' P RW B4.5 Weld Visual Approved Dwg. & Proj.Spec' P RW B4.6 NDT as applicable NDT/Proj. specifications P W/A A as applicable4.7 Submission of final dossiar/protocol Approved Dwg. & Proj.Spec' P DR A

Legend : Inspection Grades :A : Approved DR : Document Review A : Inspection and approval from ECL is mandatory for further continuation of workM : Monitor P : Perform B : ECL may perform random inspection on their descretion.

Responsibility

Inspection grade

RW: Random WitnesW : Witness C : Inspection is the responsibility of , ECL will review documents.



DOCUMENT CONTROL PROCEDURE(DCP)PROJECT NAME DCP NO. :

JOB DESCRIPTION DATE :

RESPONSIBILITES

contractor ECL

1 Request for Inspection G R & AC OC ECL/QA/QC/F-007

2 Inspection Report(rolled) G AC & A OC ECL/QA/QC/F-025

3 Inspection Report(Built-Up) G AC & A OC ECL/QA/QC/F-024

4 Release Note R G PLNG,EXE,CON'TOR,OC ECL/QA/QC/F-005

5 Despatch Challan G S SBY ECL/QA/QC/F-033

6 Inspection Report(Blasting) G G FILE ECL/QA/QC/F-023

7 Blasting Release Note R G PLNG,EXE,CONTRACTOR ECL/QA/QC/F-006

8 WQT Record G A CONTRACTOR,OC ECL/QA/QC/F-009

9 WPS/PQR G A CONTRACTOR,OC ECL/QA/QC/F-001

LEGEND: "G" - GENERATION ; "R"-RECEIVE ; "S" - SIGN OFF AND "A" - APPROVAL,"AC" ACT, "OC" OFFICE COPY

SL# ACTIVITY DESCRIPTION Distribution format Ref: Remarks



DOCUMENT CONTROL PROCEDURE(DCP)PROJECT NAME DCP NO. : JOB DESCRIPTION DATE :

Sl. No. Activity Description Format RefResponsibility

RemarksContractor ECL

1 Request for Inspection ECL/QA/QC/F-007 Drawing / Sketch each item G R

2 Inspection Report(rolled) ECL/QA/QC/F-025 Drawing / Spec. each item G S

3 ECL/QA/QC/F-024 Drawing/Spec. each item G S

4 Release Note ECL/QA/QC/F-005 Inspection Report each item R G

5 Despatch Challan ECL/QA/QC/F-033 Release Note each item G S

6 ECL/QA/QC/F-023 each item G S

7 Blasting Release Note ECL/QA/QC/F-006 each item R G

8 ECL/QA/QC/F-003 ASME Sec.XI each welder G A

9 ASME Sec.XI each process/variables G A

10 Approved Electrode List ECL/QA/QC/F-004 ASME Sec.II Part C R G ECL/QA/QC/F-013 R011 Inspection & Test Plan ECL/QA/QC/F-031 Drawing / Spec. each project G A

12 NDT Activities ASME Sec. V each spot G ALEGEND: "G" - GENERATION ; "R"-RECEIVE ; "S" - SIGN OFF AND "A" - APPROVAL

APPROVED BY WILLY BOEKHOFF

CHECKED BY G BASKAR

PREPARED BY AJIT RAO

Approved Documents

Frequency of Inspection

Job Procedure for Fab. ECL/JP/FBSS-01 R0

Inspection Report(Built-Up)

TO BE ENCL.WITH NDT STATUS, CONTRACTOR COPY

Inspection Report(Blasting)

Spec. for Surface Preperation & Paiting

Blasting Specification ECL/SPP-01 R0

Daily Inspection Report(Blasting)

Welder Qualification CertificateWelding Procedure Spec. / Procedure Qualification Record

ECL/QA/QC/F-001 ECL/QA/QC/F-002 WPS & PQR STATUS

ECL/QA/QC/F-016 R5

each batch of electrodes / filler wire / fluxes

ECL/QA/QC/F-026 ECL/QA/QC/F-027

DESCRIPTION NAME SIGNATURE DATE REV NO.

PIPE LINE SPECIFICATION

FORMAT # ECL/QA/QC/F033, R-3

SL. MEDIUM MEDIUM DESCRIPTION DESIGN PRESSURE DESIGN MATERIAL FILLER WIRE / ELECTRODE TYPE OF NDT REMARKS

NO. CODE in kg/cm2 g TEMP.DEG. C GRADE TYPE PROCESS ROOT FILL UP / FINAL ROOT DP RT

1 IA INSTRUMENT AIR 12 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM

2 PA PLANT AIR 12 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM

3 CWS COOLING WATER SUPPLY 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E6013 10% 10% CRM

4 CWR COOLING WATER RETURN 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E6013 10% 10% CRM

5 DW DRINKING WATER 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E6013 10% 10% CRM

6 FW1 FIRE WATER ABOVE GROUND 10.6 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM

7 FW2 FIRE WATER UNDER GROUND 10.6 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM

8 TW TREATED WATER LINE 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% CRM

9 ST1 STEAM LINE1 12 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% BOILER



12 CL1,CL2,CL3,CL4 CONDENSATE LINE 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% BOILER

13 FI FURNACE OIL LINE 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% CRM

14 NG NATURAL GAS - LOW PRESSURE 11 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% CRM

15 SA SPENT ACID 10 90 FRP FRP ARP

16 FA FRESH ACID 10 90 FRP FRP ARP

17 RA RINSE ACID 10 90 FRP FRP ARP

18 SUW SUMP WATER 10 90 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% ARP

19 N2 NITROGEN 10 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% ARP

20 SW SERVICE WATER 10 60 IS 1239 / IS 3589 ERW SMAW E7018 10% 10% CRM

21 RE ROLLING EMULSION 10 90 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM

22 ChA CHROMIC ACID 10 90 FRP FRP ARP

23 H2 HYDROGEN 10 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% ARP

24 HNX N2+H2 10 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% ARP

25 COLD BOX PIPING AR, O2, N2 10 -183 TO -191 SA 5083 SML GTAW ER 5183 ER 5183 N.A 100% O2 PLANT

26 O2 O2 LINE 10 -183 TYP. 321 SML GTAW + SMAW ER 347 E 347 N.A 100% O2 PLANT

27 MH-P OIL SUPPLY 210 ASTM A 106 GR.B SML GTAW ER - 70 S2 ER - 70 S2 N.A 10% HYDRAULIC

28 MH-P ACTION LINE NO. 210 ASTM A 106 GR.B SML GTAW ER - 70 S2 ER - 70 S2 N.A 10% HYDRAULIC

29 MH-T OIL RETURN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

30 MH-D OIL DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

31 MH-FD FMV OIL DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

32 MH-MD MAGNESCALE DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

33 MH-OC OIL CHANGE 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

34 MH-OD OIL DUMP 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

35 AH-MD MANDRAL DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

36 RC-B BY PASS LINE 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC

37 NG NATURAL GAS - HIGH PRESSURE 120 -29 API- 5L Gr. X-65 SML SMAW E-6010 E7010 G 100% 100%

38 MH OIL SUPPLY 315 60 TYP.304 SML GTAW+SMAW ER-308L E-308L-16 10% 100% HYDRAULIC

DATE: 25-09-2006

39 MH OIL RETURN 10 60 TYP.304 SML GTAW+SMAW ER-308L E-308L-16 N.A 10% HYDRAULIC

40 MH OIL DRAIN 10 60 TYP.304 SML GTAW+SMAW ER-308L E-308L-16 N.A 10% HYDRAULIC

41 MH OIL SUPPLY 315 60 ASTM A 106 GR.B + SML GTAW+SMAW ER-309L E-309L 10% 100% HYDRAULIC

TYP. 304

42 MH OIL RETURN 10 60 ASTM A 106 GR.B + SML GTAW+SMAW ER-309L E-309L N.A 10% HYDRAULIC

TYP. 304 N.A

43 MH OIL DRAIN 10 60 ASTM A 106 GR.B + SML GTAW+SMAW ER-309L E-309L N.A 10% HYDRAULIC

TYP. 304

44 AW(H20+SLUDGE) ALKALINE WASTE AND SLUDGE LIINE 4 40 TO 70 IS 1239 / IS 3589 ERW SMAW E-6010 E-6013 10% 10% ETP

General Notes

1 All lines of dia. 2" and below Pipes shall be done welding of full GTAW for both root and fillup/final passes irrespective of service.

2 All lines of above 2" dia. and a pressure of above 10 kg/cm2 shall be done welding of root by GTAW and fillup/final by SMAW processes irrespective of service.

3 Edge preperation of joints shall be followed as mentioned in Drawing.

4 All lines of 2" and below , where socket welding is involved . 100% DPT of welding is advisible.


Essar Constructions Limited - HaziraMonthly Progress Report - QA/QC (Mech.)

Sep. 2006

Sl no. AreaTest carried out

RemarksUT in mtrs RT in inches DP in mtrs.

1 Sinter plant 0 315 22 196 78 274

2 Caster

3 EAF

4 QM-II

5 Power plant

6 Plate mill

7 Corex

8 CRM

9 Central store

10 CMS

11 NFY

12 Material handling

13 Miscellaneous

14 Lime plant

15 Blasting worksTotal

Note:

Final inspection in MT

Hydro test (mtr)

Holiday test(mtr)

FORMAT # ECL/QA/QC/F035, R-0ESSAR CONSTRUCTIONS LTD.,-HAZIRA. (QA/QC-MECH)

PROJECT NAMEDRAWING NUMBERMARK NUMBERQTY

INSPECTED BY ACCEPTED / REJECTED

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

0

5

10

15

20

25

30

35

04 5 6 7

1013 15 16

1923 25 27 29

2622 20 18

14 127 6

3 2 1 1 0

CAMBER ON EOT

Column E

LENGTH IN METER

VA

LU

ES

IN

"M

M"

ESSAR CONSTRUCTIONS LTD.,-HAZIRA. (QA/QC-MECH)

REMARKS: SEE PROTOCOL

ACCEPTED / REJECTED

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

0

5

10

15

20

25

30

35

04 5 6 7

1013 15 16

1923 25 27 29

2622 20 18

14 127 6

3 2 1 1 0

CAMBER ON EOT

Column E

LENGTH IN METER

VA

LU

ES

IN

"M

M"


NON CONFORMITY REPORT

Contractor Name:

Date : NCR No : ECL/QA/QC/Area: PROJECT :AREA

Engineering Procurement Blasting & Painting

Civil Mechanical Others

Non - Conformance observation details (Be Specific)

Dept. in-charge(QA/QC) Excecution(ECL) Inspector (QA/QC) Sign. & Date Sign. & Date Sign & Date

Corrective Action Agreed upon

Agreed completion Date:Contractor Sign.

Preventive action Agreed upon

Contractor Sign,: Agreed completion Date:

Inspector (QA/QC) : Approved by

Sign & Date: Sign & Date

Status of NCR : Close / Open


ESSAR CONSTRUCTION LTDFIELD TECHNICAL QUERIES (FTQ)

ORGINATOR : DATE :

CONTRACT NAME.:PROJECT :

NO.: FTQ/

DESCRIPTION OF QUERY (BE SPECIFIC)

DATE RESPONSE REQUIRED BY:

MECH PIPING STRUCT BLASTING PAINTING

SPECIFICATION REFERENCE:

PROPOSED SOLUTION BY ORIGINATOR:

ORIGINATED BY: NAME: SIGNATURE:

__________ ____________MANAGER DATE

ACCETANCE:

____________ SIGN DATE

Distribution: Original to OriginatorCopy to : Project Manager, Field Engineer, QA/QC File

ORIGINATOR

DRAWING NO.:

DISCIPLINE OF FTQ

DESIGN

AGREED BY DESIGN / ALTERNATIVE SOLUTION BY DESIGN: (DELETE AS APPLICABLE)

PR

OJE

CT

M

AN

AG

ER


ESSAR CONSTRUCTIONS LTDFIELD OBSERVATION REPORT (FOR)ORGINATOR NAME: Discipline of “FOR” Date:

COMPANY: CONTRACT NAME:FOR NO.

OR

IGIN

AT

OR

Procedure as per specification/ normal practice:

Proposal for corrective action

EC

L –

QA

/QC

Preventive measures to avoid recurrence in future:

Date: Signature:

Action needed: Yes or No (if no inform PM-ECL to close “FOR”

EC

L -

PM

Resolution / Concurrence:

Date : Name: Signature

EC

L-Q

A/Q

C

Action Taken

Description of Field Observation:

Date : Name: Signature:

EC

L-Q

A/Q

C

Date: Name : Signature:


Inspection Report for Column

Drawing No: Column No.:

Area :

Sr.No. Description Drg, Dimension Tolerance as per IS 7215.

1 Straightness ( y )

2 Over all Length ( L) Upto 10 mtr - +/- 5mm

3 Max. 1 mm

4 Water level ( If required)

5 Square ness of Flange 0..005X b or max. 2mm

6 Diagonal 0.0012 X L or Max.7 mm

i) VISUAL INSPECTION :

Longitudinal - 0.001 X L or max 10 mm

Tranverse - 0.001 X L or max 10 mm

Over 10 mtr - 0.0005 l subject or Max. +/- 8 mm

Base Plate Flatness / Straightness

ii) NDT :

iii) Remarks ( if any) :

CONTRACTOR ECL.

QA/QC Execution

Inspection Report for Column

Column No.:

RemarksActual Dimension

ECL

QA/QC


Inspection Report for Crane Girder

Drawing No: Crane Girder No.:

Area :

Sr.No. Description Drg, Dimension Tolerance as per IS 7215.

1 Straightness (Camber)Y1

Y2 Max 5 mm

2 Squareness of Flange 0..005 X b or max. 2mm

3 Over all Length (L ) Upto 12 mtr - +/- 3 mm

4 Buckling in web Upto 500 mm - 0.5 mm

500 mm to 1000 mm - 1.0 mm

Over 1000 mm - 2.0 mm

5

I) VISUAL INSPECTION :

0.0001 x L or Max. 10 mm whichever less

Over 12 mtr - 0.0025 L or Max. +/- 5 mm

End Plate straightness / flatness

ii) NDT :

iii) REMARKS ( if any) :

CONTRACTOR ECL.

QA/QC Execution

Inspection Report for Crane Girder

Crane Girder No.:

RemarksActual Dimension

ECL

QA/QC


FINAL INSPECTION REPORTS - DUCTS

Drawing No: Mark No:

Service/Purpose : Date:

( L )

(Ø D)

Sr.No. Description Drg, Dimension Remarks

1 Diameter (Ø) D+/-1 % or Max.20mm

2 Straightness N.A 0.5mm/Mtr. Or max.5mm

3 Ovality N.A (Max.D1-.Min. D2)/2 = Max.t/2

4 Length (L) 2.5mm/Mtr.

VISUAL INSPECTION OF PIPE /DUCT :

NDT OF THE PIPE /DUCT:

CONTRACTOR ECL ECL

QA/QC EXECUTION QA/QC

NOTE: ALL DIMENSIONS ARE IN "mm"

Tolerance as per spec. /Codes/Drgs.

Actual Dimension

PHOTO


WPS Matl.

ESSAR CONSTRUCTIONS LTD. NO. Type

HAZIRA.

WELDER IDENTITY CARD

NAME OF THE WELDER :

COMPANY NAME :

IDENTITY NO. :

PROJECT NAME :

APPROVED BY APPROVED BY

SEAL ESSAR CONSTRUCTIONS LTD SEAL


Test Coupon Welding Filler wire / Range Qualified Position Date Approved

Dia. Thk Range Process Electrode Dia. Thk Range Qualified of Qfln. By ECL

in. (mm) Type in. (mm)

APPROVED BY

SEAL ESSAR CONSTRUCTIONS LTD



LIST OF SPECIFICATIONS / PROCEDURES

DESCRIPTION SPEC. / PROCEDURE NO.

A SPECIFICATIONS

1 ECL/SP/FB-01 R0

2 ECL/SP/WD-01 R0

B PROCEDURES

1 ECL/JP/QA/01 R0

2 ECL/JP/QA/02

3 ECL/JP/QA/03

4 ECL/JP/QA/04

5 ECL/JP/QA/05

6 ECL/JP/QA/06

7 ECL/JP/QA/07

8 ECL/JP/QA/08

9 ECL/JP/QA/09

10 ECL/JP/QA/10

11 ECL/JP/QA/11

C QUALITY MANUAL

1 ECL/ QA/QC-HAZ-QM-01

SL NO.

GENERAL NOTES & INSTRUCTIONS FOR FABRICATION

STANDARD WELDING SPECIFICATION

PROCEDURE FOR INCOMING MATERIAL INSPECTION

Procedure for qualification of welding personnel

Procedure for Qualification of WPS & PQR

Procedure for fabrication structural steel

Procedure for visual Examination

Procedure for Surface preparation and painting

Procedure for Dye penetration Examination

Procedure for Radiography examination

Procedure for Ultrasonic examination

Procedure for Control of Non Conforming Product

Procedure for calibration of measuring equipments

Quality Manual

Date : 28/01/05Ref No.: ECL/QA/QC/CORR.035

To,Royal Arc Electrodes Pvt. Limited.Mumbai - 400064

Attention Mr. B. A Patil,Sales Executive.

Dear Sir,

Subject :Approval of your Welding Electrode Royal - Therm (E 7018)

With reference to your letter M. G. W. P / 2004 Dated : 13/10/04 for the above -mentioned subject. We have reviewed and tested the electrodes and fonund suitable for use in our Project work at Hazira. The Details are

Trade Name : Royal - ThermDescription : Low Hydogen TypeDiamaters : 2.5, 3.15 & 4.0Welding Polarity : DCEPWelding Position : All positions for Butt Welding except vertical down.

Please keep us up to date for any change in Trade name / Manufacturing system.Also you are requested to ensure proper co-relating batch certificates are furnished along with every supply.

This approval is valid based on the consistence in Quality which has to be checked / reviewed by us periodically.

For Essar Constructions Limited.

Authorized Signatory

FLUID SYSEM LINE NAME MATERIAL ELECTRODE

GRADE TYPE ROOT PROCESS FINAL

MILL HYDRALIC MH-P OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW ER70 S2

SYSTEM MH-P ACTION LINE NO. ASTM A 106 SML ER70 S2 GTAW ER70 S2

MH-T OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018

MH-D OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018

MH-FD FMV OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018

MH-MD MAGNESCALE DRAIN ASTM A 106 SML ER70 S2 GTAW E7018

MH-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018

MH-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018

AUXILLARY AH-P OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW ER70 S2

HYDRAULIC AH-P ACTION LINE NO. ASTM A 106 SML ER70 S2 GTAW ER70 S2

SYSTEM AH-T OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018

AH-D OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018

AH-MD MANDRAL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018

AH-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018

AH-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018

ROLL RC-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW ER70 S2

COOLANT ASTM A 106 SML ER70 S2 GTAW ER70 S2

SYSTEM RC-R OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018

RC-D OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018

RC-B BY PASS LINE ASTM A 106 SML ER70 S2 GTAW E7018

RC-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018

RC-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018

GEAR GL-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW E7018

LUBRICATION

SYSTEM GL-R OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018

GL-B BY PASS LINE ASTM A 106 SML ER70 S2 GTAW E7018

GL-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018

GL-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018

MOTOR ML-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW E7018

LUBRICATION

SYSTEM ML-R OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018

ML-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018

ML-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018

OILING SYSTEM OL-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW E7018

OL-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018

SUMP DRAINAGE SD DUMP OUT ASTM A 106 SML ER70 S2 GTAW E7018

SYSTEM

GENERAL NOTES :

1. Welding process of 1/2" to 2" dia. Pipes shall be of full GTAW for both root and fillup/final passes.2. All lines having a pressure of above 10 kg/cm2 shall be done welding of root by GTAW and fillup/final by SMAW processes.

ELECTRODE NORMAL TEST WELD TYPE OF NDT REMARKS

PROCESS PRESSURE PRESSURE TYPE ROOT DP RT

GTAW 210 kg/sq.cm 315 kg/sq.cm SW 100% 100%

GTAW 10 min. FOR BW

SMAW 5 kg/sq.cm <50 NB 100% 10%

SMAW 10 min. SW 100% FOR

SMAW 65-80 NB 100% BUTT

SMAW BW 100% WELD

SMAW 100%

SMAW 100%

GTAW 70 kg/sq.cm 105 kg/sq.cm SW 100% 100%

GTAW 10 min. FOR BW

SMAW 5 kg/sq.cm <50 NB 100% 10%



SMAW BW 100% WELD

SMAW 100%

GTAW 8 kg/sq.cm 16 kg/sq.cm BW 100% 10%

GTAW 10 min.

SMAW 5 kg/sq.cm <50 NB 100% 10%



SMAW BW 100% WELD

SMAW 100%

SMAW 5 kg/sq.cm 10 kg/sq.cm SW & 100% 10%

10 min. BW FOR BW

SMAW <50 NB 100% 10%

SMAW SW 100% FOR


SMAW BW 100% WELD

SMAW 2.5 kg/sq.cm 5 kg/sq.cm SW & YES 10%

10 min. BW FOR BW

SMAW 5 kg/sq.cm <50 NB YES 10%

SMAW 10 min. SW YES FOR

SMAW 65-100 NB YES BUTT

BW WELD

SMAW 3 kg/sq.cm 6 kg/sq.cm SW YES

SMAW 10 min. YES

SMAW 3 kg/sq.cm <50 NB YES 10%

SW FOR

65-80 NB BUTT

BW WELD

1. Welding process of 1/2" to 2" dia. Pipes shall be of full GTAW for both root and fillup/final passes.2. All lines having a pressure of above 10 kg/cm2 shall be done welding of root by GTAW and fillup/final by SMAW processes.

ECL - SURFACE COATING YARDDATE :REPORT NO. :

DAILY PROGRESS REPORT

DRG. NO. DESCRIPTION MKD. NO. QTY. REMARKS

AGENCY ECL

SL. NO.

TOTAL WT.

BLAST WT.

BLASTED ITEM NO.


UT TECHNIQUE SHEETNAME : TECH NO. :

EMP. NO. : DATE :

JOB DESCRIPTION

JOB NO. : MATERIAL 1 : MATERIAL 2 :

SEAM NO. : JOINT TYPE : BUTT / TEE

THICKNESS 1 : THICKNESS 2 : GROOVE : SINGLE / DOUBLE

WELD LENGTH : WELD REINFORCEMENT :

FLAW DETECTOR : COUPLANT :

UT TEST PARAMETERS

TRANSDUCER DETAILS CALIBERATION PARAMETERS

ANGLE 0 45 60 70 BASIC CALIBERATION BLOCK THK. / HOLE DIA :

FREQUENCY PROBE ANGLE FSH dB BEAM PATH

CRYSTAL SIZE T/4

TWIN / SINGLE T/2

CABLE TYPE 3T/4

SPECIFICATION ACCEPTANCE STANDARD :

DATA SHEET

SL. NO. SCANNING AREA X POSTION Y POSITION DEPTH BEAM PATH FSH (%) REMARKS

REMARKS

APPROVED BY

PREPARED BY

NAME SIGNATURE

psi n/mm244.341 0.266046 rate

28755

23.33333333333

IXAR3" 4" EL UNIT CHARGE / DAY

RATE 10.5 11.5 95 1000QTY 466.5 648 3 10

4898.25 7452 285 10000

27635.25

GAMMAX WORK ORDER NO. ECL/MEC/7200002143 DATED : 16/02/053" 4" EL UT DISCOUNT (5%)

RATE 9 10 70 90 0.05QTY 61515 25130 660 1100

553635 251300 46200 99000 47506.75950135

in Al piping3" 4" ellip

QTY 6000 2500 400RATE 12 13.25 125Total 72000 33125 50000Service Charge 7344 3378.75 5100 Total net ValueGrand Total 79344 36503.75 55100 170947.75GAMMAX - IXAR 5923.25RADIOGRAPHY

FF 1.44CiRHM 500 mR/Hr meterTHKHVT 1.3SFD 1Exposure Time =

E316-15 FN(MIN)=3 TO REDUCE HOT CRACKINGS P - SOLIDIFICATION CRACKING

ACTIVATED - TIG WELDING(A-TIG)CO2 LASERS - Nd-YAG LASERS50MICRON WITH 17.2MM SS PLATE

FRICTIONAL WELDINGHEAT (MAX) = 0.8MELTING POINTAL ALLOYS THK - 1.2 TO 50MM

REPAIRSMANUFACTURINOPERATIONS

749 14580

3 4 diff 2875.53195 2875.5

1 0.92 1.8

0RT RATE GAIN FOR ESSAR FROM CONVERTING 3" TO 4"lg 3" 4" rate 3 rate 4 diff 3 - 4

3195 2396.25 28755 23962.5 4792.53000 2250 27000 22500 45002000 1500 18000 15000 3000

0 0 0 00 0 0 00 0 0 00 0 0 00 0 0 00 0 0 00 0 0 0

0 2397028755

4785

MOBILISATION5000

1 TOTAL SERVICE TAX ON TOTAL5000 27635.25 2818.795

GRAND TOTAL 30454.05

TOTAL NET VALUE

TOTAL SERVICE TAX ON TOTAL997641.8 101759.5

902628.25 1099401IXAR3" 4" ellip ADD.

6000 2500 400 10000 Mobilisation10.5 11.5 95 10000 Unt Charge / day

63000 28750 38000 22040 ADD. Total + Service charge6426 2932.5 3876 Total net Value

69426 31682.5 41876 165024.5

inch

gain1.51.51.5

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