Quality Assurance of M.S. Quality Assurance of M.S. pipelinepipeline

ByBy

Manoj RaghavanManoj Raghavan

SGS India Pvt. Ltd.SGS India Pvt. Ltd.

AHMEDABAD

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QUALITY CONCEPTQUALITY

Quality is closely allied to cost and customer needs.

“Quality” may simply be defined as fitness for the purpose at lowest cost.

As per International Organization for Standardization (ISO), ‘Quality’ can be defined as the totality of feature and characteristics of a product or services that bear on its ability to satisfy stated or implied needs.

INSPECTION

“Inspection is the process of measuring the quality of a product or service in terms of established standards.”

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OBJECTIVE OF INSPECTION

Distinguishing between good and bad products,

Determining if a process is changing,

Rating product quality,

Measuring process capability,

Determining the precision of measuring instruments, and

Securing product design information.

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OUT COME OF INSPECTION

Conformance:

Conformance means judging whether the product conforms to specification. Conformance decisions are taken by trained inspectors/inspection team deputed on the job. Acceptable products/stage of work is released for dispatch/further activities.

Non-conformance:

Non-conforming products may be fit or unfit for use. Inspector/Inspecting team, on detecting a nonconforming product or stage of work, prepares a report to that effect. This is marked as “Hold” and is subjected to further investigation. Outcome of further investigation can be of the following :

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OUT COME OF INSPECTION

Waiver NC by quality department/client due to non critical matters

Repairing the item

Scrap or discard the item.

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WHEN AND WHERE TO INSPECT

Following should be decided before the inspection starts :

1. Where to inspect ?

2. When to inspect ?

3. How to inspect ?

4. How much to inspect ?

Quality Assurance Plan (QAP) is the document in which all these detail are available.

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QUALITY ASSURANCE PLAN

QAP is prepared before commencing the execution of the project

Prepared by the EPC contractor/manufacturer

Reviewed and approved by consultant/TPI

Authorized by the Client

It contains the following details:

Item and its component details

Stages of activity to be inspected and sampling criteria

Inspecting authority and type of inspection

Acceptance criteria and standard/code/spec to be followed

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QA QC OF M.S. PIPE LINE PROJECT

INSPECTION OF M.S. PIPELINE

INSPECTION OF M.S. PIPELINE

SITE CONSTRUCTION ACTIVITY’S INSPECTIONSITE CONSTRUCTION

ACTIVITY’S INSPECTION

•PUMPS•EXPANSION BELLOW•EOT CRANE•FITTINGS•FLANGES•SURGE VALVE

•PUMPS•EXPANSION BELLOW•EOT CRANE•FITTINGS•FLANGES•SURGE VALVE

• PIPE MANUFACTURING• INSIDE COATING• OUTSIDE COATING

• PIPE MANUFACTURING• INSIDE COATING• OUTSIDE COATING

•TRANSFORMERS•MOTORS•PANEL•CABLE•INSTRUMENTATIONS

•TRANSFORMERS•MOTORS•PANEL•CABLE•INSTRUMENTATIONS

PIPE LAYING AT SITE

PIPE LAYING AT SITE

PUMPING STATION

PUMPING STATION

•TRENCHING•BEDDING•PIPE STRINGING•JOINT WELDING •NDT• JOINT COATING•VALVE/AIR VENT INSTALLATION•THURST BLOCKS•ENCASINGS•HYDROTEST

•TRENCHING•BEDDING•PIPE STRINGING•JOINT WELDING •NDT• JOINT COATING•VALVE/AIR VENT INSTALLATION•THURST BLOCKS•ENCASINGS•HYDROTEST

•PUMP & MOTOR INSTALLATION •HEADER PIPE•VALVE•SUB-STATION SETUP

•PUMP & MOTOR INSTALLATION •HEADER PIPE•VALVE•SUB-STATION SETUP

PROCUREMENT INSPECTION

PROCUREMENT INSPECTION

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PROCUREMENT INSPECTION

Inspection of pipe manufacturing and coating

Raw material testing and electrode /flux testing

Welder/welding operator qualification test

Welding procedure specification and procedure qualification test

Pipe forming check, dimension check and visual check

Ultrasonic test of weld line

Bevel end check

Hydrostatic test witness

Final dimension and visual check

Marking and releasing for coating

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PROCUREMENT INSPECTION

CLIENT

TPI Ahmedabad

TPI Executing office

INSPECTION LOCATION

Insp

ection R

equ

est Flow

Rep

ort Flow

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RAW MATERIAL TESTING Raw Material : Coils - IS 10748 Plates - IS 2062 Check the Coils/ Plates

Physically for the Identification of the following details Name of the Manufacturer Thickness of the Plate IS Specification No. & Grade Heat No./ Cast No. or Coil No./Plate No. ISI Mark ( If required as per the Tender)

Review of Results of MTCs for chemical and physical properties.

Three Samples for test drawn from a lot of 500 MT in the presence of Client and tested for tensile test, bend test and chemical analysis. Sample No.1 to be tested in the Laboratory approved by Engineer- In-

charge Sample No.2 will be kept by the Dept for record. Sample No.3 will be Kept by the Contractor for Record

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INSPECTION OF WELDING

Welding Procedure Specification (WPS): A WPS is a written qualified welding procedure prepared to

provide direction for making production welds to the code requirement.

Procedure Qualification Record (PQR): A PQR is a record of the welding data used to weld a test

coupon. It also contains the test result of the test weld.

Welder Performance Qualification (WPQ): A WPQ is a document where the test result and data of the

ability of a welder/welding operator to carry out an operation skillfully and to deposit sound metal, is recorded.

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WPS

Joint detail Base material & its thickness Process / processes employed Consumables employed Positions of welding Preheat, interpass temp & preheat maintenance Post weld heat treatment Type of machines employed Welding parameters selected Method of initial & interpass cleaning Back gouging methods

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WPS

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WELD DEFECTS

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JOINT DESIGN

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JOINT DESIGN

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INSPECTION OF PIPE

Length, ovality in diameter, wall thickness checked at various locations.

Visual inspection carried on each and every pipe to check for welding defects such as porosity, pin holes, undercuts, slag, and fabrication defects such as dents, scaling, scooping etc.

Weldline is subjected to ultrasonic test which is a Non destructive test.

Every pipe is then subjected to hydrostatic test for pressure retention and leakage check.

One pipe from every 40 pipes (500 mtrs) is subjected to product test i.e. tensile test, bend test and chemical test.

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COATING INSPECTION

Upon the receipt of pipes in coating yard, the inspectors check the inspection document of the pipes.

Sand blasting is done as surface preparation prior to applying coating. Its checked with a comparator.

Outside coating: Coaltar tape; continuity of coating is checked by Holiday test and bonding by Peel of test. Thickness by Elcometer.

Inside coating: Black epoxy paint; continuity is checked by Holiday test and bonding by adhesion test. Thickness by Elcometer.

Release note issued for all accepted pipes.

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Preparation of Quality Assurance plan for construction

Review of test certificate, equipments, etc.

Physical Verification at Site w.r.t to approved drawings

Periodic quality audit of how the system is functioning

Quality records and Inspection and Test Plans.

Quality control of the material used during the construction

Calibration of equipments, measuring and testing devices against certified standard procedures.

Check for non-conformities with contract technical requirements, technical specifications or deviation from approved submittals (drawings or material), help contractor to close them and appraise the client about the deviation on immediate basis.

THIRD PARTY INSPECTION FOR QA & QC OF SITE CONSTRUCTION WORK

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CONTRACTOR’S AUDIT

REVIEW OF CONTRACTOR’S/PROJECT DOCUMENT

ONSITE INSPECTION ON DAILY BASIS AS PER APPROVED QAP/ITP/FQP

HIGHLIGHTING THE DEVIATION AND INSTRUCT FOR RECTIFICATION

RE- INSPECTION FOR DEVIATION

CLIENT’S APPROVAL FOR DEVIATION (IF ANY)

CLEARNACE OF UNIT/ITEM/PART

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INSPECTION ON PIPE LAYING

Verification of coated pipe on receipt at laying site.

Checking of route, level and dimension of the trench as per approved L-section

Sampling of bedding material and review of its test report and dimensional check of bedding.

Technical audit of individual contractors and their documents like WPS, WPQ, PQR, QAP, Welding schedule, repair procedures, NDE Procedures etc.

Conduct welder qualification test and weld joint codification.

Supervision of lowering, fit-up and welding of pipes.

Monitoring radiography test, interpretation of films and reporting the result and supervising repair and retests.

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Inspection of fixing of surge equipment, gate valves, air vent valves, miters, flow meters.

Supervision of concrete chambers, encasing and thrust blocks.

Hydrostatic test of pipeline.

Supervising backfilling and stage wise soil compaction.

Surveillance of day-to-day activities at site and review of the documents to achieve quality at site. And reporting the same on weekly basis to client.

Highlighting the quality issues to client and issuing letter to contractor if required.

Review of contractor’s documents prior to any Statutory authority’s visit.

Preparing Punch list / Check list for the completed activities .

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Supervision of construction of sump, pumping station and sub station.

Laboratory Tests on Building Materials such as Cement, Aggregate, Brick, Block, Rebar, Structural section, Wood, Tile, etc as per relevant Indian Standards.

Concrete mix design for strength, workability & durability of concrete for various requirements.

Tests to evaluate performance of Construction aids/ Chemicals such as Admixtures, Modified Mortars, Epoxies, Grouts, Sealants etc.

Tests on water for assessment of its suitability for concreting

Facilities for various Non-Destructive Test such as Rebound Hammer test, Ultrasonic Pulse Velocity tests, Core Extraction test.

Installation of pump motors, valves, instruments and header pipes.

Commissioning of pumping station.

CONSTRUCTION SUPERVISION OF PUMPING STATION

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COMMISSIONING OF THE PROJECT

Witnessing of operation of pumps on full capacity with monitoring the discharge at the far end.

Records power consumption, discharge of water and efficiency.

Checks the entire pipeline for any leakage or damage.

Checks all airvents, gate valves flow meter, zero velocity valves and all mounted instruments.

Submits following documents to client:

Approved ‘As built’ drawings

Radiography films and its reports

Release notes and stage wise certificates

Mechanical completion report.

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THANK YOU