Form: EIPL/QC/F-32, Rev.

01
ENMAX ENGINEERING (INDIA) PRIVATE.LIMITED
Survey No.15, Suraram, Hyderabad - 500 055, India.
Quality Assurance Plan for Waste Heat Boiler
Project details Inspection details Standards followed Reference Documents

Client : M/s. GODREJ INDUSTRIES LIMITED EIPL : YES ASME : N.A QAP No: EIPL/1030-01/WHB/QAP

Project : SULPHONATION PLANT (5098) CUSTOMER : N.A IBR : 1950 LATEST AMENDMENTS Rev.No : 00

Maker's No : J1030-01 IBR : YES PED: N.A Date : 08.08.2022

Drawing No : EIPL-J1030-01-001 Rev.03 Lloyd's: N.A TEMA : N.A Pages : 1 OF 5

Equipment : WASTE HEAT BOILER SI / TPI : N.A EIPL : YES

Code of Construction : IBR 1950 with Latest Ammendments

Legend
P (Performed) : Astage of Inspection in production record of examination shall be maintained EIPL : Enmax Engineering (India) Pvt.Ltd
TPI : Third Party Inspection
Inspection SI : Statutory Inspection
W (Witness) : A stage of inspection in production, which shall be notified with sufficient period to SI / TPI. Work may proceed with the
points LPT : Liquid Penetrant Test
consent of SI / TPI.Record of examination shall be maintained and made available for SI / TPI
WPS : Welding Procedure Specification
PQR : Procedure Qualification Record
H (Hold) : A stage of inspection in production beyond which work shall not proceed until the stage is signed by QC inspector / SI / TPI
WPQ : Welder's Performance Qualification
Record of Revisions QAP : Quality Assurance Plan
Rev. Date Revision details QC : Quality Control
Drg : Drawing
Mtl.Spec. : Material Specification
TC : Test Certificate
BG : Back gouging
NDE : Non Destructive Examination
Rev : Revision
I.R : Inspection Report
Code of Const : Code of Construction
Eqpt : Equipment

Prepared by Checked & Approved by Customer / SI / TPI

Engineer (QA / QC) H.O.D (QA/QC)

 Form: EIPL/QC/F-32, Rev.01
ENMAX ENGINEERING (INDIA) PRIVATE.LIMITED
Survey No.15, Suraram, Hyderabad - 500 055, India.
Quality Assurance Plan for Waste Heat Boiler
Client : M/s. GODREJ INDUSTRIES LIMITED Equipment :Waste Heat Boiler Pages : 2 OF 5
Extent of Acceptance Format of Inspection by
S.No QC Activity Characeristics Type of inspection Ref.doc Remarks
Test Standard Record EIPL IBR Client
1.0 General Procedure and Documentation

Stress
1.1 Design Calculation & Drawing Code Compliance Review 100% I.B.R I.B.R P, H A R
Calculations

1.2 QAP Inspection & Quality Records Review 100% Applicable Project ------ Applicable QAP P, H R R

Applicable WPS,
1.3 WPS, PQR Code Requirement Review of WPS & PQR 100% ASME Sec IX ASME Sec IX P, H R R
PQR

1.4 WPQ Code Requirement Review of WPQ 100% ASME Sec IX ASME Sec IX WPQ P, H R R

Applicable Weld
1.5 Weld Map Drawing Requirement Review of weld map 100% Drawing As per WPS, PQR P, H R R
map
2.0 Raw Material Inspection

Surface, dimensions, mechanical & chemical

Material Identification for shell
properties & Stamping of Job No, Part No, Visual, Measurement, Part List, Material * PRESURE
2.1 plates, tube sheets.Tubes, 100% Drawing EIPL/QC/F-12 P,H H R
Specification, T.C Verification Specificaion PARTS ONLLY
Nozzle Pipes,Flanges,Man Hole
Heat No, Plate No.

3.0 Pre Fabrication

3.1 Marking & Cutting of material Dimension's Measurement 100% Drawing Drawing EIPL/QC/F-12 P,H R R

Tube sheet dimensions Measurement

inspection Tube Sheet Holes pitch of tube hole Measurement

3.2 100% Drawing Drawing EIPL/QC/F-15 P,H R R
Marking & After Drilling size of tube hole,Number of Holes Measurement

finish of tube hole visual

Circumference, Diameter Measurement

Ovality Measurement

Shell length Measurement

Fit-up of Shell L-Seam with Drawing, EIPL/QC/F-13
4.1 Alignment Measurement 100% Drawing P, H H R
production test coupon IBR EIPL/QC/F-23
Measurement With
Profile
template
Root gap Measurement
Tack weld soundness PT
 Form: EIPL/QC/F-32, Rev.01
ENMAX ENGINEERING (INDIA) PRIVATE.LIMITED
Survey No.15, Suraram, Hyderabad - 500 055, India.
Quality Assurance Plan for Waste Heat Boiler
Client : M/s. GODREJ INDUSTRIES LIMITED Equipment :Waste Heat Boiler Pages : 3 OF 5
Extent of Acceptance Format of Inspection by
S.No QC Activity Characeristics Type of inspection Ref.doc Remarks
Test Standard Record EIPL IBR Client
4.0 Fabrication Assembly

Weld size & finish Measurement Drawing,

100% Drawing EIPL/QC/F-26 P,H R
4.2 Welding of L-Seam Weld soundness RT IBR R

Production Test Coupon Mechanical Tests 100% I.B.R I.B.R Test Report P,H H

Circumference, Diameter Measurement

Ovality Measurement

Fit-up of Shell to Shell Shell length Measurement EIPL/QC/F-13

4.3 100% Drawing Drawing,IBR P,H H R
C-Seam EIPL/QC/F-23
Alignment Measurement

Root gap Measurement

Tack weld soundness P.T

Weld size & finish Measurement

4.4 Welding of C-Seam 100% Drawing Drawing, EIPL/QC/F-26 P,H R R
Weld soundness RT

Orientation Measurement
Opening Markings on Shell for
4.5 all Nozzles, Manhole and Elevation Measurement 100% Drawing Drawing EIPL/QC/F-14 P, H R R
Mudholes
Size of opening & quantity Measurement

Orientation ,Linearity Measurement, Visual

Alignment & Projection Measurement

4.7 Fit-up of shell to tube sheets 100% Drawing Drawing EIPL/QC/F-22 P, H R R
Root Gap , Bevel Angle Measurement

Tack weld soundness P.T

Welding inspection after Completion of weld Visual

4.8 Welding of shell to tube sheets 100% Drawing Drawing EIPL/QC/F-22 P, H R R
BGDP P.T

Orientation,Water Level Visuaal

Fit up of nozzles, man hole and Projection Measurement
4.9 other branch connections to 100% Drawing Drawing EIPL/QC/F-14 P, H H R
shell Alignment & squareness Measurement

Root gap & weld preparation Measurement

 Form: EIPL/QC/F-32, Rev.01
ENMAX ENGINEERING (INDIA) PRIVATE.LIMITED
Survey No.15, Suraram, Hyderabad - 500 055, India.
Quality Assurance Plan for Waste Heat Boiler
Client : M/s. GODREJ INDUSTRIES LIMITED Equipment :Waste Heat Boiler Pages : 4 OF 5

Extent of Acceptance Format of Inspection by

S.No QC Activity Characeristics Type of inspection Ref.doc Remarks
Test Standard Record EIPL IBR Client
Visuval Visuval
welding of nozzles, man hole weld size Visuval
4.9 and other branch connections 100% Drawing Drawing P, H H R
to shell weld finish Visuval

weld soundness PT

Orientation Measurement

Internal sub assemblies and Set up & Over all dimensions Measurement
4.10 100% Drawing Drawing ---- P, H R R
structural attachments
weld completeness Visual
Weld size & finish Measurement
Orientation Measurement
Set up & Over all dimensions Measurement
4.11 Saddles Fit UP & welding Alignment , squareness Measurement 100% Drawing Drawing EIPL/QC/F-22 P, H R R

Weld size & finish Visual & Measurement

Orientation Measurement
Inside Visual Inspection Before All Internal Attachment Measurement
4.12 100% Drawing Drawing --- P, H - R
Inserting Boiler tubes Alignment , squareness Measurement
Weld size & finish Measurement
Alingment Measurement
Tubes assembly with
Joint Configuration Measurement
4.13 Tubesheet Welding and 100% Drawing Drawing EIPL/QC/F-22 P,H R R
Dimensions (Projection of Tubes) Measurement
expansion.
Light Expansion 2 to 5% Measurement
Weld Size & Finish Visual & Measurement EIPL/QC/F-06
4.14 Welding of tubes 100% Drawing Drawing P,H -- R
Weld soundness PT EIPL/QC/F-23
Pneumatic test for R.F Pad & Visual inspection &
Air Leak tightness
4.15 Shell Pressure gauge 100% Drawing Drawing EIPL/QC/F-27 P, H -- R
with Soap solution apply
(0.5 Kg/Cm²(g)) monitoring

5.0 Brought Out Items

Specification Visual & TC Parts list /

5.1 Fasteners 100% Mtl.Spec TC / Lab report P, H - -
Dimensions Measurement Drawing

Specification Visual & TC Parts list /

5.2 Gaskets 100% Mtl.Spec -------- P, H - -
Dimensions Measurement Drawing
 Form: EIPL/QC/F-32, Rev.01
ENMAX ENGINEERING (INDIA) PRIVATE.LIMITED
Survey No.15, Suraram, Hyderabad - 500 055, India.
Quality Assurance Plan for Waste Heat Boiler
Client : M/s. GODREJ INDUSTRIES LIMITED Equipment :Waste Heat Boiler Pages : 5 OF 5
Extent of Acceptance Format of Inspection by
S.No QC Activity Characeristics Type of inspection Ref.doc Remarks
Test Standard Record EIPL IBR Client
6.0 Final Dimensions,Hydro Test, Pneumatic Test, Surface Preparation and Painting

Completeness of workmanship & welding Review & Visual

6.1 Final Dimensions 100% Drawing Drawing EIPL/QC/F-25 P, H H W
Over all dimensions of Equipment Measurement
NDE Review
Visual inspection &
6.2 Hydrostatic test Leak Tightness Pressure gauge 100% Drawing Drawing EIPL/QC/F-28 P, H H W
monitoring

6.3 External surface preparation Surface roughness Visual 100% Drawing Drawing EIPL/QC/F-30 P, H - R

Drawing/ Painting Drawing/ Painting

6.4 Painting of External Paint DFT in Microns Measurement 100% EIPL/QC/F-30 P, H - R
Spec. Spec.
7.0 Documentation and Dispatch
stamping Visual Rub-off &
Stamping & Documentation Code &
7.1 100% ------ All Internal P, H R R
Review Verification of documents Visual As per QAP
Reports
7.2 Issue of Release note Issue of release note Visual 100% Drawing ------ Release Note P, H H R
Following Documents shall be prepared and submitted.
a) Quality assurance plan
b) Material Inspection reports
c) Materials test certificates
d)Stage wise Inspection reports
e) Weld Map
f) Radiaography plan
g) NDE Reports
h) Final dimensional report
i) Final Hydrostatic
j) Asbuilt drawing
k) Rub off Final Stampings