Date : 23/1/2010

QUALITY CONTROL PLAN

Sheet: 1 OF 16

DOC. NO : QCP 03/034-08

Client : ASORC
JOB NO : 065/09
Project No :441-A-00-06-330
TYPE OF UINT : WATER TUBE BOILER(D.TYPE)
TAG NO : 30 - X - 331 A
MANF. SERIAL NO. : 1652
INSPECTION AUTHORITY : ONEBEACON AMERICA INSURANCE CO.
Code : NBIC-PART 3 2007-ADDENDA 2008
DRAWING No :3239

INSPECTOR SYMBOL TYPE OF TEST OR WORK SYMBOL Q. C. PROC. REF.

SITE PRODUCTION ENG. 1 VISUAL EXAM. VT EMC-VT-01 REV 0

SITE QC INSPECTOR 2 RADIOGRAPHIC EXAM. RT EMC-RT-01 REV 0

AUTHORIZED INSPECTOR 3 ULTRASONIC EXAM. UT EMC-UT-01 REV 0

CLIENT REP. 4 MAGNETIC PARTICLE EXAM. MT EMC-MT-01 REV 0

HOLD POINT H DYE PENETRANT EXAM. PT EMC-PT-01 REV 0

WITNESS POINT W HYDROSTATIC TEST HT EMC-HYD-P-1 REV 0

REPORT REVIEW R POSTWELD HEATREATMENT PWHT EMC-HT-P-01 REV 0

SPOT WITNESS S/W WORK PLAN WP -------------------

Rev. Date Description Prepared Approved Client Rep. Reviewed by

0 5 -7- 09 Original Issue QC INSPECTOR QC MANAGER Authorized Inspector

ENG/ ABD ELWAHAB

1 25-8-2009 Revised Issue FARAG

2 23-1-2010 Revised Issue

 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
2
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
APPROVAL R
1
Review of original drawing &calculation. original drawings H R R
2
Review of quality control plan H R R
3
Review of WPSs & PQRs ASME IX H R R
4
Review of WPQs ASME IX H R R
5 Review of procedures for cutting, lifting & H H R R
handling
6
Review of Painting Procedure H R R
7
Review of Cuality Control Procedures H R R
8
Review of Work Plan H R R
9
Review of Sequence Plan for Dismantling H H R R
MATERIAL
10
Review of refractory material certificates Material certificate H H R R
11 ASORC
Review of Painting Data Sheet Secification
H H R R
12
Review of insulation material certificates Material certificate H H R R
13 Review of fabrication Material certificate H H R R
material(piping,tubes,etc) certificates.
DISMANTLING
14 Dismantling external attachment ( valves, WP W BY ASORC
instrumentation sets ,) .
15
Removing of out casing . WP H H W
16
Removing of refractory WP H H W
17
Fixing the drums by temporary support . WP H H W
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
3
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
18
Cutting the risers tubes from the front wall WP H H W
19
Cutting the risers tubes from the rear wall WP H H W
20
Cutting the feeder tubes from the front wall WP H H W
21
Cutting the feeder tubes from the rear wall WP H H W
22
lifting two header from the front wall WP H H W
23
lifting two header from the rear wall WP H H W
24
Dismantling of the super heater WP H H W
25 Cutting D shape tubes from the lower WP H H W
drum .
26 Cutting D shape tubes from the upper WP H H W
drum
27
Cutting bank tubes from the lower drum WP H H W
28
Cutting bank tubes from the upper drum WP H H W
Removing the tube ends from the both
29 WP H H W
Drums
Check surface conditions for the drum ASME V
30 ARTICLE 6 VT & PT & MT H H H H
holes
FABRICATION
SUPER HEATER
31 QC Surveillance of Material Verification Matrial Certificate H H H
FIRST MAIN HYDRANT 8
Approved
32 Cutting pipe ,plate & surface preparation . drawings VT & DT H H W
Approved
33 Fit up tees to pipes. drawings& VT & DT H H H H
WPS
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
4
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
34 Welding PW 51 VT H H W
35 Complete Weld ASME V VT & RT H H H H
36 Repair for Welding ( if any ) PW 51 VT H H W
37 Re RT for Repairing ASME V RT H H H H
Approved
38 Fit up both pipes to middle plate . drawings& VT & DT H H H H
WPS

39 Welding PW 51 VT H H W
40 Complete Weld ASME V VT & PT H H H H
41 Repair for Welding ( if any ) PW 51 VT H H W
Approved
42 Marking holes and orientation check. drawings& VT & DT H H H H
ASME V
43 Opening holes ARTICLE 6 VT & PT H H W
Approved
44 Fit up end plates to pipes . drawings& VT & DT H H H
WPS

45 Welding PW 51 VT H H W
46 Complete Weld ASME V VT & PT H H H H
47 Repair for Welding ( if any ) PW 51 VT H H W
48 SECOND MAIN HYDRANT 8
Approved
49 Cutting pipe ,plate & surface preparation . drawings VT & DT H H W
Approved
50 Fit up tees to pipes. drawings& VT & DT H H H H
WPS

51 Welding PW 51 VT H H W
52 Complete Weld ASME V VT & RT H H H H
53 Repair for Welding ( if any ) PW 51 VT H H W
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
5
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
54 Re RT for Repairing ASME V RT H H H H
Approved
55 Marking holes and orientation check. drawings& VT & DT H H H H
ASME V
56 Opening holes ARTICLE 6 VT & PT H H W
Approved
57 Fit up end plates to pipes . drawings& VT & DT H H H H
WPS
ASME V
58 Welding ARTICLE 6 VT H H W
59 Complete Weld ASME V VT & PT H H H H
60 Repair for Welding ( if any ) PW 51 VT H H W

SUPER HEATER ASSEMBLY

Approved
61 Assembly both headers and fixation drawings& VT & DT H H H
Approved
62 Prepared sample &templates drawings VT & DT H H H W
VT & MT & DT & Ball Test
63 Bending Tests QC Procedure
& Thick. Measurements
H H H H
Approved
64 Bending the tubes drawings VT & DT H H W
VT & MT & DT & Ball Test
65 Bending Tests QC Procedure & Thick. Measurements & H H H H
Spong Check
Fit up the inside row of the tubes to both Approved
66 drawings& VT & DT H H H H
headers WPS

67 Welding PW 51 VT H H W
68 Complete Weld ASME V VT & PT H H H H
69 Repair for Welding ( if any ) PW 51 VT H H W

70
Fit up the middle row of the tubes to both Approved
drawings& VT & DT H H
headers WPS
ASME V
71 Welding ARTICLE 6 VT H H W
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
6
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
72 Complete Weld ASME V VT & PT H H H H
73 Repair for Welding ( if any ) PW 51 VT H H W

74
Fit up the out side row of the tubes to both Approved
drawings& VT & DT H H
headers WPS

75 Welding PW 51 VT H H W
76 Complete Weld ASME V VT & PT H H H H
77 Repair for Welding ( if any ) PW 51 VT H H W
Approved
78 Fit up vents to pipes . drawings& VT & DT H H H H
WPS s
ASME V
79 Welding ARTICLE 6 VT H H W
80 Complete Weld ASME V VT & PT H H H H
81 Repair for Welding ( if any ) PW 51 VT H H W
Approved
82 Fit up drains to pipes . drawings& VT & DT H H H H
WPS

83 Welding PW 51 VT H H W
84 Complete Weld ASME V VT & PT H H H H
85 Repair for Welding ( if any ) PW 51 VT H H W
Approved
86 Fit up nozzle neck to flanges. drawings& VT & DT H H H H
WP

87 Welding PW 51 VT H H W
88 Complete Weld ASME V VT & RT H H H H
89 Repair for Welding ( if any ) PW 51 VT H H W
90 Re RT for Repairing ASME V RT H H H H
Approved
91 Fit up nozzle to headers. drawings& VT & DT H H H H
WPS
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
7
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
92 Welding PW 51 VT H H W
93 Complete Weld ASME V VT & PT H H H H
94 Repair for Welding ( if any ) PW 51 VT H H W
Approved
95 Final dimensional check drawings DT H H H H
Approved VT
96 Final visual check drawings H H H H
97 Heat treatment (annealing) Chart DATA SHEET VT& hardness test H H R H
98 Hydro test PG 99 VT H H H H
MANUFACTURER
99 Sandblasting and Painting SPECIFICATION VT & DFT Measurment H H H
100 Documentation review. H H R R
101 FRONT & REAR HEADERS
102 QC Surveillance of Material Verification Matrial Certificate H H H
103 FRONT SIDE HEADER
104 UPPER HEADER
Approved
105 Cutting pipe ,plate & surface preparation . drawings VT & DT H H W
Approved
106 Marking holes and orientation check. drawings VT & DT H H H H
Approved
107 Opening holes . drawings VT & DT H H W
Approved
108 Fit up end plates to header. drawings& VT & DT H H H H
WPS

109 Welding PW 51 VT H H W
110 Complete Weld ASME V VT & PT H H H H
111 Repair for Welding ( if any ) PW 51 VT H H W
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
8
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
Approved
112 Fit up vents to header. drawings& VT & DT H H H W
WPS

113 Welding PW 51 VT H H W
114 Complete Weld ASME V VT & PT H H H H
115 Repair for Welding ( if any ) PW 51 VT H H W

LOWER HEADER
Approved
116 Cutting pipe ,plate & surface preparation . drawings VT & DT H H W
Approved
117 Marking holes and orientation check.` drawings VT & DT H H H H
Approved
118 Opening holes . drawings VT & DT H H W
Approved
119 Fit up end plates to header . drawings& VT & DT H H H
WPS

120 Welding PW 51 VT H H W
121 Complete Weld ASME V VT & PT H H H H
122 Repair for Welding ( if any ) PW 51 VT H H W
Approved
123 Fit up drain and nozzles to header . drawings& VT & DT H H H
WPS

124 Welding PW 51 VT H H W
125 Complete Weld ASME V VT & PT H H H H
126 Repair for Welding ( if any ) PW 51 VT H H W

FRONT WALL ASSEMBLY

Approved
127 Swaging tubes drawings VT & DT H H W
128 Heat treatment (annealing) Chart DATA SHEET VT & Hardness T H H R H
Adjuset both headers by temporary Approved
129 drawings VT & DT H H H
supports
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
9
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
Approved
130 Fit up the tubes (21 tubes)to both headers . drawings& VT & DT H H H H
WPS

131 Welding PW 51 VT H H W
132 Complete Weld ASME V VT & PT H H H H
133 Repair for Welding ( if any ) PW 51 VT H H W
Approved
134 Fit up tube to tube drawings& VT &DT H H H
WPS

135 Welding PW 51 VT H H W
136 Complete Weld ASME V VT & PT H H H H
137 Repair for Welding ( if any ) PW 51 VT H H W

REAR SIDE HEADER

UPPER HEADER
Approved
138 Cutting pipe ,plate & surface preparation . drawings VT & DT H H W
Approved
139 Marking holes and orientation check. drawings VT & DT H H H H
Approved
140 Opening holes . drawings VT & DT H H W
Approved
141 Fit up end plates to header. drawings& VT & DT H H H H
WPS

142 Welding PW 51 VT H H W
143 Complete Weld ASME V VT & PT H H H H
144 Repair for Welding ( if any ) PW 51 VT H H W
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
10
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
Approved
drawings&
145 Fit up vents to header. WPS VT & DT H H H W

146 Welding PW 51 VT H H W
147 Complete Weld ASME V VT & PT H H H H
148 Repair for Welding ( if any ) PW 51 VT H H W
LOWER HEADER
Approved
149 Cutting pipe ,plate & surface preparation . drawings VT & DT H H W
Approved
150 Marking holes and orientation check.` drawings VT & DT H H H H
Approved
151 Opening holes . drawings VT & DT H H W
Approved
152 Fit up end plates to header . drawings& VT & DT H H H
WPS

153 Welding PW 51 VT H H W
154 Complete Weld ASME V VT & PT H H H H
155 Repair for Welding ( if any ) PW 51 VT H H W
Approved
156 Fit up drain and nozzles to header . drawings& VT & DT H H H
WPS

157 Welding PW 51 VT H H W
158 Complete Weld ASME V VT & PT H H H H
159 Repair for Welding ( if any ) PW 51 VT H H W

REAR WALL ASSEMBLY

Approved
160 Swaging tubes drawings VT & DT H H W
161 Heat treatment (annealing) Chart DATA SHEET VT & Hardness T H H R H
Adjuset both headers by temporary Approved
162 drawings VT & DT H H H
supports
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
11
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
Approved
163 Fit up the tubes (33 tube)to both headers drawings& VT &DT H H H H
WPS

164 Welding PW 51 VT H H W
165 Complete Weld ASME V VT & PT H H H H
167 Repair for Welding ( if any ) PW 51 VT H H W
Approved
168 Fit up tube to tube drawings& VT &DT H H H
WPS

169 Welding PW 51 VT H H W
170 Complete Weld ASME V VT & PT H H H H
171 Repair for Welding ( if any ) PW 51 VT H H W
Prepare Ligth opining Position in rear wall Approved
172 drawings VT H H H W
tube
Approved
173 Fit up spool pipe with rear wall tube drawings VT H H H H
174 Welding PW 51 VT H H W
175 Complete Weld ASME V VT & PT H H H H
176 Repair for Welding ( if any ) PW 51 VT H H W
177 D - SHAPE TUBES
178 QC Surveillance of Material Verification Matrial Certificate H H H
Approved
179 Cutting tube &surface preparation. drawings VT & DT H H H
Approved VT & DT & Ball Test &
180 Prepared Bending sample & template. drawings Thickness Measurements
H H H H
Approved
181 Bending tubes. drawings VT & DT H H W
VT & DT & Ball Test &
182 Bending Test QC Porcedure Spong Check & Thickness H H H
Measurements
Approved
183 Swaging. drawings VT & DT H H H H
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
12
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
VT& hardness test
184 Heat treatment (annealing) Chart DATA SHEET H H R H
Approved
185 Fit up every eight tubes together. drawings& VT & DT H H
WPS

186 Welding PW 51 VT H H W
187 Complete Weld ASME V VT & PT H H H
188 Repair for Welding ( if any ) PW 51 VT H H W
Prepare Ligth opining Position in rear wall Approved
189 drawings VT H H W
tube
Approved
190 Fit up spool pipe with D shapl tube drawings VT H H H W
191 Welding PW 51 VT H H W
192 Complete Weld ASME V VT & PT H H H H
193 Repair for Welding ( if any ) PW 51 VT H H W
194 QC Surveillance of Material Verification Matrial Certificate H H H
Approved
195 Cutting tube &surface preparation. drawings VT & DT H H H
Prepared Bending sample & template for Approved VT & DT & Ball Test &
196 drawings Thickness Measurements
H H H H
every row.
Approved
197 Bending tubes. drawings VT & DT H H W
VT & DT & Ball Test &
198 Bending Test QC Porcedure Spong Check & Thickness H H H
Measurements
Approved
199 Swaging. drawings VT & DT H H H
VT& hardness test
200 Heat treatment (annealing) Chart DATA SHEET H H R H
Approved
201 Prepare Ligth Position in D tube drawings
Approved
202 Fit up spool pipe with D tube drawings

203 Welding PW 51 VT H H W
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
13
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
204 Complete Weld ASME V VT & PT H H H H
205 Repair for Welding ( if any ) PW 51 VT H H W

RISER TUBES
206 QC Surveillance of Material Verification Matrial Certificate H H H
Approved
207 Cutting tube &surface preparation. drawings VT & DT H H H
Prepared Bending sample & template for Approved VT & DT & Ball Test &
208 drawings Thickness Measurements
H H H H
every row.
Approved
209 Bending tubes. drawings VT & DT H H W
VT & DT & Ball Test &
210 Bending Test QC Porcedure Spong Check & Thickness H H H
Measurements
Approved
211 Swaging for one side (the header inlet ). drawings VT & DT H H H
VT& hardness test
212 Heat treatment (annealing) Chart DATA SHEET H H R H

FEEDER TUBES
213 QC Surveillance of Material Verification Matrial Certificate H H H
Approved
214 Cutting tube &surface preparation. drawings VT & DT H H H
Prepared Bending sample & template for Approved VT & DT & Ball Test &
215 drawings Thickness Measurements
H H H H
every row.
Approved
216 Bending tubes. drawings VT & DT H H W
VT & DT & Ball Test &
217 Bending Test QC Porcedure Spong Check & Thickness H H H
Measurements
Approved
218 Swaging for both sides. drawings VT & DT H H H
VT& hardness test
219 Heat treatment (annealing) Chart DATA SHEET H H R H

ASSEMBLY
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
14
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
BANK TUBES
Approved
220 Re-Adjust the Drums Temperary Supports drawings& VT & DT H H H
Approved
Assembly each bank tube to upper and drawings & and
222 Approved VT & DT H H W
lower drum . procedure
Approved
223 Adjusting the tubes on both drums. drawings& VT & DT H H H
Approved
224 Expanding and Flaring . drawings& VT & DT H H H
Approved
225 Fit up tube to tube from item no. 6 drawings& VT & DT H H W
WPS

226 Welding PW 51 VT H H W
227 Complete Weld ASME V VT & PT H H H
228 Repair for Welding ( if any ) PW 51 VT H H W
Approved
228 Fit up tube to tube from item no. 7 drawings& VT & DT H H W
WPS
ASME V
229 Welding ARTICLE 6 VT H H W
230 Complete Weld ASME V VT & PT H H H
231 Repair for Welding ( if any ) PW 51 VT H H W
Approved
232 Prepare Soot blower Position in bank tube drawings VT H H W
Approved
233 Fit up spool pipe with bank tube drawings VT H H H W
234 Welding PW 51 VT H H W
235 Complete Weld ASME V VT & PT H H H
236 Repair for Welding ( if any ) PW 51 VT H H W

D - SHAPE TUBES
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
15
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
Approved
237 Assembly D shape tubes to upper drum . drawings& VT & DT H H W
Approved
238 Assembly D shape tubes to lower drum drawings& VT & DT H H W
Approved
239 Adjusting the tubes on both drums. drawings& VT & DT H H H
Approved
240 Expanding and Flaring . drawings& VT & DT H H W
Fit up every 8 tubes to 8 tubes in Approved
241 drawings& VT & DT H H W
sequence . WPS
ASME V
242 Welding ARTICLE 6 VT H H W
243 Complete Weld ASME V VT & PT H H H
244 Repair for Welding ( if any ) PW 51 VT H H W

FEEDER & RISER TUBES

Assembly and Adjust four tubes in four Approved
245 drawings VT & DT H H W
corners in the feeder and riser tubes
Assembly riser tubes to upper drum with Approved
246 drawings VT & DT H H W
front and rear headers one by one.
Approved
247 Expanding and Flaring in drum side . drawings VT & DT H H W
Welding for front and rear headers side ASME V
248 ARTICLE 6 VT H H W
one by one
249 Complete Weld ASME V VT & PT H H H
250 Repair for Welding ( if any ) PW 51 VT H H W
Assembly feeder tubes to lower drum with Approved
251 drawings VT & DT H H W
front and rear headers one by one.
Approved
252 Expanding and Flaring in lower drum side drawings VT & DT H H W
Welding for front and rear headers side ASME V
253 ARTICLE 6 VT H H W
one by one
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
16
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
254 Complete Weld ASME V VT & PT H H H
255 Repair for Welding ( if any ) PW 51 VT H H W
256 D - TUBE & FRON REAR WALL TUBES
Welding for front and rear wall tubes with ASME V
257 ARTICLE 6 VT H H W
the D - tube
258 Complete Weld ASME V VT & PT H H H H
259 Repair for Welding ( if any ) PW 51 VT H H W
DESUPERHEATER

DESUPERHEATER FABRICATION

260 QC Surveillance of Material Verification Matrial Certificate H H H

FIRST HEADER FABRICATION
Approved
261 Cutting pipe & surface preparation. drawings VT & DT H H W
Approved
262 Cutting spool Pipes & surface preparation drawings VT & DT H H W
Approved
263 Marking holes and orientation check. drawings VT & DT H H H H
Approved
264 Opening holes . drawings VT & DT H H W
Approved
265 Swaging tubes from both sides. drawings VT & DT H H W
VT& hardness test
266 Heat treatment (annealing) Chart DATA SHEET H H R W
Approved
267 Fit up elbows to pipes . drawings& VT & DT H H H
WPS

268 Welding PW 51 VT H H W
269 Complete Weld ASME V VT & RT H H H H
270 Repair for Welding ( if any ) PW 51 VT H H W
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
17
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
271 Re RT for Repairing ASME V RT H H H H
Approved
272 Fit up elbows to header . drawings& VT & DT H H H
WPS

273 Welding PW 51 VT H H W
274 Complete Weld ASME V VT & PT H H H H
275 Repair for Welding ( if any ) PW 51 VT H H W
276 SECOND HEADER FABRICATION W
Approved
277 Cutting pipe & surface preparation . drawings VT & DT H H W
Approved
278 Cutting spool pipes & surface preparation drawings VT & DT H H W
Approved
279 Marking holes and orientation check. drawings VT & DT H H H W
Approved
280 Open holes . drawings VT & DT H H H
Approved
281 Swaging tubes from both sides. drawings VT & DT H H W
VT& hardness test
282 Heat treatment (annealing) Chart DATA SHEET H H R W
Approved
283 Fit up elbows to pipes . drawings& VT & DT H H H
WPS

284 Welding PW 51 VT H H W
285 Complete Weld ASME V VT & RT H H H H
286 Repair for Welding ( if any ) PW 51 VT H H W
287 Re RT for Repairing ASME V RT H H H H
Approved
288 Fit up elbows to header . drawings& VT & DT H H H
WPS

289 Welding PW 51 VT H H W
290 Complete Weld ASME V VT & PT H H H H
 Date : 23/1/ 2010
QUALITY CONTROL PLAN Sheet :
Revision :
18
OF 16
1

Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
291 Repair for Welding ( if any ) PW 51 VT H H W

HEADERS FABRICATION FINAL

ASSEMBLY
Inter the first header and second header Approved
292 drawings VT & DT H H W
in the lower drum
Approved
293 Fit up pipe spools to elbows. drawings& VT & DT H H H
WPS

294 Welding PW 51 VT H H W
295 Complete Weld ASME V VT & RT H H H H
296 Repair for Welding ( if any ) PW 51 VT H H W
297 Re RT for Repairing ASME V RT H H H H
Approved
298 Final dimensional check drawings DT H H H H
Approved VT
299 Final visual check drawings H H H H
Fit-up Piping from S.H to De-super heater Approved
300 drawings VT & DT H H H
inlet.
Welding the both inlet and outlet De- ASME V
301 ARTICLE 6 VT & PT H H H
super heater
302 Welding PW 51 VT H H W
303 Complete Weld ASME V VT & RT H H H H
304 Repair for Welding ( if any ) PW 51 VT H H W
305 Re RT for Repairing ASME V RT H H H H
VT
306 Hydro test PG 99 H H H H
AIR DUCTS
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Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
A-DUCT FABRICATION

307 QC Surveillance of Material Verification Matrial Certificate H H H

Cutting plates and steel member & surface Approved
308 drawings VT & DT H H W
preparation.
Approved
309 Opening connecting flange holes . drawings VT & DT H H W
Approved
310 Fit up steel member and flange. drawings & WPS VT & DT H H W
311 Complete weld WPS VT & DT H H W
312 Sand blasting and painting CLIENT SPECS. VT & DT H H H
GAS DUCTS

G-DUCT FABRICATION

313 QC Surveillance of Material Verification Matrial Certificate H H H

Cutting plates and steel member & surface Approved
314 drawings VT & DT H H W
preparation.
Approved
315 Opening connecting flange holes . drawings VT & DT H H W
Approved
316 Fit up steel member and flange. drawings & WPS VT & DT H H W
317 Complete weld WPS VT & DT H H W

318 Sand blasting and painting CLIENT SPECS. VT & DT H H H

DRUM internal
Approved
319 Check drum internal drawings VT H H H H
320 Repair defect if any WPS VT H H H H
EXTERNAL SOOT BLOWERS PIPES
Approved
321 Cutting pipes & surface preparation. drawings VT & DT H H
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Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
322
Assembly base plates for soot blowers on Approved
drawings& VT & DT H H
bank tube WPS

323 Welding PW 51 VT H H W
324 Complete Weld ASME V VT & PT H H H H
325 Repair for Welding ( if any ) PW 51 VT H H W
Approved
326 Fit up pipe to base plate drawings& VT & DT H H
WPS

327 Welding PW 51 VT H H W
328 Complete Weld ASME V VT & PT H H H H
329 Repair for Welding ( if any ) PW 51 VT H H W
Approved
330 Fit up pipes to flanges drawings& VT & DT H H
WPS

331 Welding PW 51 VT H H W
332 Complete Weld ASME V VT & PT H H H H
333 Repair for Welding ( if any ) PW 51 VT H H W
WIND BOX SUPPORT BOX Approved
drawings&
FABRICATION WPS

334 Welding PW 51 VT H H W
335 Complete Weld ASME V VT & PT H H H
336 Repair for Welding ( if any ) PW 51 VT H H W
Approved
337 Refractory casting drawings&

338 CASING & REFRACTORY WORKS

339 QC Surveillance of Material Verification Matrial Certificate H H H
Cutting plates and steel member & surface Approved
340 drawings VT & DT H H W
preparation.
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Revision :
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Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
341 Complete weld WPS VT & DT H H W

PIPING FABRICATION
From upper drum to Superheater
From superheater to desuperheater
From desuperheater to Main header
342 QC Surveillance of Material Verification Matrial Certificate H H H
Approved
343 Cutting pipes & surface preparation. drawings VT & DT H H W
Approved
344 Fit up pipe to pipe & flanges and elbows drawings & WPS

345 Welding PW 51 VT H H W
346 Complete Weld ASME V VT & RT H H H H
347 Repair for Welding ( if any ) PW 51 VT H H W
348 Re RT for Repairing ASME V RT H H H H

ISULATION WORKS
Prepare Insulation Clips and Steel Approved
349 drawings VT & DT H H W
member for fram.
350 Complete weld WPS VT & DT H H W
FINAL INSPECTION
Approved
351 Final dimensional check drawings DT H H H H
Approved VT
352 Final visual check drawings H H H H
VT
353 Hydro test . PG 99 H H H H

354 Sand blasting & painting CLIENT SPEC. VT & DFT H H H

QC Surveillance of Material Verification for
354 Matrial Certificate H H H
Insulation and Refractory works
 Date : 23/1/ 2010
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Revision :
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Client: ASORC Project: REVAMPING Of TWO BOILERS FOR ASORC Tag No : 30-X-331A Item: WATER TUBE BOILER(D.TYPE)
Acceptance Remarks Or Non
S. No. Process Description
Criteria Type 1 Sign Date 2 Sign Date 3 Sign Date 4 Sign Date Conformance
Approved
355 Boiler refractory casting . drawings VT H H H

356 Complete weld WPS VT & DT H H W

Refractory and casing work for burner, VT
357 W.P H H H
man holes and sight glass
VT
358 Smoke test W.P H H H
359 Boiler insulation work W.P VT H H H
360 Boiler icon plates. W.P VT H H H
361 Boiler dry out . W.P VT H H H
362 Boiler commissioning & start up . W.P VT H H H
VT
363 Review name plate with NB NB H H H H
VT
364 Fix name plate H H H H
ASME VT
365 Stamping R Symbol Stamp CODE
H H H H
366 Documentation review. H H R R