Quality Assurance of M.S.

pipeline
By
Manoj Raghavan
SGS India Pvt. Ltd.

AHMEDABAD
 QUALITY CONCEPT
QUALITY
 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
INSPECTION OFOF
M.S.
M.S. PIPELINE
PIPELINE

PROCUREMENT
PROCUREMENT SITE
SITECONSTRUCTION
CONSTRUCTION
INSPECTION
INSPECTION ACTIVITY’S
ACTIVITY’SINSPECTION
INSPECTION

•PUMPS
•PUMPS •TRANSFORMERS
•TRANSFORMERS PIPE
PIPELAYING
LAYINGAT
AT PUMPING
PUMPING
•EXPANSION
•EXPANSION •MOTORS
•MOTORS
• •PIPE SITE
SITE STATION
STATION
PIPE BELLOW
BELLOW •PANEL
•PANEL
MANUFACTURING
MANUFACTURING •EOT
•EOTCRANE
CRANE •CABLE
•CABLE
• •INSIDE
INSIDECOATING
COATING •FITTINGS
•FITTINGS
• •OUTSIDE •INSTRUMENTATI
•INSTRUMENTATI
OUTSIDE •FLANGES
•FLANGES ONS
ONS
COATING
COATING •SURGE
•SURGEVALVE
VALVE
•TRENCHING
•TRENCHING •PUMP
•PUMP&&MOTOR
MOTOR
•BEDDING
•BEDDING INSTALLATION
INSTALLATION
•PIPE
•PIPESTRINGING
STRINGING •HEADER
•HEADERPIPE
PIPE
•JOINT
•JOINTWELDING
WELDING •VALVE
•VALVE
•NDT
•NDT •SUB-STATION
•SUB-STATION
• •JOINT
JOINTCOATING
COATING
•VALVE/AIR
SETUP
SETUP
•VALVE/AIRVENT
VENT
INSTALLATION
INSTALLATION
•THURST
•THURSTBLOCKS
BLOCKS
•ENCASINGS
•ENCASINGS
•HYDROTEST
•HYDROTEST

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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
Inspection Request Flow

TPI Ahmedabad

Report Flow
TPI Executing office

INSPECTION LOCATION

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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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 THIRD PARTY INSPECTION FOR QA & QC OF
SITE CONSTRUCTION WORK
 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.

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 CONTRACTOR’S AUDIT

REVIEW OF CONTRACTOR’S/PROJECT
DOCUMENT

ONSITE INSPECTION ON DAILY BASIS

AS PER APPROVED QAP/ITP/FQP

RE- INSPECTION
HIGHLIGHTING THE DEVIATION FOR DEVIATION
AND INSTRUCT FOR RECTIFICATION

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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 CONSTRUCTION SUPERVISION OF PUMPING
STATION
 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.

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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

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