QA-0601

QUALITY ASSURANCE
Revision 00

Date :
LIST OF FORMATS QUALITY CONTROL
Page 1 of 2

Sl. No. Description Format No. No. of sheets Effective from Retention period

1 Raw Material Flow Sheet 06-001-02 1 5 years

2 Radiographic Inspection Report 06-007-00 1 5 years

3 Inspection Report ( Liquid

Penetrant Test ) 06-008-00 1 5 years

4 Inspection Report ( Hydrostatic 06-009-00 1 5 years

Test )

5 Final Ispection Report 06-010-00 1 5 years

6 Inspection Report 06-012-00 1 5 years

7 Non Confirmation Report 06-013-02 2 3 years

8 Material Rejection Report 06-014-00 1 1 year

9 WeldingProcedure Secification 06-017-00 2 Ongoing

10 Procedure Qualification Record (PQR) 06-018-00 3 Ongoing

11 Welder Performance Qualification

06-019-01
Record 2 Ongoing

12 Dry Run Test Report - TCS 06-025-02 1 5 years

13 Dry Run Test Report - DF 06-029-00 1 5 years

14 Inspection Report 06-026-00 1 3 years

15 Despatch Clearance Note 06 - 028 - 00 1 3 years

16 History Card 06-030-00 1 Ongoing

17 List of Inspection Measuring and Test

Equipments Master List 06-035-02 1 Ongoing

18 List of Inspection Measuring and Test

Equipments In Usage 06-036-02 1 Ongoing

19 Inspection Dossier 06-037-00 1 5 years

20 Dimension Report for Shell 06-038-00 1 5 years

21 Dimension Report for Flanges 06-039-00 1 5 years

22 Inspection Report - Part Process 06-027-00 1 5 years

23 Inspection Report - Boughtougt 06-026-00 1 5 years

 RAW MATERIAL FLOW SHEET
06-001-02

PROJECT : P.O.No. : Report No. :

PROJECT No. : SYSTEM : Date :
CUSTOMER : UNIT : Q.P No. :

Sl. No. Q.P Stage Name of the Drg. No. Spec./ Gr. Tk./ Size Heat No./ Mfg. Test certificate No. / Date
No. Component C.T.No.

---

QC DEPT.
GEA BGR. INSPECTION AUTHORITY
 06-007-00

Report No. :
INSPECTION REPORT
DATE :

CUSTOMER : EQUIPMENT :
CUSTOMER P.O. NO. : EQUIPMENT SL.NO. :
GEA BGR PROJECT NO. : DRAWING NO. :
PROJECT : QUALITY PLAN NO. :
SYSTEM : STAGE NO. :
RADIOGRAPHIC INSPECTION REPORT

NAME OF THE PART : TECHNIQUE :

PART NO. : TYPE OF I.Q.I. :

QUANTITY : TYPE OF FILM :

NO. OF SHOTS : FFD/SFD :

EXTENT OF TEST : EXPOSURE TIME :

DATE OF TEST : DENSITY :

R.T. SOURCE : SENSITIVITY :

KV/CURI USED : ACCEPTANCE :

STANDARD

SL.NO. WELD JOINT REFERENCE NUMBER. SIZE OF FILM IN THK EVALUATION VERDICT
(") IN MM REMARKS

Q.C. DEPARTMENT INSPECTING

GEA BGR AUTHORITY
 06-008-00
Report No. :
INSPECTION REPORT DATE :
CUSTOMER : EQUIPMENT :
CUSTOMER P.O. NO. : EQUIPMENT SL.NO. :
GEA BGR PROJECT NO. : DRAWING NO. :
PROJECT : QUALITY PLAN NO. :
SYSTEM : STAGE NO. :
LIQUID PENETRANT TEST
NAME OF THE PART

PART NO / WELD JOINT DETAILS

MATERIAL

QUANTITY

DATE OF TEST

STAGE OF TEST

EXTENT OF TEST

SURFACE CONDITION

LIQUID PENETRANT TEST CLEANER : P.MET. PC 21

PENETRANT : P.MET. PP 15
DEVELOPER : P.MET. PD 31

ACCEPTANCE STANDARD

EVALUATION PERSON'S
QUALIFICATION

VIEWING CONDITION

TYPE & DETAIL OF DEFECT

EVALUATION RESULT

Q.C.DEPARTMENT INSPECTING
GEA BGR AUTHORITY
 06-009-00
Report No. :
INSPECTION REPORT DATE :
CUSTOMER : EQUIPMENT :
CUSTOMER P.O. NO. : EQUIPMENT SL.NO. :
GEA BGR PROJECT NO. : DRAWING NO. :
PROJECT : QUALITY PLAN NO. :
SYSTEM : STAGE NO. :
HYDROSTATIC TEST
DESCRIPTION

DESIGN CODE

DESIGN PRESSURE

DESIGN TEMPERATURE

TEST PRESSURE / TEMPERATURE

DURATION OF TESTING

DATE OF TEST

QUANTITY

OBSERVATION

PRESSURE GAUGE DETAILS Sl.No. Range Calibration

Kg/Cm2 Due Date

TEST RESULT

Q.C. DEPARTMENT INSPECTING

GEA BGR AUTHORITY
 06-010-00
Report No. :
INSPECTION REPORT Date :
CUSTOMER : EQUIPMENT :
CUSTOMER P.O. NO. : EQUIPMENT SL.NO.:
GEA BGR PROJECT NO. : DRAWING NO. :
PROJECT : QUALITY PLAN NO. :
SYSTEM : STAGE NO. :
FINAL INSPECTION

Q.C. DEPARTMENT INSPECTING

GEA BGR AUTHORITY
 06-012-00
Report No. :
INSPECTION REPORT Date :
CUSTOMER : EQUIPMENT :
CUSTOMER P.O. NO. : EQUIPMENT SL.NO. :
GEA BGR PROJECT NO. : DRAWING NO. :
PROJECT : QUALITY PLAN NO. :
SYSTEM : STAGE NO. :
INSPECTION REPORT

Q.C. DEPARTMENT INSPECTING

GEA BGR AUTHORITY
 06-013-02
Sheet 02 of 02

Ref. : NCR No.

Quality Control / Site Engineer Check Points during Repair / Rework

Recommended by :

Head (Design) Head (FED) Head (Works) Head (QA)

Signature & Date

REPAIR / REWORK COMPLETION

Checked by : Engineer (QC) / Site Engineer Checked by Chief (QC ) / Chief (FED )
Signature & Date Signature & Date

PREVENTIVE ACTION PROPOSED

Head (Design) Head ( Works) Head ( Quality Assurance )

Distribution : QA / QC / Design / Mfg. / FED / Management Representative

 06-014-00

MATERIALS REJECTION NOTE

PROJECT : MRN NO :
PROJECT NO : DATE :
SYSTEM :
VENDOR NAME :

SL.NO DESCRIPTION REASON FOR REJECTION QTY REMARKS

Purchase Order No. / Vendor DC No. :

I.C. Sl.No. / GRN No. :

COPY- TO : PURCHASE THRO STORES

: PLANNING DEPT.

Q.C. GEA BGR APPROVED

Prepared
 REF. :
DATE : 06-017-00

ELECTRICAL CHARACTERISTICS (QW-409)

Current AC or DC : Polarity :

Amps (Range) : Volt(Range) :

Travel Speed :

Tungsten Electrode size and type :

Mode of Metal Transfer for GMAW :

Electro wire feed speed range :

TECHNIQUE (QW-410)

String or Weave bead :

Orifice or Gas cup size :

Initial and Interpass cleaning :

Method of Back Gouging : Oscillation :

Contact tube to work distance :

Multiple or single pass :

Travel speed (range) : Electrode :

Peening :

Others :

FILLER METAL ELECTRICAL DATA TRAVEL SPEED

PROCESS
WELD Layers OTHERS
SPEC. DIA POLARI AMPS VOLTS RANGE

Prepared by Approved by

GEA BGR ENERGY SYSTEM ( I )LTD..

SHEET 2 OF 2
Ref : PQR No.
Date : 14.12.2006.
06-018-00
SHEET 03OF03
GUIDED BEND TEST (QW- 160)

Test certificate ref. :

Type and figure No. Result

TOUGHNESS TESTS (QW- 170)

Test certificate ref. : NOT APPLICABLE

Specimen Notch Notch Test Impact Lateral Exp. Drop Weight
No. Location Type Temp. Value % Shear Mils Break No Break

FILLET WELD TEST (QW- 180)

Test certificate ref. :

Results satifactory : Penetration into
parental metal :
Type and character failure: Macro Results :
Welder's Name : Stamp No. :

OTHER TESTS
Visual Examination : Report No :
(QW- 194)
L.P. Examination : Report No :
(QW- 195)

Hardness Test : Report No. :

Ferrite Count Test % : Report No. :

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

Date :
 06-019-01
SHEET 01OF02

WELDER PERFORMANCE QUALIFICATION RECORD

Welder's Name : Stamp No :

Supporting WPS No. : Rev. Date :

Supporting PQR No. : Rev. Date :

The above welder is qualified for following ranges

Variable Actual values used in Qualification range

qualification

Process

Process Type

Backing [Metal, Weld Metal,

Flux etc. (QW-402) ]

Material Specn. (QW-403)

Thickness

Groove

Fillet

Totally overlay thickness bearrier

Layer min.4mm.

Groove

Fillet

Filler Metal (QW-404)

Specn. No. ASME

Class AWS

F. No.

Position(QW- 405)

Weld Progression (QW- 410)

Gas type (QW- 408)

Electrical Characteristics
(QW- 409)
Current

Polarity
WELDER NAME :
REF :
DATE : 06-019-01
SHEET 02OF02

GUIDED BEND TEST (QW- 160)

[QW- 462.2 (a), QW- 462.3 (a), QW- 462.3 (b) ]

Test certificate ref. :.

Type and figure No. Result

Radiographic Test Results

( QW-304 & QW-305 )

For alternative qualification of groove welds by radiography.

Radiographic results: NOT APPLICABLE.

Fillet Weld Test Results

[QW- 462.4 (a), QW- 462.4 (b) ]

Fracture test (Describe the location, nature and size of any crack or tearing of the specimen)

Length and percent of Defects - %

Macro- test- Fusion -

Appearance - Fillet size (leg) - in - in convexity / in concavity

Other Test Results

Visual Examination :
Liquid penetant test :
Observed Value :

We certify that the statements in this record are correct and the test welds were prepared ,
welded and tested in accordance with the requirements of Section IX of ASME CODE. 2004 Edition.

Date :

Test Conducted By. Test Witnessed by

 06-025-02
Report No. :
DRY RUN TEST REPORT Date :
PROJECT : PROJECT NO. : SYSTEM :
CUSTOMER P.O NO : EQUIPMENT : EQUIPMENT SL.NO :
DRAWING NO. : Q.P. NO. : Q.P.STAGE NO. :
APPD.PROC. :
S.NO. SPECIFICATION AND RANGE OF TEST RESULT
S.NO. SPECIFICATION AND RANGE OF TEST RESULT

01 OPERATION OF ALL MOVABLE ITEMS

Check for smooth and free of screen - manually & electrically

02 TIGHTENING OF BOLTS AND NUTS ( RANDOM TEST )

a.Check whether locktite has been applied

03 ARRANGEMENT OF ALL ASSEMBLIES AND CONNECTIONS

ACCORING TO ASSEMBLY DRAWING

04 DIMENSIONS ACCORDING TO ASSEMBLY DRAWING

05 INTERNAL ITEMS OF AUSTENTIC MATERIAL ARE FREE OF

SLAGS AND ANNEALING COLOUR

06 MINIMAL RADIAL AN LATERAL PLAY OF THE SCREENS

OF BALL SEPARATOR

07 SCREEN ANGLE AT BACK WASH POSITION ( 6°) TOLERANCE + / -1°

08 SCREEN ANGLE AT OPERATION POSITION ( 30° ) TOLERANCE + / -1°

09 ADJUSTMENT OF LIMIT STOPS AT WORM GEARS ON

BALL SEPARATOR

10 CHECK OF NAME PLATE

11 SCREEN OPERATING TIME

a.From Operation mode to Backwash mode
b.From Backwash mode to Operation mode

12 DATE OF TEST

13 DIMENSIONS
REQUIRED
a. Gap between shell and shoe plate 3mm Max
b. Gap between rim sheet and shell 3mm Max
c. Gap between rim sheet and side wall plate 1 To 3mm max
d. Gap between rim sheet and ball extraction baffle. 1 To 2mm max
e. Gap between Ball extraction to screen gap 1 To 2mm max
f. Screen overlapped on B.E Opening plate. 20 to 25mm
g. The gap between the inner diameter of the shell and 5 to 10mm
screen rib

Q.C DEPARTMENT INSPECTING

GEA INDIA AUTHORITY
 06-029-00
Report No.
DRY RUN TEST REPORT Date
PROJECT : PROJECT NO. : SYSTEM :
CUSTOMER P.O NO. : EQUIPMENT : EQUIPMENT SL.NO. 13:
PROC. No. :
DRAWING NO. : Q.P. NO. : Q.P.STAGE NO. :

S.NO. SPECIFICATION AND RANGE OF TEST RESULT

01 TIGHTENING OF BOLTS AND NUTS ( RANDOM TEST )

a.Check all assembly fasteners are as per the drawing & Bill of materials
b.Check whether locktite has been applied

02 All INTERNAL ITEMS OF AUSTENTIC MATERIAL ARE FREE OF

SLAGS AND ANNEALING COLOUR

03 CHECK ALL ASSEMBLIES AND CONNECTIONS ARE ACCORDING TO

THE G.A. DRAWING

04 CHECK DIMENSIONS AFTER ASSEMBLY OF INTERNAL COMPONENTS

REQUIRED
a. Gap between Injection arm and Screen Basket.
b. Gap between Screen Basket and shell plate

05 DIMENSIONS ACCORDING TO ASSEMBLY DRAWING

06 OPERATION OF STRAINER
a.Check for operation of min. 15 minutes time.

b.Check the direction of rotation of the injection arm to the clock wise when
viewed from Flow Direction.

c.Check for any undue vibration / noise in the Geared Motor

d.Check the speed of the injection arm

07 CHECK FOR SMOOTH AND FREE OPERATION OF INJECTION ARM

MANUALLY BY KEEPING GEAR MOTOR DRIVE IN MANUAL MODE

08 CHECK FOR NO PLAY IN THE RADIAL DIRECTION OF THE INJECTION

ARM

09 CHECK OF NAME PLATE ASPER G.A. DRAWING

10 DATE OF TEST

Q.C DEPARTMENT INSPECTION

GEA BGR AUTHORITY
 06 - 028 - 00

DESPATCH CLEARANCE NOTE

NO :
DATE :

CUSTOMER :

PURCHASE ORDER NO. :

PROJECT NAME :

PROJECT NO. :

COMPONENT CODE :

PACKING LIST NO. / CASE NO. :

EQUIPMENT NAME : QUANTITY

UNIT NO. :

QUANTITY :

THE CASE CONTAINS ITEMS AS PER PACKING LIST

TAKEN OVER Q.C. DEPARTMENT

STORES
CC to : Project Engineering / Stores
 06-030-00

Instrument Name : Range : Card No :

Instrument ID : Least Count: Purchase Dt:

Calibration Ref : Make : Usage From :

Recalib Duration :

Calibrated
Sno --------------------- Test Agency TC No. & Date Remarks
ON DUE
 List of Inspection Measuring and Test Equipments
MASTER LIST 06-035-02
List No. : Date :

Sno Card Instrument Range Used Purchase

No From Date

Note : # - ADDED AFTER FRESH / RECALIBRATION.

** - INSTRUMENTS ARE REMOVE FROM USAGE, REASON FOR REMOVAL REFER

RESPECTIVE HISTORY CARDS.

PREPARED BY : CHECKED & APPROVED BY

Distribution to : stores department ACKNOWLEDGED BY : STORE DEPT.
 List of Inspection Measuring and Test Equipments
In Usage 06-036-00.
List No. : Date :

Sno Name Intr. Range Calib. Card Remark

Code Due No

Prepared By : Checked & Approved By :

Distribution to : Store Department Acknowledged by : Store Dept.

 QUALITY CONTROL DEPARTMENT
INSPECTION DOSSIER
CONTENTS
06-037-00

CUSTOMER : P.O. NO. :

PROJECT : Q.P. NO. :
PROJ.NO : TDS NO. :
SYSTEM : QTY. :

Q.P. QTY REPORT NO / DATE PAGE NO MFRS.

DESCRIPTION
STAGE NO NOS T.C NO.

PREPARED BY : APPROVED BY :
DATE : DATE :

DISTRIBUTION TO :
DATE :
 06- 038- 00
DIMENSION REPORT FOR SHELL
Project : Quality Plan No. : Report No. :
Project No. : Stage No. : Date :
Equipment : Drawing No. : Measuring Tape No. :
Equipment Sl No. : Stage / Final : Vernier Caliper No. :

From Main Flange From Nozzle Flange

Offset Dimension Other Dimension
Face to Nozzle Centre Face to Shell Centre
NOZZLE LOCATION ORIENTATION
NO As per Actuals As per Actuals As per Actuals As per Actuals
Drawing Drawing Drawing Drawing
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

ARRANGEMENT-A

Dimension, Orientation and workmanship Dimensions are within acceptable limit : Yes / No.

Q.C. DEPARTMENT INSPECTING AUTHORITY

GEA BGR
 06-039-00
DIMENSION REPORT FOR FLANGES
Project : Q.P. No. : Report No. :
Project No. : Stage No. : Date :
Equipment : Drawing No. / Rev. : Measuring Tape No. :
Equipment Sl No. : Stage / Final : Vernier Caliper No. :

Sl. Part No. Heat No. As per Drawing Dimension ( in mm ) Actual Dimension ( in mm )
No. OD ID PCD Tk. Holes No. of OD ID PCD Tk. Holes No. of
Dia. Holes. Dia. Holes.

Dimensions are with in acceptable limit : Yes / No

Q.C. DEPARTMENT INSPECTION AUTHORITY

GEA BGR
 06-026-01
VENDOR'S NAME & LOCATION REPORT NO. DATE OF INSPECTION DIVISION :
INSPECTION
REPORT CODIFICATION :
PROJECT : PURCHASE ORDER NO. INSPECTION STATUS QAP. NO. : DRG / SPECN. NO. :
STAGE
PROJECT NO. : FINAL REV. :
SL. QTY. QTY. QTY. QTY. RECTIFY& HOLD & NCR NO.
Q.P.STAGE NO. DESCRIPTION INSPECTOR'S OBSERVATION / REMARKS
NO. ORD. INS. ACC. REJ. REOFFER REOFFER IF ANY

VENDOR GEABGR INSPECTION ENGINEER CLIENT / III PARTY INSPECTION

SIGN : SIGN : SIGN :

NAME : NAME : NAME :
DATE : DATE : DATE :

CC TO : QUALITY CONTROL / PURCHASE / PROJECTS / VENDOR

 06-026-01
VENDOR'S NAME & LOCATION REPORT NO. DATE OF INSPECTION DIVISION :
INSPECTION REPORT
CODIFICATION :
PROJECT : PURCHASE ORDER NO. : INSPECTION STATUS Q.P. NO. : DRG / SPECN. NO. :
STAGE
PROJECT NO. : FINAL REV. :
SL. QTY. QTY. QTY. QTY. RECTIFY HOLD NCR NO.
QP STAGE NO. DESCRIPTION INSPECTOR'S OBSERVATION / REMARKS
NO. ORD. INS. ACC. REJ. & REOFFER & REOFFER IF ANY

VENDOR INSPECTION ENGINEER CLIENT / III PARTY INSPECTION

SIGN SIGN : SIGN

NAME : NAME : NAME :
DATE : DATE : DATE :
CC TO : QUALITY CONTROL / PURCHASE / PROJECTS / VENDOR
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