Name of Sub Project:

Date:
FOR MANUFACTURE OF SPIRALLY WELDED MS PIPES WITH INLINING & COATING PROCESSES , INSPECTION AND TESTING PLAN
Sl. No.
1

Component /
Material

Characteristics Check

Category

Type of Check

Quantum of
Check

Reference
Documents

Acceptance Norms

Format of Record

MTC

Agency
Engineer
& TPI

RAW MATERIAL CONTROL

Critical

Chemical Analysis

1 per section or
lot

IS 10748 Gr. 3/ IS
3589

IS 10748 Gr. 3/ IS 3589

1. Tensile

Critical

UTM

1 Samples per
every 40 tonnes

IS 10748 Gr. 3/ IS
3589

IS 10748 Gr. 3/ IS 3589

2. Bend Test

Critical

UTM

One Sample per

Batch

IS 10748 Gr. 3/ IS
3589

IS 10748 Gr. 3/ IS 3589

c. Dimension

Major

Measuring
Instrument

100%

IS 5504-1997 &
Customer
Specification if any

d. Surface Defect

Major

Visual

100%

Major

Visual, Template,
Measurement

a. Chemical

Manufacturer's Register/
IS 5504-1997 &
Customer Specification if Report (MEIL/QAQC/F013)
any

IS 3589/IS 5504

IS 3589/IS 5504

100%

IS 5504:1997

IS 5504:1997

100%

ASME Sec II part C

for weld wire & flux,
IS 3658:1999
& IS 814-1991 for
stick electrode

WPS (MEIL/ QAQC/F024)

Repair Rectification
report (MEIL/QAQC/F014)

b. Physical

1.1

2
2.1

2.2

HR Coils

PROCESS CONTROL
Pipe Forming

Welding & NDT

Consumables

Edge Milling & Forming

Chemical composition,
Mechanical
Properties and DPT
Materials

Major

2.3

a) Determination of
WPS for SAW
welding Parameter
Pipe manufacturing b) SAW pipe
Process
manufacturing process in
length of 5.0-12.2 Mtr.

Critical

2.4

Repair welding

Repair of weld defects

2.5

DPT

End Preparation

2.6

Lab Report
(MEIL/QAQC / F- 011)

Verification of batch
TCs

ASME Sec II part C for

weld wire & flux, IS 3658
:1999 for NDT materials

MTC

& IS 814-1991 for stick

electrode

Mechanical Test

100%

ASME Sec IX/PQR

ASME Sec IX/PQR

/WPS

Critical

Visual

100%

IS 5504 :1997

IS 5504 :1997

Repaired Weld Defects

Critical

Visual

10%

ASME Sec. V Article ASME Sec. V Article

6.0
6.0

DPT report
(MEIL/QAQC/F-017)

a) Bevel end Outside

b) Root face.
C) End Flushing : ID &
OD 100mm from both
weld ends

Critical

100%

IS 5504 :1997

IS 5504 :1997

Bevelling Inspection
report (MEIL/QAQC/F006)

RW

100%

IS 5504 : 1997

IS 5504 : 1997

RW

Visual & Bevel

gauge

FINAL INSPECTION & TESTING

a. Dimension

Critical

Measuring
Instrument

Inspection Report
(MEIL/PR/F-010)

Remarks

Sl. No.

3.1

Component /
Material

Characteristics Check

Category

Agency
Engineer
& TPI

RW

Ultrasonic Test Report

(MEIL/QAQC/F-015)

IS 5504-1997

Inspection Report
(MEIL/QAQC / F- 011 )

IS 5504 : 1997

IS 5504 : 1997

Inspection Report
(MEIL/QAQC / F- 005)

Manufacturer's Register/
Report (MEIL/QAQC / F007 )

RW

RW

Critical

Ultrasonic

As per agreement
specififcations
IS 4260
(10% of Weld
Length)

IS 4260

d. Mechanical Test

Critical

Root & Face Bend

Test

Sampling as per
IS 4711

IS 5504-1997

Hydraulic Pressure
at manufacturer's
work at
100%
a)15 kg/cm2
& b) 22 kg/cm2

Format of Record

Inspection Report
(MEIL/PR/F-009)

c. Soundness of Weld

INNER LINING & OUTER COATING

Pipes

Cement

1. Dimension

Major

Measuring
Instrument

100%

IS 3589-2001

IS 3589-2001

2. Surface Defect

Major

Visual

100%

IS 3589-2001

IS 3589-2001

a. Chemical

Critical

Chemical Analysis

One Sample
IS 269 / IS 8112 / IS IS 269 / IS 8112 / IS
forevery 200Bags 12330
12330

Suppliers MTC

b. Physical
1. Fineness

do

By Sieve

do

do

do

Lab Report

2. Standard Consistency do

Lab Test

do

do

do

Lab Report

do

Lab Test

do

do

do

Lab Report

do

Lab Test

do

do

do

Lab Report

5. Compressive Strength do

Lab Test

do

do

do

Lab Report

a. Delitereous Material
Aggregate(Sand)

4.4

Weld Mesh for

outer Coating &
Inside MS Rings

4.5

Water

Lab report

b. Soundness

do

do

do

do

do

do

c. Specific Gravity

do

do

do

do

do

do

d. Grading & Size

do

do

do

do

do

do

As per customer
specification IS:
1566

Wire Mesh Size:

50x50x3.0 mm, & Inside
6mm dia MS Rings 04
nos. at each end of the
pipe

Suppliers MTC

Dimension

Suitability of Water for

Concrete Works
a. Mix Design

4.6

As per welding
As per welding practise
practise (IS 816 & IS
(IS 816 & IS 822)
822)

Visual

3. Setting Time Initial,

Final
4. Soundness

4.3

Acceptance Norms

Critical

Inspection of
Welded Pipes

4.1

4.2

100%

Reference
Documents

b. Welding

e. Hydraulic Pressure
Test for Pressures as per Critical
agreement specifications
4

Quantum of
Check

Type of Check

Outer & Inner

Coating Mix

Major

Minor

Major
Major

Lab Test

1 per batch

Measuring
Instrument

Lab Test
Measurment

100%

Once in a Year
1 Per Batch

IS 3589 / IS11906

IS 456/IS 3589
IS 1916:1989

IS 3589 / IS11906

IS 456/IS 3589

Lab TC

Outer Cement Mortar

ratio : 1:3, Inner Cement
Manufacturer's Register/
ratio: 1:2
Report (MEIL/QAQC / F007 )

Remarks

Sl. No.
4.6

Component /
Material
Outer & Inner
Coating Mix

Characteristics Check

b. Cube Strength

4.7

4.8
5

Outside & Inside

Coating

Major

Curing

Proper curing

6.1

Type of Check

Compressive
Strength

Quantum of
Check

3 Per Batch

Thickness guages/
vernier caliper

Reference
Documents
IS 784
Purchaser's
Specification &
IS 3589 / 2001

100%

IS 3589: 2001

Acceptance Norms

Format of Record
Manufacturer's Register/
Report (MEIL/QAQC / F007 )

IS 784
Purchaser's
Specification &
IS 3589 / 2001
Gunneting thickness: Manufacturer's Register/
30mm, Inlining thickness Report (MEIL/QAQC / F: 12 mm, Cut back : 007 )
150 mm,

Critical

1. Visual
2. Co-relating with
cube strength

100%

Major

Visual

100%

IS 3589 : 2001 &

IS 5504 : 1997

IS 3589 : 2001 &

5504 : 1997

IS

Major

Measuring
Instrument &
Gauges

100%

IS 3589 : 2001 &

IS 5504 : 1997

IS 3589 : 2001 &

5504 : 1997

IS

Major

Visual

100%

IS 3589 : 2001 &

IS 5504 : 1997

IS 3589 : 2001 &

5504 : 1997

IS

IS 3589 : 2001

IS 3589 : 2001

Agency
Engineer
& TPI

RW

RW

RW

Remarks

FINAL INSPECTION & TESTING

Fabricated , Lined
& Coated Pipe b. Dimension
c. Marking

Critical

Coating thickness

a. Surface Defects

5.1

Category

Manufacturer's Register/
Report (MEIL/QAQC / F007 )

SEALING & STAMPING

Stenciling IA
Stamp

Legibility of Stamp

Major

Visual

100%

Test Reports

Samples
inspected by
TPI are
double
stamped

1. Reviwed items may be randomly witnessed by the concerned if necessary.

2. All measuring instruments and testing equipmenets shall be calibrated periodically and put up for verification to Third Party Inspection Agency.
3. Legend: M: Manufacturer, TPI: Third Party Inspection, R; Review, W: Witness, RW: Random Witness (10%),V: Verify
4. MS Pipe 1540mm OD/1040mm OD x 8mm thickness, Outer Coating 30mm thk Cement Mortar (CM 1:3) with Wire Mesh 50x50x3mm, Inlining 12mm thk Cement Mortaar (CM:1:2) using 4 No. of 6mm Dia. MS Rings
5. Stenciling with the lettering - APMDP - KAKINADA is to be marked on the Finished MS Pipes
Approved By
Signature:
Name:
Designation: