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Chapter13: QAP's KUWASIP 1/10
______________
CONTRACTOR
_________EMPLOYER
QUALITY ASSURNCE PLAN
QUALITY ASSURANCE PLAN FOR THE MANUFACTURE OF DUCTILE IRON PIPES, INSPECTION & TESTING PLAN
Charcterstics check Cate!r"Ae#c"
Re$arksM % TPI
RA MATERIAL CONTROL
1 Major Chemical 1/lot or atch M!C ! " "
# $errosilico% & S& A( Major Chemical 1/lot or atch M!C ! " "
3 Major Chemical 1/lot or atch M!C ! " "
) Ma*%esi+m P+rit, o- M* Major Chemical 1/lot or atch M!C ! " "
. i%c P+rit, o- % Major Chemical 1/lot or atch M!C ! " "
Ceme%t Material co%-ormatio% Major 1/lot or atch As per IS 11# As per IS 11# M!C ! " W
2 +t+me% Pai%t Spec-ic ra4it, Major 1/lot or atch M!C ! " "
PROCESS CONTROL
1 5eati%* !reatme%t Major Ph,sical 100& ! " "
# i%c coati%* 6epsoit o- 7i% Major Ph,sical 1 per atch ! " "
S'N!
(
C!$)!#e#t*Materia'
T")e !+Check
Qa#t$ !+Check
Re+ere#ceD!c$e#ts
Acce)ta#ceN!r$s
F!r$at!+ Rec!r-
$ (i8+i9 Metal orpi* Iro%
& C SI & M &S & P
AsperMa%+-act+rersSta%9ar9
AsperMa%+-act+rersSta%9ar9
AsperMa%+-act+rersSta%9ar9
AsperMa%+-act+rersSta%9ar9
Silica Sa%/ ;i4erSa%9
Sie4e A%al,sisCompactio%
As per IS 3#< =#000/ IS=33
As per IS 3#< =#000
As per IS 3#< =#000
As per IS 3#< =#000
AsperMa%+-act+rersSta%9ar9
AsperMa%+-act+rersSta%9ar9
Ph,sical >Chemcial
Samples co+l9 ?e9ra@% -rom -i%ishe9pipes also
Speci-ic*rar4it,
AsperMa%+-act+rers
Sta%9ar9
AsperMa%+-act+rers
Sta%9ar9
!emperat+rerecor9i%* time c,cle
AsperMa%+-act+rersSta%9ar9
AsperMa%+-act+rersSta%9ar9
5eat!reatme%t
Chart
As per IS 3#< =#000
As per IS 3#< =#000
Ma%+-act+rers I%ter%al
;ecor9
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Chapter13: QAP's KUWASIP #/10
______________
CONTRACTOR
_________EMPLOYER
Charcterstics check Cate!r"Ae#c"
Re$arksM % TPI
S'N!(
C!$)!#e#t*Materia'
T")e !+Check
Qa#t$ !+Check
Re+ere#ceD!c$e#ts
Acce)ta#ceN!r$s
F!r$at!+ Rec!r-
INSPECTION AND TESTING
1 "is+al As per IS 3#
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QUALITY ASSURNCE PLAN
PRODUCT NAME. AC PIPES & SPECIALS
Charcterstics check Cate!r" T")e !+ Check Ae#c" Re$arks
RA MATERIAL CONTROL
1 As?estos $i?re Critical Ph,sical !ests Ma%+-act+rer ;e4ie@ ?, IA
CEME! Major IS #
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#D< Major 100& ==9o== ==9o== ==9o==
3D0 Machi#i# & testi# !+ )i)es
3D1 Pipe -i%ishi%* Major Meas+reme%t 100& IS 1. perio9
Co+%ti%* themat+rit, perio9
Ma%+-act+rerIA
!esti%* o-Co+pli%*s
!esti%* 5,9ra+licall,@ith pipe
"is+al chec -ora%, lea
As per IS23
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)D Mari%* Mari%* Major Ste%cili%* 100& ==9o== ==9o==
.D0 RU%%ER SEALING RINGS FOR AC COUPLING & CID 0OINTS.
.D1 "is+al EJami%atio% "is+al checi%* IS .33=1
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2D0
2D1 "is+al EJami%atio% $i%ish a%9 mari%* Major "is+al ==9o==
2D# Meas+reme%t Major ==9o==
2D3 Stri*ht%ess !est ==9o== Major ==9o==
2D) U%i-ormit, Major 6isc !est ==9o== ==9o== ==9o== ==9o== ==9o==
2D. Major ==9o== ==9o== ==9o== ==9o== ==9o==
2D Cr+shi%* stress Major Ph,sical !est ==9o== ==9o== ==9o== ==9o== ==9o==
2D2 r+stii%* Stress Major Ph,sical !est ==9o== ==9o== ==9o== ==9o== ==9o==
2D e9i%* stress Major Ph,sical !est ==9o== ==9o== ==9o== ==9o== ==9o==
N!te. /
ACCEPTANCE CRITERIA TESTS$i%al I%spectio%/!est -or ADCD Press+re Pipes
100& ?,Ma%+-act+rers
As per IS1.
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QUALITY ASSURANCE PLAN
PRODUCT NAME. R(C(C( PIPES.
Cate!r" T")e !+ Check Ae#c" Re$arks
3(2 RA MATERIAL CONTROL
3(3 Ce$e#t . 1D Chemical Critical 1 / (ot S+pplier's !C
= 9o = , sie4e 1 / (ot = 9o = = 9o = = 9o = = 9o = = 9o =
= 9o = (a? !est 1 / (ot = 9o = = 9o = = 9o = = 9o = = 9o =
= 9o = (a? !est 1 / (ot = 9o = = 9o = = 9o = = 9o = = 9o =
9D So+%9%ess = 9o = (a? !est 1 / (ot = 9o = = 9o = = 9o = = 9o = = 9o =
= 9o = = 9o = 1 / (ot = 9o = = 9o = = 9o = = 9o = = 9o =
3(4 Areate Major (a? !est 1 / (ot IS : 33 IS : 33
?D So+%9%ess = 9o = = 9o = = 9o = = 9o = = 9o = = 9o = = 9o = = 9o =
cD Speci-ic *ra4it, = 9o = = 9o = = 9o = = 9o = = 9o = = 9o = = 9o = = 9o =
9D ra9i%* > si7e = 9o = = 9o = = 9o = = 9o = = 9o = = 9o = = 9o =
S'(N!(
C!$)!#e#t *Materia'
CharacteristicsCheck
Qa#t$ !+Check
Re+ere#ceD!c$e#ts
Acce)ta#ceN!r$s
F!r$at !+ Rec!r-
ChemicalA%al,sis
IS : 1#330 FSee%ote #G
IS : 1#330 FSee%ote #G
1DS+pplier#D IA
1DScr+ti%, o- recor9s?, IA#D Co+%ter chec ?,IA o% receit atma%+-act+rers placeD
#D Ph,sicalaD $i%e%ess
?D Sta%9ar9co%siste%c,
cD Setti%* !imeco%siste%c,
eD Compressi4e
stre%*th
aD 6eleterio+smaterials
aD S+pplier's !C?D Ma%+-act+rer's;e*ister
aD S+pplier's!C?D
'
Scr+ti%, o- recor9s ?,IA
1DScr+ti%, o- recor9s?, IA
#D ;a%9om ph,sical4eri-icatio% ?, IA
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Cate!r" T")e !+ Check Ae#c" Re$arksS'(N!(
C!$)!#e#t *Materia'
CharacteristicsCheck
Qa#t$ !+Check
Re+ere#ceD!c$e#ts
Acce)ta#ceN!r$s
F!r$at !+ Rec!r-
3(5 ater Major = 9o = B%ce i% a ,ear IS : ). IS : ). o4tD !est (a? Ma%+-act+rer Scr+ti%, o- !C ?, IA
3(6 Rei#+!rce$e#t aD Chemical Major = 9o = 1 / (ot
?D Ph,sical Major U!M 1 / (ot
cD 6ime%sio% Major = 9o = = 9o = = 9o = = 9o =
3(7 R88er Ri#s aD 6ime%sio%s Critical = 9o = = 9o = S+pplier's ;eport
?D Ph,sical !est Critical (a? !est 1 / (ot = 9o = = 9o = S+pplier's !C
Critical (a? !est 1 / (ot = 9o = = 9o = S+pplier's !C
9D Corrossio% !est
4(2 PROCESS CONTROL
4(3 aD Q+alit, o- Ceme%t Critical 1 / atch or shi-t
Sol+?ilit, o- Water i%co%crete @ors
IS :)3# PtDI orIS : )3# PtDII orIS : ## a%,*ra9e Fsee %ote)G
IS :)3# PtDI orIS : )3# PtDII orIS : ## a%,*ra9e
aD S+pplier's !C?D Ma%+-act+rer's;e*ister
aD S+pplier?D IA 1DScr+ti%, o- recor9s?, IA#D Co+%ter chec ?,IA at ma%+-act+rerplace
IS :)3# PtDI orIS : )3# PtDII orIS : ## a%,*ra9e Fsee %ote)G
IS :)3# PtDI orIS : )3# PtDII orIS : ## a%,*ra9e
aD S+pplier's !C?D Ma%+-act+rer's;e*ister
aD S+pplier?D IA
1DScr+ti%, o- recor9s?, IA#D Co+%ter chec ?,IA at ma%+-act+rerplace
Meas+ri%*
I%str+me%ts
AP( #D. 6SP/ I(
II IS:#. P!=1
1DScr+ti%, o- reports
?, IA#DA+9it chec ?, IA
IS : .3# !,pe Iat+ral orIspore%e
IS : .3# !,pe Iat+ral orIspore%e
1DS+pplier#DMa%+-act+rer
1DScr+ti%, o- reports?, IA Fsee %ote .G
1D S+pplier#D IA
1DScr+ti%, o- !C ?, IA#D Co+%ter chec ?,IA o% receipt atma%+-act+rer placeD
cD Pol,meri9e%ti-icatio%
1D S+pplier#D IA
1DScr+ti%, o- !C ?, IA#D Co+%ter chec ?,IA o% receipt atma%+-act+rer placeD
6etails are ,et to ?ea94ise9
C!#crete !rM!rtar
A%al,sis o-co%crete
IS: ).C( )D.D1
IS: ).C( )D.D1
Ma%+-act+rer'sre*ister
aDMa%+-act+rer
?D IA
1DScr+ti%, o- recor9s?, IA
#D ;a%9om chec IA
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Cate!r" T")e !+ Check Ae#c" Re$arksS'(N!(
C!$)!#e#t *Materia'
CharacteristicsCheck
Qa#t$ !+Check
Re+ere#ceD!c$e#ts
Acce)ta#ceN!r$s
F!r$at !+ Rec!r-
Critical 3 / atch IS : ). IS : ).
4(4 Cai# aD Wei*ht o- ca*e Critical , @ei*hi%* M/C B%e per 9esi*% IS : ). IS : ).
?D 6ime%sio% Major IS : ). IS : ).
4(5 aD Spee9 Major ;PM I%9icator
?D !hic%ess o- core Major Spie +a*e IS : ). IS : ).
5(2 FINAL INSPECTION & TESTING
5(3 Major "is+al 100& IS : ). IS : ).
?D 6ime%sio% Major 100& IS : ). IS : ).
cD strai*ht%ess o- ?ore =9o= a+*e 100& IS : ). IS : ).
9D 5,9rostatic test Critical #& IS : ). IS : ). See %ote
eD A?sorptio% test Critical -or each pipe IS : ). IS : ).
?D Compressio%Stre%*th Fat # 9a,sG
Compressio%test
Ma%+-act+rer'sre*ister
aDMa%+-act+rer?D IA
1DScr+ti%, o- recor9s?, IA#D ;a%9om test to IA
Fsee %ote 1G
Ma%+-act+rer'sre*ister
aDMa%+-act+rer?D IA
1DScr+ti%, o- recor9s?, IA#D ;a%9om test to IAFsee %ote 1G
Meas+ri%*I%str+me%ts
B%e eachpipe/mo+l9
Ma%+-act+rer'sre*ister
aDMa%+-act+rer?D IA
1DScr+ti%, o- recor9s?, IA#D ;a%9om chec IA
C!#creti# !+)i)e
B%e eachpipe/mo+l9
Ma%+-act+rerso@% st9
Ma%+-act+ererso@% st9
Ma%+-act+rer'sre*ister
1DMa%+-act+rer
B%e eachpipe/mo+l9
Ma%+-act+rer'sre*ister
1DMa%+-act+rer#D IA
1GSecr+ti%, o-;e*ister ?, IA#G ;a%9om chec ?,IA
Fi#a' Cre-Pi)e
aD S+r-ace cracsprojectio% i% ?ore etcD
Ma%+-act+rer'sre*ister a%9 testreport
1DMa%+-act+rer#D IA
1D A+9it chec o%sample ?, IA
Meas+ri%*i%str+me%ts >
+a*es
Ma%+-act+rer'sre*ister a%9 testreport
1DMa%+-act+rer#D IA
1D A+9it chec o%sample ?, IA
Ma%+-act+rer'sre*ister a%9 testreport
1DMa%+-act+rer#D IA
1D A+9it chec o%sample ?, IA
Press+re test@ith p+mp
Ma%+-act+rer'sre*ister a%9 testreport
1DMa%+-act+rer#D IA
As per IS: 3.
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Cate!r" T")e !+ Check Ae#c" Re$arksS'(N!(
C!$)!#e#t *Materia'
CharacteristicsCheck
Qa#t$ !+Check
Re+ere#ceD!c$e#ts
Acce)ta#ceN!r$s
F!r$at !+ Rec!r-
Critical As per IS: 3. +%loa9i%*D
3(Proper co=relatio% m+st ?e esta?lishe9 ?, appro4e9 a*e%c, -or c+?e stre%*th ?et@ee% 4i?rator, a%9 ce%tri-+*al process i% case pipes are ma%+-act+re9 ?,Ce%tri-+*al procesD I% a?se%ce o- the same co%4ersio% -actor -or # 9a,s compressi4e stre%*th o- c+?e shall ?e tae% as 1D#. Fre-er cla+se )D.D1 o- IS : ).G
4( B%l, s+lphate resisti%* portla%9 ceme%t to IS:#330/1
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