SL NO. DESCRIPTION FORMAT NO.

1 Procedure Qualification Records ECL/QA/QC/F-001

2 Welding Procedure Specifications ECL/QA/QC/F-002
3 Welder Qualification Certificate ECL/QA/QC/F-003
4 Approved Electrode List ECL/QA/QC/F-004
5 Release Note for Fabrication ECL/QA/QC/F-005
6 Release Note for Blasting ECL/QA/QC/F-006
7 Request for Inspection Works ECL/QA/QC/F-007
8 Non Destructive Test Offering ECL/QA/QC/F-008
9 Welder Qualification Test Request ECL/QA/QC/F-009
10 Welder Qualification Test Records ECL/QA/QC/F-010
11 Final Inpsection Report for Structurals - Client ECL/QA/QC/F-011
12 Final Inpsection Report for Structurals - Contractor ECL/QA/QC/F-012
13 Electrode Approval Test ECL/QA/QC/F-013
14 Debit Recovery ECL/QA/QC/F-014
15 X- Ray Details ECL/QA/QC/F-015
16 WPS & PQR Status ECL/QA/QC/F-016
17 List of Files ECL/QA/QC/F-017
18 Details of Approval ECL/QA/QC/F-018
19 Thickness Measurement Report ECL/QA/QC/F-019
20 DP Test Report ECL/QA/QC/F-020
21 List of Release Notes ECL/QA/QC/F-021
22 List of Instruments at QA/QC, ECL ECL/QA/QC/F-022
23 Blasting / Painting Status Report ECL/QA/QC/F-023
24 Inspection Report ECL/QA/QC/F-024
25 Detailed Inspection Report ECL/QA/QC/F-025
26 Ultrasonic Inspection Report ECL/QA/QC/F-026
27 Radiographic Inspection Report ECL/QA/QC/F-027
28 Daily Paint Inspection Report ECL/QA/QC/F-028
29 Material Inspection Report ECL/QA/QC/F-029
30 Protocol for Erection ECL/QA/QC/F-030
31 Inspection & Test Plan ECL/QA/QC/F-031
32 Document Control Procedure ECL/QA/QC/F-032
33 Pipe Line Specification ECL/QA/QC/F-033
34 Monthly Progress Report ECL/QA/QC/F-034
35 Camber Inspection report ECL/QA/QC/F-035
36 Non-Confirmity Report (NCR) ECL/QA/QC/F-036
37 Field Technical Queries (FTQ) ECL/QA/QC/F-037
38 Field Observation Report (FOR) ECL/QA/QC/F-038
39 Inspection Report for Column
ECL/QA/QC/F-039
40 Inspection Report for Crane Girder
ECL/QA/QC/F-040
41 Inspection Report for Pipe/Duct
ECL/QA/QC/F-041
42 Welder's ID Card
ECL/QA/QC/F-042
LIST OF FORMATS
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Format No: ECL/QA/QC/F-001
PROJECT: JOB REF :
NAME OF THE CONTRACTOR:
PQR NO. :
WPS NO.: REV: DATE:
SUPPORTING PQR NO. : DATE:
WELDING PROCESS : TYPE :
JOINTS
*sketch to be attached here
(For combination qualification the deposited metal thickness shall be recorded for
each filler metal of the process weld)
MATERIAL SPECIFICATION : TEMPERATURE :
TYPE OF GRADE : TIME :
P NO. : TO P NO. : OTHERS :
THICKNESS OF TEST COUPON :
DIAMETER OF TEST COUPON :
OTHERS
WELD METAL ANALYSIS A NO. :
SIZE OF FILLER METAL : TYPER OF GAS :
FILLER METAL F NO. : COMPOSITION OF GAS :
SFA SPECIFICATION : MIXTURE
AWS CLASSIFICATION : OTHERS :
OTHERS :
POSITION OF GROOVE :
WELD PROGRESSION : CURRENT :
OTHERS : POLARITY :
AMPS :
PREHEAT TEMPERATURE : VOLTS :
INTERPASS TEMPERATURE :
OTHERS : OTHERS :
TRAVEL SPEED :
STRING OR WEAVE BEAD :
OSCILLATION :
MULTIPASS OF SINGLE PASS :
SINGLE OR MULTIPLE ELECTRODES :
ESSAR CONSTRUCTIONS LTD.
GROOVE DESIGN OF TEST COUPON
BASE METAL POST WELD HEAT TREATMENT
GAS FILLER METALS
POSITION ELECTRICAL CHARECTERISITCS
PROCEDURE QUALIFICATION RECORD (PQR)
PREHEAT
TECHNIQUE
HAZIRA.
TENSILE TEST
SPECIMEN WIDTH THICKNESS AREA ULTIMATE ULTIMATE TYPE OF FAILURE
NO. mm mm mm2 LOAD Kg. STRESS
GUIDED BEND TEST
FACE BEND FB1
FACE BEND FB2
ROOT BEND RB1
ROOT BEND RB2
TOUGHNESS TESTS
SPEC. NO. NOTCH NOTCH TEST IMPACT LATERAL REQUIRED
LOCATION TEST TEMP. VALUE EXP. VALUES
FILLET WELD TEST
RESULT
PENETRATION INTO METAL
MACRO RESULTS :
OTHER TESTS
TYPE OF TEST :
DEPOSIT ANALYSIS :
OTHERS :
WELDERS NAME :
BLOCK NO. :
STAMP NO. :
TEST CONDUCTED BY: DATE :
LAB TEST REPORT NO. : DATE :
We certify that statement in this Record are correct and the Test Welds were
prepared welded and tested in accordance with requirements of Sec IX of the ASME code.
DATE : FOR ESSAR CONST. LTD.
RESULT TYPE AND FIGURE NO.
TESTS
Format No: ECL/QA/QC/F-002
PROJECT: JOB REF :
NAME OF THE CONTRACTOR:
WPS NO.: REV: DATE:
SUPPORTING PQR NO. : DATE:
WELDING PROCESS : TYPE :
QW-402
JOINTS
TYPE OF JOINT :
PRODUCT FORM :
BACKING :
BACKING MATERIAL :
OTHER :
QW-403
BASE METALS
P. NO. : GROUP NO. : TO P. NO.: GROUP NO. :
SPECIFICATION : TO SPECIFICATION :
TYPE & GRADE: TYPE & GRADE:
THICKNESS RANGE : FILLET :
PIPE DIA. : FILLET :
OTHERS :
QW-404
FILLER METALS
SFA : PROCESS(ES) :
AWS NO. : TRADE NAME :
F NO. : A NO. :
SIZE OF FILLER METAL :
WELD METAL THICKNESS :
THICKNESS RANGE :
ELECTRODE FLUX (CLASS) : FLUX TRADE NAME:
CONSUMABLE INSERT :
OTHERS :
QW-405
POSITION
POSITION(S) OF GROOVE : POSITION(S) OF FILLET :
WELD PROGRESSION :
QW-406
PRE HEAT
PRE HEAT TEMP. (MIN) : INTERPASS TEMP.(MAX) :
PREHEAT MAINTENANCE : TEMP. MEASUREMENT:
METHOD OF PREHEATING :
QW-407
POSTWELD HEAT TREATMENT
TEMP. RANGE : HOLDING TIME :
QW-408
GAS
SHIELDING GAS(ES) :
PERCENTAGE COMPOSITION : FLOW RATE :
(MIXTURE)
GAS BACKING : PURGING RATE :
TRAILING SHIELDING GAS :
QW-409
ELECTRICAL
CURRENT / POLARITY :
VOLT
WELD LAYER PROCESS CLASS DIA MM TYPE AMP RANGE
POLARITY RANGE
ROOT
SUBSEQUENT
FINAL
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
WELDING PROCEDURE SPECIFICATION (WPS)
FILLER METAL CURRENT
TRAVEL SPEED
RANGE
OTHERS
JOINT DETAILS
WELD DETAILS
QW-410
TECHNIQUE METHOD OF BACKGOUGING :
BEAD TYPE : CONTACT TUBE TO WORK DISTANCE :
PASSES PER SIDE : PEENING :
ORIFICE OR GAS CUP SIZE : OTHER :
INITIAL AND INTERPASS CLEANING :
NOTES :
1. Tack weld ends are to be ground taper to merge with final weld.
2. Minimum number of tack weld shall be as per approved procedure.
3. Storage and backing of low hydrogen electrode will be done as per approved procedure.
SKETCH
FORMAT NO: ECL/QA/QC/F-003
Date of Test : _______________________________
Stamp No.: Old :___________________ New : _____________________
Welders's Name : ____________________________________________________
Welding Process(es) used : _________________________ Type : _________________
Identification of WPS followed by welder during welding the test coupon : ______________________________________
Base material(s) welded : ____________________________ Thickness : ______________________________________
MANUAL OR SEMI-AUTOMATIC VARIABLES FOR EACH PROCESS Actual Variables
Backing ( metal, weld metal welded from both sides, flux etc.) _________________ _________________
ASME P - No. : __________ to ASME P - No. : __________________ _________________ _________________
( ) Plate ( ) Pipe (enter diameter, if pipe) _________________ _________________
Filler material specification (SFA) : ___________ Classification : __________ _________________ _________________
Filler metal F No. : _______________ _________________ _________________
Consumable insert for GTAW or PAW _________________ _________________
Weld deposit / Base metal thickness _________________ _________________
Process : ___________ 3 layers minimum Yes _________________ _________________
Welding position (1G, 5G, etc.) _________________ _________________
Progression (uphill / downhill) _________________ _________________
Backing gas for GTAW, PAW or GMAW ; Fuel Gas for OFW _________________ _________________
GMAW transfer mode _________________ _________________
Welding Current type / polarity (GTAW only) _________________ _________________
MACHINE WELDING VARIABLES FOR PROCESS USED
Direct / Remote visual control _________________ _________________
Automatic voltage control (GTAW) _________________ _________________
Automatic joint tracking _________________ _________________
Welding position (1G, 5G, etc.) _________________ _________________
Cosumable Insert _________________ _________________
Backing (metal, weld metal, welded from both sides, flux, etc.) _________________ _________________
RESULTS
Visual examination results : __________________________________________________
Radiographic test results : ______________ Report No. / Date : ________________________
Fillet Weld - Fracture test : ____________ Report No. / Date : _____________ Length and % of defects : ________ mm
Macro test Fusion : _____________ Fillet leg size : _________ mm x _________ mm Concavity/Convexity : ______ mm
We clarify that the statements in this record are correct and that the test coupons were prepared, welded and
tested in accordance with requirements of Section IX of ASME Code.
ECL Insp. Contractor
Signature : Signature :
Date : Date :
Range Qualified
GUIDED BEND TEST RESULTS
TEST RESULTS TEST
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
WELDER / WELDING OPERATOR QUALIFICATION TESTS
WELDERS PHOTO
FORMAT NO: ECL/QA/QC/F-004 R7
Date : 16/09//06
A. SMAW
E 6010 E 6013 E 7018
1 ADOR Nil a. Superbond - S Supabase A 5.1
Welding b. Superbond - SS A 5.1
2 ESAB Citoflex a. ESAB - 28 a. OK 48.2 A 5.1
Pipeweld - 6010R b. Ferrospeed plus b. ESAB - 36H A 5.1
3 General Nil a. Gri - Pink Gri - Green A 5.1
Electrodes b. Gri - Blue A 5.1
4 Dwekam Nil DK - 13S DK - 18 A 5.1
Electrodes A 5.1
5 D & H Nil a. Medio Supratherme A 5.1
b. Exobel A 5.1
6 Honavar Cellumate Regular - S Ultimate A 5.1
7 Lincon Fleetweld 5P Nil Nil A 5.1
8 Royal Arc Nil Royal - S Royal-therm A 5.1
Electrodes
9 Anand Arc Nil Anand SS Anandtherme A 5.1
10 Rajratna Nil a. Ratna 6013 X Ratna 7018 A 5.1
b. Ratna 6013 XX A 5.1
11 Adison Nil Steel craft - H Dynacraft - 18 A 5.1
B. SAW Wire & Fluxes
Wire EL-8 Flux F7AZ
1 ESAB OK Autorod 12.08L OK Flux 10.71L
2 Anand - Arc Anand SAW - 1 Anand Melt - 1
3 Dwekam Mergearc Grade - A Mergearc SAF - 2
Electrodes Ltd.
C. GTAW Wires
1 Honavar
2 ESAB
Approved by Willy Boekhoff 16.09.06 7
Reviewed by [Link] 16.09.06 7
Prepared by S. Manisundar 16.09.06 7
Name Signature Date Rev no. Remarks
OK Tigrod S2 A 5.18
SL. No. Company
Brand Name
Remarks
Bare Wire - ER 70 S2
HW70S2 A 5.18
A 5.17
A 5.17
A 5.17
SL. No. Company
Brand Name
Remarks
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Approved Electrode List
Company SL. No. Remarks
Brand Name
Format No. : ECL/QA/QC/F-005 R1
Date :
From: QA/QC (Mech) Report no.:
ECL, Hazira. Sheet no.:
Please arrange to shift the following materials from Fabrication yard to blasting yard which are
inspected & cleared today in all respects :
SL DESCRIPTION OF ITEMS /
No. IDENTIFICATION MARK
ESSAR CONSTRUCTIONS LTD.
HAZIRA
RELEASE NOTE
QTY. AGENCY DRAWING NO. REMARKS
Format No. : ECL/QA/QC/F-006 R0
Date :
From: QA/QC (Mech) Report no.:
ECL, Hazira. Sheet no.:
Please arrange to shift the following materials from Blasting yard to erection site which are
inspected & cleared today in all respects :
SL DESCRIPTION OF ITEMS /
No. IDENTIFICATION MARK
ESSAR CONSTRUCTIONS LTD.
HAZIRA
BLASTING RELEASE NOTE
QTY. AGENCY DRAWING NO. REMARKS
FORMAT NO: ECL/QA/QC/F-007 R0
To, Date :
QA/QC Dept. Report No.:
Hazira, Surat.
Please arrange to conduct stage inspection / final inspection of the following items
as on ___________________.
For ESSAR Constructions Ltd.
Request for Inspection
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Time Remarks
SL.
No
Description Location
FORMAT NO: ECL/QA/QC/F-008 R0
To,
QA/QC Dept.
Hazira, Surat.
Dear Sir,
Kindly arrange to conduct UT / RT / DPT of the following joints as detailed below :
Contractor QA/QC ECL QA/QC
Drg. No. Mark No. Joint No.
Date :
Report No.:
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
NDT Offering
Welder
No.
Thickness Length Remarks SL. No
FORMAT NO: ECL/QA/QC/F-009 R0
To, Date :
QA/QC Dept. Report No.:
Hazira, Surat.
Dear Sir,
Kindly arange for the inspection witness of the following welders qualification test
Contractor QA \ QC ECIL QA \ QC
Process Position
Thk .
(mm)
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Dia. (in) Remarks Material
Welder Qualification Test Request
SL.
No
Name of the welder
FORMAT NO: ECL/QA/QC/F-010 R0
Class Size
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Polarity Remarks
WELDER QUALIFICATION TEST RECORDS
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Current
Amp.
Voltage
V.
Electrode End
Time
Type
Start
Time
Root Gap
mm
Sl.
No
Welder Name Process Material
Thk .
(mm)
Dia.
(in)
Position
FORMAT NO: ECL/QA/QC/F-011 R0
SITE : Date : ______________
CLIENT:
INSPECTION AUTHORITY :
WORK DESCRIPTION :
JOB / DRG NO. : MKD NO. :
UBEL
ECL
( EXC. )
ECL
(QA\QC)
UBEL
ECL
( EXC. )
ECL
(QA\QC)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
UBEL
( QA \ QC )
CLIENT
ECL
( EXECUTION )
ECL
( QA \ QC )
Sheet No. : ______________
FINAL INSPECTION REPORT - STRUCTURALS
REPORT
NO.
DATE
WELD VISUAL
RESULT
REPORT
NO.
DATE
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Report No. : ______________
SL.
No
DESCRIPTION
FIT UP UT REPORT
WELDER
NO.
DATE RESULT
Joint
No.
Type of
joint
Date
RADIOGRAPHY
ACCEPTANCE ACCEPTANCE
FINAL INSPECTION REPORT - STRUCTURALS
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
REMARKS
FORMAT NO: ECL/QA/QC/F-012 R0
CLIENT / SITE : REPORT NO. :
PROJECT / DRG. NO. & REV. : DATE :
PART NO. / MKD. NO. :
TOTAL WEIGHT :
QUANTITY :
ECL INSPN CLIENT
1
DIMENSIONAL CHECKING
(SKETCH TO BE ATTACHED)
2 STRAIGHTNESS
3 WELD VISUAL INSPECTION
4
NDT
(APPLICABLE / NOT
APPLICABLE)
5 CONFIRMITY TO DRAWING
NOTE : THE ABOVE ITEM / PART IS RELEASED FOR SURFACE PREPERATION
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
FINAL INSPECTION REPORT STRUCTURALS
ACCEPTANCE
DESCRITPION SL. NO. REMARKS
CLIENT
___________________
INSPECTION
____________________
ECL
________________
Format No: ECL/QA/QC/F-013 R0
BRAND NAME : Report No. :
COMPANY : Date :
BATCH NO. :
MFG. DATE :
SL WELDER WELDER WELDING MATERIAL CURRENT VOLTAGE START END REMARKS
NO. NAME NO. PROCESS SIZE CLASS Position Thk. mm Angle Position Thk mm Size A V TIME TIME
Agency Inspection Authority Client
GROOVE FILLET ELECTRODE
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
ELECTRODE APPROVAL TEST
FORMAT NO: ECL/QA/QC/F-014 R1
DEBIT NOTE FOR RECOVERY OF THE PENALTY AMOUNT OF RT REPAIR AND / OR PENALTY SHOTS
TOTAL DEBIT IN RS.:
3" width - Rs.8.50/inch 4" width - Rs.9.50/inch
R. NO. DATE
REP .
NO.
DATE R. NO. DATE
1 0.00
2 0.00
3 0.00
4 0.00
5 0.00
6 0.00
7 0.00
8 0.00
9 0.00
10 0.00
GRAND TOTAL 0
REPAIR SHOTS (A)
PENALTY
AMOUNT IN
RS.(A+B)
REM
FILM
SIZE(LXW)
FILM
SIZE(LXW)
PENALTY / EXTRA SHOTS (B)
0
SL NO.
DESCRIPTION
/ MKD NO.
AGENCY :
LOCATION :
DURATION :
JOINT
NO.
FILM
SECTION
FIRST SHOOT
FORMAT NO: ECL/QA/QC/F-015 R0
Sheet No. :
LINE NO. JOINT NO. STATUS REP . NO. DATE STATUS REP . NO. DATE STATUS REP . NO. DATE
WELDER
NO.
X - RAY
NO.
SEGMENT
RESULT R1 RESULT R2 RESULT R3
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
X - RAY DETAILS
SL
NO.
IDENTIFICATION
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
REMARKS
FORMAT NO: ECL/QA/QC/F-016 R7 Date : 26/07/06
1 SMAW E 6013 IS 2062 GR. A / B IS 2062 GR. A / B ECL/NSC/CS/ WPS- 01 R0 ECL/NSC/CS/PQR -01 4.76 mm TO 24 mm
2 SMAW E6010 / E6013 A 106 GR. B A 106 GR. B ECL/SCPL/CS/ WPS- 02 ECL/SCPL/CS/PQR -02
UPTO AND INCL. 12 mm. DIA. 2 7/8 & ABOVE - Our
copy avalibale at NFY
3 SMAW E 7018 SA 515 Gr.70 SA 515 Gr.70 ECL/NSC/CS/ WPS- 03 R0 ECL/NSC/CS/PQR -03 4.8 mm TO 32 mm
4 SMAW E 7018 IS 2062 GR. A / B IS 2062 GR. A / B ECL/NSC/CS/ WPS- 04 R0 ECL/NSC/CS/PQR -04 4.8 mm TO 203 mm
5 SMAW + SAW E-7018 & EL8/F7AZ IS 2062 GR. A / B IS 2062 GR. A / B ECL/NSC/SS/ WPS- 05 ECL/NSC/SS/PQR -05 4.8 mm TO 60 mm
6 GTAW & SMAW ER-347 & E-347-5/16 A 312 GR. TYP.321 A 312 GR. TYP.321 ECL/NSC/SS/ WPS- 06 ECL/NSC/SS/PQR -06 1.6mm TO 14.22mm. DIA. 2 7/8 & ABOVE
7 GTAW & SMAW ER-70 S2 & E 7018 A 106 GR. B A 106 GR. B ECL/NAS/CS/ WPS- 07 ECL/NAS/CS/ PQR- 07 4.8mm TO 32 mm. DIA.2 7/8 AND ABOVE
8 SMAW E 8018 W2 IS IRSM 5147 IS IRSM 5147 ECL/NSC/CS/ WPS- 08 ECL/NSC/CS/PQR -08 4.8 mm TO 24 mm
9 GTAW ER 347 SA 213 TYP.321 SA 213 TYP.321 ECL/PT/SS/ WPS- 09 ECL/PT/SS/ PQR- 09 R0 1.6mm TO 17.12mm. DIA. 2 7/8 & ABOVE
10 SAW EL8 / F7AZ IS 2062 GR. A / B IS 2062 GR. A / B ECL/PT/CS/ WPS- 10 R0 ECL/PT/CS/PQR -10 UPTO AND INCLUDING 40 mm.
11 SMAW E 6010 & E 7018 A 106 GR. B A 106 GR. B ECL/RDS/CS/ WPS- 11 R2 ECL/RDE/CS/PQR -11 R1
1.6mm TO 14.22 mm. DIA. 2 7/8 AND ABOVE Our
copy avalibale at NFY
12 GTAW ER 5183 SB-241 GR 5083 SB-241 GR 5083 ECL/NSC/ALU/ WPS- 12 ECL/NSC/ALU/ PQR- 12 UPTO & INCLUDING [Link]. 4 & ABOVE.
13 SMAW E 6010 & E 7010 G API 5L Gr.65 API 5L Gr.65 ECL/AC/CS/ WPS- 13 ECL/AC/CS/ PQR- 13 Thk. - 4.8 mm to 19.1 mm. Dia - 12.75" & above
14 GTAW & SMAW ER-70 S2 & E 7018 IS 1239 IS 1239 ECL/AS/CS/ WPS- 14 ECL/NAS/CS/ PQR- 14 1.6 mm TO 10.98 mm. DIA.2 7/8 AND ABOVE
Created By : GB
ELECTRODE
MATERIAL SPECIFICATION
WPS NO. PQR NO. LIMITS
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
TYPE & GRADE TO TYPE & GRADE
WPS & PQR STATUS
SL
NO.
WELDING
PROCESS
FORMAT NO: ECL/QA/QC/F-017 R1 Date : 30/09/06
SL NO.
DESCRIPTION FILE NO.
1 APPROVED WPS & PQR ECL/QA/QC/001
2 CORRESPONDENCE ECL/QA/QC/002
3 NCR FILE ECL/QA/QC/003
4 WELDERPERFRMANCE REPORT& WELDER LIST ECL/QA/QC/004
5 WQT & WELDERS ID CARD RECORD ECL/QA/QC/005
6 BUILT-UP-INSPECTION REPORTS - RMH (MATERIAL HANDLING) ECL/QA/QC/006
7 BUILT-UP-INSPECTION REPORTS - RMISC ( MISC ITEMS) ECL/QA/QC/007
8 BUILT-UP-INSPECTION REPORTS - RLIME ( LIME PLANT) ECL/QA/QC/008
9 BUILT-UP-INSPECTION REPORTS - RPMIL (PLATE MILL) ECL/QA/QC/009
10 BUILT-UP-INSPECTION REPORTS - RPOW (POWER PLANT) ECL/QA/QC/010
11 BUILT-UP-INSPECTION REPORTS - RQM2 (MOD-V) ECL/QA/QC/011
12 BUILT-UP-INSPECTION REPORTS - RSMP ( CASTER/EAF-4) ECL/QA/QC/012
13 BUILT-UP-INSPECTION REPORTS - RWRP ECL/QA/QC/013
14 INSPECTION REPORTS - ROLLED SECTIONS ECL/QA/QC/014
15 FINAL INSPECTION REPORTS - S/B & PAINTING ECL/QA/QC/015
16 RELEASE NOTE - S/B & PAINTING ECL/QA/QC/016
17 ULTRASONIC TEST REPORTS ECL/QA/QC/017
18 RADIOGRAPHY TEST REPORTS ECL/QA/QC/018
19 R.I.W FILE - FAB ECL/QA/QC/019
20 R.I.W FILE - S/B & PAINTING ECL/QA/QC/020
21 ELECTRODE TEST CERTIFICATE ECL/QA/QC/021
22 INSTRUMENTS DETAILS ECL/QA/QC/022
23 BUILT-UP-INSPECTION REPORTS - RCRX ( COREX ) ECL/QA/QC/023
24 CONTRACTORS BILL ECL/QA/QC/024
25 MATERIAL TEST CERTIFICATES ECL/QA/QC/025
26 WORK ORDER ECL/QA/QC/026
27 QUOTATION FOR INSPECTION KITS ECL/QA/QC/027
28 MATERIAL INSPECTION REPORTS ECL/QA/QC/028
29 MASTER LIST OF FORMATS ECL/QA/QC/029
30 CALIBERATION REPORTS ECL/QA/QC/030
31 INSPECTION AND TEST PLAN ECL/QA/QC/031
32 MINUTES OF MEETING ECL/QA/QC/032
33 SPECIFICATIONS AND JOB PROCEDURE ECL/QA/QC/033
LIST OF FILES
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
FORMAT NO: ECL/QA/QC/F018 R0
Brand Name : Date of Test :
Company Name : Batch No. :
Size(DXL)mm : Welder No. :
Material Specification : Method of Testing :
C Mn Si S P Cr Ni
Mo Cb Cu Ti V Fe C.E
As Welded / After Heat Treatment : As welded
Elongation Temp. Energy Absorbed
ksi Mpa ksi Mpa (%) deg. C Joules
DATE Type
Soaking Temperature
(deg. C)
DIFFUSIBLE H
2
PER 100gm OF WELD METAL :
SPECIAL PROPERTIES IF ANY :
REMARKS
REMARKS DATE
AJIT RAO
WITNESSED BY
G BASKAR
APPROVED BY
C.V.N IMPACT TEST
RESULT Soaking Peroid (hrs)
RADIOGRAPHY TEST DETAILS OF HEAT TREATMENT
Yield Stress U.T.S
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
DETAILS OF APPROVAL
ALL WELD METAL TENSION TEST
CHEMICAL ANALYSIS OF WELD METAL (%)
MECHANICAL PROPERTIES OF ALL WELD METAL
FORMAT NO: ECL/QA/QC/F019 R0
Client ___________________________
Transducer 0 45 60 70
Frequency
Crystal Size
Twin/Single
Compression Wave : Transducer Rel dB Loss dB Actual dB
Shear Wave :
Sl No. Job Identification Spot No. Dimension Thickness
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Operator Inspection Authority Client
Signature Signature Signature
Acceptance Standard
Calibrated to ___________mm Screen width sensitivity set at
_________ full screen height from the ______mm hole in
__________ Calibration Block
Scanning and transfer loss dB values are as indicated in Table.
Specification
_________ back wall Echo to _________ full screen height
plus dB values as indicated in Table.
Material ________________________
Technique _____________________
Surface Condition _______________
Couplant _______________________
Identification
Calibration Sensitivity Calibration Standard
Calibrated to ___________mm Screen width sensitivity set at
Observations Result
Report No. :
Date of Inspection :
Project _________________________
Component ______________________
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Thickness Measurement Report
Equipment ____________________
FORMAT NO: ECL/QA/QC/F020 R0
Report No.:
Date :
Test Site
Method :
Type :
Cleaner : PC120B
Penetrant : PP110B
Developer : PD130B
Drg. No. :
Dimensions & Results :
Remarks
Notes
Witnessed By Inspection Authority Client
Signature Signature Signature
Solvent Removable
Manual
ASME Section VIII Div. I Appendix 6
Standard Specification :
Acceptance Criteria :
Batch No. : Date of Mfg. :
ESSAR CONSTRUCTIONS ( INDIA ) LTD.
HAZIRA.
Dye Penetrant Test Report
Client :
Object :
Material Specification :
Accessories
Observations
Batch No. : Date of Mfg. : Date of Expiry :
Batch No. : Date of Mfg. :
Date of Expiry :
Date of Expiry :
ASME E - 709
FORMAT NO: ECL/QA/QC/F-021 R3 Date : 29.09.06
SL
No.
PROJECTS
RELEASE
NOTE
BLASTING
RELEASE NOTE
1
CRM COMPLEX, Hydrogen Plant, BAF, EOT,
Shearing Line (U-V), Packaging Line, Tank &
Looper Structure, Continuous Tandem Mill, Boiler
House Structure, ETP, Chiller Plant & Utility Miter
Bends
RGL BGL
2 EAF - CCP, Caster - III RSMP BSMP
3 Galvanizing Furnace - II RGF BGF
4
Power Plant, CWC Pump House Structure,
Busbar Support
RPOW BPOW
5 Quick Melt Plant RQM2 BQM2
6 Waste Recovery Plant RWRP BWRP
7 Material Handling, Bogie RMH BMH
8 Oxygen Plant ROP BOP
9
LIME KILN - #3 - Dololime, Flexowell, Process Air
System, Support Platform, Kiln Shell Structure &
Hopper.
RLIME BLIME
10 Acid Regeneration Plant RAP BAP
11 Plate Mill RPMIL BPMIL
12 Miscallaneous RMISC BMISC
13 Iran Project RI-01 BI-01
14 Corex RCRX BCRX
1 Quick Melt Plant NY/RQM2 NY/BQM3
2 Oxygen Plant NY/ROP NY/BOP
NEW FABRICATION YARD
LIST OF RELEASE NOTES
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
OLD FABRICATION YARD
FORMAT NO: ECL/QA/QC/F-022 R1 Date : 29.09.06
SL# DESCRIPTION MAKE STICKER# RANGE LEAST COUNT
CAL.
STATUS
DATE
[Link].
DUE ON REMARKS
1 Ultrasonic Flaw detector Modsonic 001 10mm-5M nil yes 16/12/04
2 Profile guage Ferroderm 002 0-1 mm 0.002 yes 25/11/04
3 WFT Guage caltech 003 25-600mic. 25 mic. yes 27/12/04
4 WFT Guage caltech 004 25-600mic. 25 mic. yes 27/12/04
5 WFT Guage caltech 005 25-600mic. 25 mic. yes 27/12/04
6 Boroscope HEINE 006 1mm&more nil no
7 Welding gauge-1 GIC 007 fillet 1"max. angle 0-60 1 mm, 5 deg.
8 Welding gauge-2 GIC 008 fillet 1"max. angle 0-60 1 mm, 5 deg.
9 Welding gauge-3 GIC 009 fillet 1"max. angle 0-60 1 mm, 5 deg.
10 Vernier Caliper Mitutoyo 010 0-300 mm 0.02 mm yes
11 Inside / Outside Caliper 011 10-320 mm no
12 Autolevel #1 Sokkia 012 upto 3 ft. yes 2/12/2004
13 Autolevel #2 Sokkia 013 upto 3 ft. yes 2/12/2004
14 ISO Comparator International Standard 014
15 Thermohygro clock #1 Eurotemp 015
from - 50 to +70 deg C,
20 - 90 % RH
0.1 deg C
16 Thermohygro clock #2 Eurotemp 016
from - 50 to +70 deg C,
20 - 90 % RH
0.1 deg C
17 Binacular Russia 017 120m/1000m
18 Portable Hardness Tester TIME Model -TH-130 018 0-50 deg C yes 14/5/04
19 Luminux High Int'ty Illum., 019 1/8" - 1"
20 Film Density comparator AGFA 020 0-4 (15 STEP INTRVL) 0.3 OPTICAL D yes 03/04/05
21 V-Wac guage G.A.L. GAGE CO. 021 POROSITY-1/8"MAX no
22 Universal Bevel Protractor Mitutoyo 022 5 min. no
23 Elcometer Yuyutsu 023 0-1250microns 1micron no
24 Ultrasonic Thickness gauge - 1 Pulse tech echo system 024 0.60 mm to 300 mm
25 RT Survey meter Minirad 025 0-500 Mr 0.5 Mr N.A
26 RT Film Viewer Eastern Engg elec. [Link]. 026
27 Densitometer Optel 027 0-4 d N.A
28 Ultrasonic Thickness gauge - 2 Pulse tech echo system 028 0.60 mm to 300 mm
LIST OF INSTRUMENTS IN QA/QC, DEPT. ECL.
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
FORMAT NO: ECL/QA/QC/F023 R0
Blasting
Date D. C. No. Blasting Primer MIO F1 Release No.
Inspection
Report
Remarks
Blasting / Painting Status
Sl. No. Description Drg. No. Mkd. No.
Received
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Blasting / Painting Status Report
Item No.
Unloaded
Area
Qty.(set/
nos.)
FORMAT NO: ECL/QA/QC/F026 R0
SR Welder
NO. No.
SIGN:
FOR CLIENT,
NAME:
DATE :
FOR ECL,
NAME :
DATE :
SIGN:
Operator by
NAME:
DATE :
SIGN :
Observation Status
Welding technique :
Applicable code : ASME V, art.- 4&5.
Acceptance standard : ASME VIII, App-12.

Item Joint No
Inspection : Material
Equipment : Einstein
Equipment Sr. no :
Couplant :
LOCATION
Ref. Block : ECL -10,16
Probe :
Probe Sr. no :
Surface Preparation :
UT Technique : Pulse-echo-
Tower No. Sr. No of Section Date : Contractor
ULTRASONIC REPORT
Report No : _______
FORMAT NO: ECL/QA/QC/F027 R0
SR THICK
NO. NESS
DATE :
SIGN:
DATE :
SIGN :
FOR ECL,
NAME :
DATE :
SIGN:
FOR NDT AGENCY.
NAME
FOR CLIENT
NAME:
OBSERVATION REMAR
KS
STATUS JOINT ID SEGM
ENT
SIZE OF
FILM
SFD :
Applicable code : ASME V ,art 2&3
Acceptance std : ASME VIII ,DIV-1
Source size :
RT Technique :
Type of Film :
Welding technique :
Source type :
Source strength :
Intensifying screen :
IQI : DIN-6 ISO 12/10 ISO
Density :
Sensitivity :
NDT Agency :
Material :
Radiography Report
Report No.___________
Tower No. Sr. No of Section Date : Contractor
FORMAT NO: ECL/QA/QC/F-029 R0 Date :
Date:
Date:
SI NO. Pack No.
Heat No. / Batch
No.
Material Description
Total Quantity (in
nos.)
Total Weight
(in MT)
Remarks
SI NO. Punch No. Dimensions
Deviations from the
Actual
Quantity
Inspected
OBSERVATIONS:
QA/QC
ECL
Purchase Order / Invoice No :
Consigners Name & Address:
MRS No. :
Issed to Agency :
MATERIAL INSPECTION REPORT
HAZIRA.
ESSAR CONSTRUCTIONS LTD.
DETAILS OF MATERIAL
DETAILS OF INSPECTION
Remarks
FORMAT NO: ECL/QA/QC/F030 R0

PROJECT NAME : REPORT NO. :
STRUCTURE / EQUIP. NAME : DATE :
DRG. NO. :
ITEM / MKD. NO. :
SL. NO. DESCRIPTION AS PER DRAWING OBSERVATION REMARKS
1 DIAGONAL
2 ELEVATION
3 VERTICALITY
4 NOZZLE ORIENTATION & ELEVATION
5 FIT UP AND WELD VISUAL
6 NDT (RT, UT, DPT)
7 BOLT TIGHTENING
8 GROUTING
9 OTHERS
RESULT:
ERECTION AGENCY ECL EXECUTION ECL QA/QC CLIENT
SIGN
NAME
DATE
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
PROTOCOL FOR STRUCTURAL ERECTION
FORMAT NO: ECL/QA/QC/F-031 R0
ITP NO. :
DATE :
Contractor ECL
LEGENDS : INSPECTION GRADES
A - APPROVE A : Inspection & Approval from ECL is mandatory for further activities.
H - HOLD B : ECL reserves the right to perform inspection as deemed necessary.
DR - DOCUMENT REVIEW
RW - RANDOM WITNESS
M - MONITOR
W - WITNESS
Inspection
Freuency
of
Inspection
Sl. No. Activity Description Responsibility
Signature
Name
PROJECT NAME
JOB DESCRIPTION
Acceptance Standard /
Specification
INSPECTION TEST PLAN
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
Agency Approved By ECL
Format Remarks Inspection Grade
Sl. No
Responsibil
ity
Inspection
grade
Format Remarks.
1.0 Prior to Fabrication
1.1 P P B
1.2 P A B
1.3 P DR B
1.4 P DR/A B
1.5 P W A
2.0
2.1 P M C
2.2 P RW B
2.3 P RW B
2.4 P M C
2.5 NDT as applicable P W/A A
2.6 Final Visual and Dimensional Inspection P W A
3.0 Sand Blasting and Painting
3.1 Verification of Batch TC's of Paint P P B
3.2 Inspection of Sand Blasted Surface P RW B
3.3 DFT Checking of Primer Coat P W B
3.4 DFT Checking of Subsequent Coats P RW B
3.5 Final Clearance/Release Note P W A
4.0 Erection
4.1 Checking of Foundation Elevation P M C Protocols
4.2 Checking of Foundation Bolts
P M
C
4.3 Final Inspection of Erected Structure P W A Protocols
4.4 Fit-up Inspection P RW B
4.5 Weld Visual P RW B
4.6 NDT as applicable P W/A A as applicable
4.7 Submission of final dossiar/protocol P DR A
Legend :
A : Approved
M : Monitor
RW: Random Witness
Marking and Cutting
Fit-up Inspection
Verification of Material Test Certificates
Identification of Welding Consumbles
Review of Consumable TC's
Establishing WPS/PQR
Approved Dwg. & [Link]'
Approved Drawings
Approved Dwg. & [Link]'
Approved Dwg. & [Link]'
NDT/Proj. specifications
specifications
Approved Drawings
Approved Dwgs.
Approved Drawings
Paintaing/Proj. specifications
Sa 2 & Project specification
Paintaing/Proj. specifications
Paintaing/Proj. specifications
Description Acceptance Standard/Specification Inspection
Approved Dwg. & Spec'
WPS & Proj. Spec.
Inspection of Groove Weld Joints
Pre-heating as applicable
Welder Qualification
During Fabrication
IS:2062-1999
Project specifications
ASME Section II Part C
ASME Sec IX
Approved Dwg. & Spec'
W : Witness
Inspection Grades :
A : Inspection and approval from ECL is mandatory for further continuation of work
B : ECL may perform random inspection on their descretion.
C : Inspection is the responsibility of , ECL will review documents.
ASME Sec IX
P : Perform
DR : Document Review
Approved Dwg. & Spec'
NDT/Proj. specifications
FORMAT NO: ECL/QA/QC/F-032 R0
DCP NO. :
DATE :
contractor ECL
1 Request for Inspection G R & AC OC ECL/QA/QC/F-007
2 Inspection Report(rolled) G AC & A OC ECL/QA/QC/F-025
3 Inspection Report(Built-Up) G AC & A OC ECL/QA/QC/F-024
4 Release Note R G PLNG,EXE,CON'TOR,OC ECL/QA/QC/F-005
5 Despatch Challan G S SBY ECL/QA/QC/F-033
6 Inspection Report(Blasting) G G FILE ECL/QA/QC/F-023
7 Blasting Release Note R G PLNG,EXE,CONTRACTOR ECL/QA/QC/F-006
8 WQT Record G A CONTRACTOR,OC ECL/QA/QC/F-009
9 WPS/PQR G A CONTRACTOR,OC ECL/QA/QC/F-001
LEGEND: "G" - GENERATION ; "R"-RECEIVE ; "S" - SIGN OFF AND "A" - APPROVAL,"AC" ACT, "OC" OFFICE COPY
Remarks SL#
RESPONSIBILITES
ACTIVITY DESCRIPTION Distribution format Ref:
JOB DESCRIPTION
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
DOCUMENT CONTROL PROCEDURE(DCP)
PROJECT NAME
FORMAT NO: ECL/QA/QC/F-032 R0
DCP NO. :
DATE :
Contractor ECL
1 Request for Inspection ECL/QA/QC/F-007 Drawing / Sketch each item G R
2 Inspection Report(rolled) ECL/QA/QC/F-025 Drawing / Spec. each item G S Job Procedure for Fab.
ECL/JP/FBSS-01 R0
3 Inspection Report(Built-Up) ECL/QA/QC/F-024 Drawing/Spec. each item G S
TO BE [Link] NDT
STATUS, CONTRACTOR
COPY
4 Release Note ECL/QA/QC/F-005 Inspection Report each item R G
5 Despatch Challan ECL/QA/QC/F-033 Release Note each item G S
6 Inspection Report(Blasting) ECL/QA/QC/F-023
Spec. for Surface
Preperation & Paiting
each item G S
Blasting Specification
ECL/SPP-01 R0
7 Blasting Release Note ECL/QA/QC/F-006
Daily Inspection
Report(Blasting)
each item R G
8
Welder Qualification
Certificate
ECL/QA/QC/F-003 ASME [Link] each welder G A
9
Welding Procedure Spec. /
Procedure Qualification
Record
ECL/QA/QC/F-001
ECL/QA/QC/F-002
ASME [Link] each process/variables G A WPS & PQR STATUS
ECL/QA/QC/F-016 R5
10 Approved Electrode List ECL/QA/QC/F-004 ASME [Link] Part C
each batch of electrodes /
filler wire / fluxes
R G
ECL/QA/QC/F-013 R0
11 Inspection & Test Plan ECL/QA/QC/F-031 Drawing / Spec. each project G A
12 NDT Activities
ECL/QA/QC/F-026
ECL/QA/QC/F-027 ASME Sec. V each spot G A
WILLY BOEKHOFF
G BASKAR
AJIT RAO
NAME DATE REV NO. DESCRIPTION SIGNATURE
APPROVED BY
CHECKED BY
PREPARED BY
LEGEND: "G" - GENERATION ; "R"-RECEIVE ; "S" - SIGN OFF AND "A" - APPROVAL
JOB DESCRIPTION
Sl. No. Activity Description Format Ref Remarks Approved Documents Frequency of Inspection
Responsibility
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
DOCUMENT CONTROL PROCEDURE(DCP)
PROJECT NAME
FORMAT # ECL/QA/QC/F033, R-3 DATE: 25-09-2006
SL. MEDIUM MEDIUM DESCRIPTION DESIGN PRESSURE DESIGN REMARKS
NO. CODE in kg/cm2 g [Link]. C GRADE TYPE PROCESS ROOT FILL UP / FINAL ROOT DP RT
1 IA INSTRUMENT AIR 12 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM
2 PA PLANT AIR 12 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM
3 CWS COOLING WATER SUPPLY 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E6013 10% 10% CRM
4 CWR COOLING WATER RETURN 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E6013 10% 10% CRM
5 DW DRINKING WATER 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E6013 10% 10% CRM
6 FW1 FIRE WATER ABOVE GROUND 10.6 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM
7 FW2 FIRE WATER UNDER GROUND 10.6 60 IS 1239 / IS 3589 ERW GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM
8 TW TREATED WATER LINE 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% CRM
9 ST1 STEAM LINE1 12 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% BOILER
10 ST2 STEAM LINE2 12 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% BOILER
11 ST3 STEAM LINE3 12 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% BOILER
12 CL1,CL2,CL3,CL4 CONDENSATE LINE 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% BOILER
13 FI FURNACE OIL LINE 10 60 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% CRM
14 NG NATURAL GAS - LOW PRESSURE 11 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% CRM
15 SA SPENT ACID 10 90 FRP FRP ARP
16 FA FRESH ACID 10 90 FRP FRP ARP
17 RA RINSE ACID 10 90 FRP FRP ARP
18 SUW SUMP WATER 10 90 IS 1239 / IS 3589 ERW SMAW E6010 E7018 10% 10% ARP
19 N2 NITROGEN 10 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% ARP
20 SW SERVICE WATER 10 60 IS 1239 / IS 3589 ERW SMAW E7018 10% 10% CRM
21 RE ROLLING EMULSION 10 90 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% CRM
22 ChA CHROMIC ACID 10 90 FRP FRP ARP
23 H2 HYDROGEN 10 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% ARP
24 HNX N2+H2 10 60 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 100% ARP
25 COLD BOX PIPING AR, O2, N2 10 -183 TO -191 SA 5083 SML GTAW ER 5183 ER 5183 N.A 100% O2 PLANT
26 O2 O2 LINE 10 -183 TYP. 321 SML GTAW + SMAW ER 347 E 347 N.A 100% O2 PLANT
27 MH-P OIL SUPPLY 210 ASTM A 106 GR.B SML GTAW ER - 70 S2 ER - 70 S2 N.A 10% HYDRAULIC
28 MH-P ACTION LINE NO. 210 ASTM A 106 GR.B SML GTAW ER - 70 S2 ER - 70 S2 N.A 10% HYDRAULIC
29 MH-T OIL RETURN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
30 MH-D OIL DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
31 MH-FD FMV OIL DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
32 MH-MD MAGNESCALE DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
33 MH-OC OIL CHANGE 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
34 MH-OD OIL DUMP 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
35 AH-MD MANDRAL DRAIN 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
36 RC-B BY PASS LINE 5 ASTM A 106 GR.B SML GTAW + SMAW ER - 70 S2 E7018 N.A 10% HYDRAULIC
37 NG NATURAL GAS - HIGH PRESSURE 120 -29 API- 5L Gr. X-65 SML SMAW E-6010 E7010 G 100% 100%
38 MH OIL SUPPLY 315 60 TYP.304 SML GTAW+SMAW ER-308L E-308L-16 10% 100% HYDRAULIC
39 MH OIL RETURN 10 60 TYP.304 SML GTAW+SMAW ER-308L E-308L-16 N.A 10% HYDRAULIC
PIPE LINE SPECIFICATION
TYPE OF NDT MATERIAL FILLER WIRE / ELECTRODE
40 MH OIL DRAIN 10 60 TYP.304 SML GTAW+SMAW ER-308L E-308L-16 N.A 10% HYDRAULIC
41 MH OIL SUPPLY 315 60 ASTM A 106 GR.B + SML GTAW+SMAW ER-309L E-309L 10% 100% HYDRAULIC
TYP. 304
42 MH OIL RETURN 10 60 ASTM A 106 GR.B + SML GTAW+SMAW ER-309L E-309L N.A 10% HYDRAULIC
TYP. 304 N.A
43 MH OIL DRAIN 10 60 ASTM A 106 GR.B + SML GTAW+SMAW ER-309L E-309L N.A 10% HYDRAULIC
TYP. 304
44 AW(H20+SLUDGE) ALKALINE WASTE AND SLUDGE LIINE 4 40 TO 70 IS 1239 / IS 3589 ERW SMAW E-6010 E-6013 10% 10% ETP
General Notes
1 All lines of dia. 2" and below Pipes shall be done welding of full GTAW for both root and fillup/final passes irrespective of service.
2 All lines of above 2" dia. and a pressure of above 10 kg/cm2 shall be done welding of root by GTAW and fillup/final by SMAW processes irrespective of service.
3 Edge preperation of joints shall be followed as mentioned in Drawing.
4 All lines of 2" and below , where socket welding is involved . 100% DPT of welding is advisible.
FORMAT # ECL/QA/QC/F034, R-1
Sep. 2006
UT in mtrs RT in inches DP in mtrs.
Final inspection
in MT
Hydro test
(mtr)
Holiday
test(mtr)
1 Sinter plant 0 315 22 196 78 274
2 Caster
3 EAF
4 QM-II
5 Power plant
6 Plate mill
7 Corex
8 CRM
9 Central store
10 CMS
11 NFY
12 Material handling
13 Miscellaneous
14 Lime plant
15 Blasting works
Note:
Total

Essar Constructions Limited - Hazira
Monthly Progress Report - QA/QC (Mech.)
Sl no. Area
Test carried out
Remarks
FORMAT # ECL/QA/QC/F035, R-0
PROJECT NAME
DRAWING NUMBER
MARK NUMBER
QTY
INSPECTED BY ACCEPTED / REJECTED
ESSAR CONSTRUCTIONS LTD.,-HAZIRA. (QA/QC-MECH)
0
4
5
6
7
10
13
15
16
19
23
25
27
29
26
22
20
18
14
0
5
10
15
20
25
30
35
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
V
A
L
U
E
S

I
N

"
M
M
"

LENGTH IN METER
CAMBER ON EOT
Series2
REMARKS: SEE PROTOCOL
ACCEPTED / REJECTED
ESSAR CONSTRUCTIONS LTD.,-HAZIRA. (QA/QC-MECH)
14
12
7
6
3
2
1 1
0
20 21 22 23 24 25 26 27
FORMAT # ECL/QA/QC/F036, R-0
Contractor Name:
Date : NCR No : ECL/QA/QC/
Area:
PROJECT :
AREA
Engineering Procurement Blasting & Painting
Civil Mechanical Others
Non - Conformance observation details (Be Specific)
Dept. in-charge(QA/QC) Excecution(ECL) Inspector (QA/QC)
Sign. & Date Sign. & Date Sign & Date
Corrective Action Agreed upon
Agreed completion Date:
Contractor Sign.
Preventive action Agreed upon
Contractor Sign,: Agreed completion Date:
Inspector (QA/QC) : Approved by
Sign & Date: Sign & Date
Status of NCR : Close / Open
NON CONFORMITY REPORT
FORMAT # ECL/QA/QC/F037, R-0
ESSAR CONSTRUCTION LTD
FIELD TECHNICAL QUERIES (FTQ)
DISCIPLINE
OF FTQ
MECH PAINTING
Distribution: Original to Originator
Copy to : Project Manager, Field Engineer, QA/QC File
__________ ____________
MANAGER DATE
P
R
O
J
E
C
T

M
A
N
A
G
E
RACCETANCE:
____________
SIGN DATE
BLASTING
SPECIFICATION REFERENCE:
PROPOSED SOLUTION BY ORIGINATOR:
D
E
S
I
G
N
ORIGINATED BY: NAME: SIGNATURE:
AGREED BY DESIGN / ALTERNATIVE SOLUTION BY DESIGN: (DELETE AS APPLICABLE)
CONTRACT NAME.:
NO.: FTQ/
DESCRIPTION OF QUERY (BE SPECIFIC)
DRAWING NO.: DATE RESPONSE REQUIRED BY:
O
R
I
G
I
N
A
T
O
R
ORGINATOR :
PROJECT :
PIPING STRUCT
DATE :
FORMAT # ECL/QA/QC/F038, R-0
ESSAR CONSTRUCTIONS LTD
FIELD OBSERVATION REPORT (FOR)
Date:
CONTRACT NAME:
FOR NO.
Date: Name : Signature:
Date : Name: Signature
E
C
L
-
Q
A
/
Q
C
Action Taken
Date : Name: Signature:
E
C
L

-

P
M
Resolution / Concurrence:
E
C
L

Q
A
/
Q
C
Preventive measures to avoid recurrence in future:
COMPANY:
Date: Signature:
Action needed: Yes or No (if no inform PM-ECL to close FOR
Discipline of FOR
O
R
I
G
I
N
A
T
O
R
Description of Field
Observation:
Procedure as per specification/ normal practice:
Proposal for corrective action
ORGINATOR NAME:
FORMAT # ECL/QA/QC/F039, R-0
Drawing No: Column No.:
Area :
[Link]. Drg, Dimension
3
4
5
6
Water level ( If required)
Square ness of Flange 0..005X b or max. 2mm
Diagonal 0.0012 X L or Max.7 mm
2 Over all Length ( L)
Upto 10 mtr - +/- 5mm
Over 10 mtr - 0.0005 l subject
or Max. +/- 8 mm
Base Plate Flatness /
Straightness Max. 1 mm
Inspection Report for Column
Description Tolerance as per IS 7215.
1 Straightness ( y ) Longitudinal - 0.001 X L or
max 10 mm
Tranverse - 0.001 X L or max
10 mm
iii) Remarks ( if any) :
CONTRACTOR ECL.
QA/QC Execution
ii) NDT :
i) VISUAL INSPECTION :
Column No.:
Actual
Dimension
Remarks
Inspection Report for Column
ECL
QA/QC
FORMAT # ECL/QA/QC/F040, R-0
Drawing No: Crane Girder No.:
Area :
[Link]. Drg, Dimension
Actual
Dimension
Y1
Y2
2
5 End Plate straightness
/ flatness
I) VISUAL INSPECTION :
4 Buckling in web
Upto 500 mm - 0.5 mm
500 mm to 1000 mm - 1.0 mm
Over 1000 mm - 2.0 mm
Squareness of Flange 0..005 X b or max. 2mm
3 Over all Length (L )
Upto 12 mtr - +/- 3 mm
Over 12 mtr - 0.0025 L or
Max. +/- 5 mm
Inspection Report for Crane Girder
Description Tolerance as per IS 7215.
1 Straightness (Camber) 0.0001 x L or Max. 10 mm
whichever less
Max 5 mm
iii) REMARKS ( if any) :
CONTRACTOR ECL. ECL
QA/QC Execution QA/QC
ii) NDT :
Remarks
Inspection Report for Crane Girder
Mark No:
Date:
( L )
( D)
[Link]. Drg, Dimension
Actual
Dimension
Remarks
1
2 N.A
3 N.A
4
ECL ECL
QA/QC EXECUTION QA/QC
NOTE: ALL DIMENSIONS ARE IN "mm"
D+/-1 % or Max.20mm
Straightness 0.5mm/Mtr. Or max.5mm
FINAL INSPECTION REPORTS - DUCTS
Description
Tolerance as per spec.
/Codes/Drgs.
Ovality ([Link]. D2)/2 = Max.t/2
Length (L) 2.5mm/Mtr.
VISUAL INSPECTION OF PIPE /DUCT :
FORMAT # ECL/QA/QC/F041, R-0
Drawing No:
Service/Purpose :
CONTRACTOR
NDT OF THE PIPE /DUCT:
Diameter ()
FORMAT NO: ECL/QA/QC/F042 R0
WPS Matl.
ESSAR CONSTRUCTIONS LTD. NO. Type
HAZIRA.
:
:
:
:
PHOTO
WELDER IDENTITY CARD
NAME OF THE WELDER
APPROVED BY
SEAL ESSAR CONSTRUCTIONS LTD SEAL
COMPANY NAME
IDENTITY NO.
PROJECT NAME
APPROVED BY
FORMAT NO: ECL/QA/QC/F042 R0
Welding Filler wire / Range Qualified Position Date Approved
Dia. Thk Range Process Electrode Dia. Thk Range Qualified of Qfln. By ECL
in. (mm) Type in. (mm)
Test Coupon
APPROVED BY
SEAL ESSAR CONSTRUCTIONS LTD
FORMAT NO: ECL/QA/QC/F023 R0
SL
NO.
DESCRIPTION SPEC. / PROCEDURE NO.
A
1 GENERAL NOTES & INSTRUCTIONS FOR FABRICATION ECL/SP/FB-01 R0
2 STANDARD WELDING SPECIFICATION ECL/SP/WD-01 R0
B
1 PROCEDURE FOR INCOMING MATERIAL INSPECTION ECL/JP/QA/01 R0
2
Procedure for qualification of welding personnel
ECL/JP/QA/02
3
Procedure for Qualification of WPS & PQR
ECL/JP/QA/03
4
Procedure for fabrication structural steel
ECL/JP/QA/04
5
Procedure for visual Examination
ECL/JP/QA/05
6
Procedure for Surface preparation and painting
ECL/JP/QA/06
7
Procedure for Dye penetration Examination
ECL/JP/QA/07
8
Procedure for Radiography examination
ECL/JP/QA/08
9
Procedure for Ultrasonic examination
ECL/JP/QA/09
10
Procedure for Control of Non Conforming Product
ECL/JP/QA/10
11
Procedure for calibration of measuring equipments
ECL/JP/QA/11
C
1 Quality Manual
ECL/ QA/QC-HAZ-QM-01
QUALITY MANUAL
PROCEDURES
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
LIST OF SPECIFICATIONS / PROCEDURES
SPECIFICATIONS
Date : 28/01/05
Ref No.: ECL/QA/QC/CORR.035
To,
Royal Arc Electrodes Pvt. Limited.
Mumbai - 400064
Attention : Mr. B. A Patil,Sales Executive.
Dear Sir,
Subject :Approval of your Welding Electrode Royal - Therm (E 7018)
With reference to your letter M. G. W. P / 2004 Dated : 13/10/04 for the above -
mentioned subject. We have reviewed and tested the electrodes and fonund suitable
for use in our Project work at Hazira. The Details are
Trade Name : Royal - Therm
Description : Low Hydogen Type
Diamaters : 2.5, 3.15 & 4.0
Welding Polarity : DCEP
Welding Position : All positions for Butt Welding except vertical down.
Please keep us up to date for any change in Trade name / Manufacturing system.
Also you are requested to ensure proper co-relating batch certificates are furnished
along with every supply.
This approval is valid based on the consistence in Quality which has to be
checked / reviewed by us periodically.
For Essar Constructions Limited.
Authorized Signatory
FLUID SYSEM LINE NAME
GRADE TYPE ROOT PROCESS FINAL
MILL HYDRALIC MH-P OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW ER70 S2
SYSTEM MH-P ACTION LINE NO. ASTM A 106 SML ER70 S2 GTAW ER70 S2
MH-T OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018
MH-D OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018
MH-FD FMV OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018
MH-MD MAGNESCALE DRAIN ASTM A 106 SML ER70 S2 GTAW E7018
MH-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018
MH-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018
AUXILLARY AH-P OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW ER70 S2
HYDRAULIC AH-P ACTION LINE NO. ASTM A 106 SML ER70 S2 GTAW ER70 S2
SYSTEM AH-T OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018
AH-D OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018
AH-MD MANDRAL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018
AH-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018
AH-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018
ROLL RC-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW ER70 S2
COOLANT ASTM A 106 SML ER70 S2 GTAW ER70 S2
SYSTEM RC-R OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018
RC-D OIL DRAIN ASTM A 106 SML ER70 S2 GTAW E7018
RC-B BY PASS LINE ASTM A 106 SML ER70 S2 GTAW E7018
RC-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018
RC-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018
GEAR GL-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW E7018
LUBRICATION
SYSTEM GL-R OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018
GL-B BY PASS LINE ASTM A 106 SML ER70 S2 GTAW E7018
GL-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018
GL-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018
MOTOR ML-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW E7018
LUBRICATION
SYSTEM ML-R OIL RETURN ASTM A 106 SML ER70 S2 GTAW E7018
ML-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018
ML-OD OIL DUMP ASTM A 106 SML ER70 S2 GTAW E7018
OILING SYSTEM OL-S OIL SUPPLY ASTM A 106 SML ER70 S2 GTAW E7018
OL-OC OIL CHANGE ASTM A 106 SML ER70 S2 GTAW E7018
SUMP DRAINAGE SD DUMP OUT ASTM A 106 SML ER70 S2 GTAW E7018
SYSTEM
GENERAL NOTES :
1. Welding process of 1/2" to 2" dia. Pipes shall be of full GTAW for both root and fillup/final passes.
2. All lines having a pressure of above 10 kg/cm2 shall be done welding of root by GTAW and fillup/final by SMAW processes.
MATERIAL ELECTRODE
NORMAL TEST WELD TYPE OF NDT REMARKS
PROCESS PRESSURE PRESSURE TYPE ROOT DP RT
GTAW 210 kg/[Link] 315 kg/[Link] SW 100% 100%
GTAW 10 min. FOR BW
SMAW 5 kg/[Link] <50 NB 100% 10%
SMAW 10 min. SW 100% FOR
SMAW 65-80 NB 100% BUTT
SMAW BW 100% WELD
SMAW 100%
SMAW 100%
GTAW 70 kg/[Link] 105 kg/[Link] SW 100% 100%
GTAW 10 min. FOR BW
SMAW 5 kg/[Link] <50 NB 100% 10%
SMAW 10 min. SW 100% FOR
SMAW 65-100 NB 100% BUTT
SMAW BW 100% WELD
SMAW 100%
GTAW 8 kg/[Link] 16 kg/[Link] BW 100% 10%
GTAW 10 min.
SMAW 5 kg/[Link] <50 NB 100% 10%
SMAW 10 min. SW 100% FOR
SMAW 65-400 NB 100% BUTT
SMAW BW 100% WELD
SMAW 100%
SMAW 5 kg/[Link] 10 kg/[Link] SW & 100% 10%
10 min. BW FOR BW
SMAW <50 NB 100% 10%
SMAW SW 100% FOR
SMAW 65-125 NB 100% BUTT
SMAW BW 100% WELD
SMAW 2.5 kg/[Link] 5 kg/[Link] SW & YES 10%
10 min. BW FOR BW
SMAW 5 kg/[Link] <50 NB YES 10%
SMAW 10 min. SW YES FOR
SMAW 65-100 NB YES BUTT
BW WELD
SMAW 3 kg/[Link] 6 kg/[Link] SW YES
SMAW 10 min. YES
SMAW 3 kg/[Link] <50 NB YES 10%
SW FOR
65-80 NB BUTT
BW WELD
1. Welding process of 1/2" to 2" dia. Pipes shall be of full GTAW for both root and fillup/final passes.
2. All lines having a pressure of above 10 kg/cm2 shall be done welding of root by GTAW and fillup/final by SMAW processes.
ELECTRODE
DATE :
REPORT NO. :
SL.
NO.
DRG. NO. DESCRIPTION MKD. NO. QTY.
TOTAL
WT.
BLAST
WT.
BLASTED
ITEM NO.
REMARKS
AGENCY ECL
ECL - SURFACE COATING YARD
DAILY PROGRESS REPORT
ANGLE 0 45 60 70
FREQUENCY PROBE ANGLE FSH dB BEAM PATH
CRYSTAL SIZE T/4
TWIN / SINGLE T/2
CABLE TYPE
3T/4
SPECIFICATION
SL. NO. X POSTION Y POSITION DEPTH BEAM PATH FSH (%) REMARKS
TRANSDUCER DETAILS
ACCEPTANCE STANDARD :
CALIBERATION PARAMETERS
GROOVE : SINGLE / DOUBLE
BASIC CALIBERATION BLOCK THK. / HOLE DIA :
WELD LENGTH : WELD REINFORCEMENT :
SCANNING AREA
FLAW DETECTOR : COUPLANT :
DATA SHEET
ESSAR CONSTRUCTIONS LTD.
HAZIRA.
JOB NO. : MATERIAL 1 : MATERIAL 2 :
SEAM NO. : JOINT TYPE : BUTT / TEE
REMARKS
JOB DESCRIPTION
UT TEST PARAMETERS
UT TECHNIQUE SHEET
TECH NO. :
DATE :
NAME :
EMP. NO. :
THICKNESS 1 : THICKNESS 2 :
APPROVED BY
PREPARED BY
SIGNATURE NAME
psi n/mm2
44.341 0.266046 rate
28755
23.33333333
IXAR
3" 4" EL UNIT CHARGE / DAY
RATE 10.5 11.5 95 1000
QTY 466.5 648 3 10
4898.25 7452 285 10000
27635.25
GAMMAX WORK ORDER NO. ECL/MEC/7200002143 DATED : 16/02/05
3" 4" EL UT DISCOUNT (5%)
RATE 9 10 70 90 0.05
QTY 61515 25130 660 1100
553635 251300 46200 99000 47506.75
950135
in Al piping
3" 4" ellip
QTY 6000 2500 400
RATE 12 13.25 125
Total 72000 33125 50000
Service Charge 7344 3378.75 5100 Total net Value
Grand Total 79344 36503.75 55100 170947.75
GAMMAX - IXAR 5923.25
RADIOGRAPHY
FF 1.44
Ci
RHM 500 mR/Hr meter
THK
HVT 1.3
SFD 1
Exposure Time =
E316-15 FN(MIN)=3 TO REDUCE HOT CRACKING
S P - SOLIDIFICATION CRACKING
ACTIVATED - TIG WELDING(A-TIG)
CO2 LASERS - Nd-YAG LASERS
50MICRON WITH 17.2MM SS PLATE
FRICTIONAL WELDING
HEAT (MAX) = 0.8MELTING POINT
AL ALLOYS THK - 1.2 TO 50MM
REPAIRS
MANUFACTURING OPERATIONS
749 14580
3 4 diff 2875.5
3195 2875.5
1 0.9
2 1.8
0
RT RATE GAIN FOR ESSAR FROM CONVERTING 3" TO 4"
lg 3" 4" rate 3 rate 4 diff 3 - 4
3195 2396.25 28755 23962.5 4792.5
3000 2250 27000 22500 4500
2000 1500 18000 15000 3000
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 23970
28755
4785
MOBILISATION
5000
1 TOTAL SERVICE TAX ON TOTAL
5000 27635.25 2818.796
GRAND TOTAL 30454.05
TOTAL NET VALUE
TOTAL SERVICE TAX ON TOTAL
997641.8 101759.5
902628.25 1099401
IXAR
3" 4" ellip ADD.
6000 2500 400 10000 Mobilisation
10.5 11.5 95 10000 Unt Charge / day
63000 28750 38000 22040 ADD. Total + Service charge
6426 2932.5 3876 Total net Value
69426 31682.5 41876 165024.5