Compendium

of
Inspection Checklists for Fabrication Division Quality
Management Department

00

29/06/2005

Rev.
No.

Date

Issued for Reference

Description

FABRICATION DIVISION
RELIANCE INDUSTRIES LIMITED, JAMNAGAR
Job Number
0

SNS

SNS

AJV

By

Chkd.

Appd.

Department/
Division

Quality Management

Location:

Jamnagar

Document No
0

Hard copy of this document shall be treated as uncontrolled if not signed by approver

Total pages - 11

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

CONTENTS
1. PIPE SPOOL FABRICATION

2. STRUCTURAL STEEL FABRICATION

3. WRAPPING & COATING OF PIPE/PIPE SPOOLS

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Page 2 of 11

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

1.

CHECK LIST FOR PIPE SPOOL INSPECTION AT

FABRICATION DIVISION

Sr. no.

Activity

Method

Verify and ensure the storage condition/stock

No mix-up between SS & CS materials
status of the material.

Whether identification of the pipe classes are

shown in the isometric & format

Verify the NDT % & PWHT requirement

written on the spool sheet w.r.t. form 167A

Spool Sheet to be cross checked with

form 167A

Whether the required WPSs are available in

line with form 167 A?

WPS apllication chart

Whether qualified welders only performing

welding / tacking?

PMI check carried out on alloy steel material

prior to welding

10

11

Project specification 22960-3PSGAW004 & Form 167A

Problem faced. Be
careful.

Verify WPQ / ID
100 % on all pipe cut pieces and on
fittings

IBR material TC verified or not?

Verification of IBR material summery

list

Heat numbers are transferred on IBR pipe cut

lengths or not?

Verification on pipes for hard punch

Remarks

LTCS pipes are identified with colour strip

(orange) or not

Verification.
Prior to induction bend positive thickness
Prior to Induction bend, the pipe thickness is
of the pipes shall be ensured. The
checked or not ? Transfer of heat number /
identfication marks i.e. Matcode / Heat
matcode number to inside the pipe is done or numbers shall be transferred to inside the
not?
pipe.
Induction bend ovality. hardness & thinning
of CS and AS checked or not ?
Induction bend ovality & thinning of SS
The bend dimensions and parameters
shall conforms to the induction bend
checked or not ?
procedure 2 PF JEP GE 001
NDT of Induction bend done or not?

12

Electrode baking

Verifying the oven record, randomly

13

Correct usage of electrode

Cross checking the electrode while

welding the job

14

Correct usage of WPS

15

Purging of the pipe

16

Preheating

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Welding Engineer is
ensuring the baking of the
electrode on daily basis.

Cross checking the electrode while

welding the job
Cross checking the purging while
welding the job
Cross checking the preheating while
welding the job
Page 3 of 11

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR
Sr. no.

Activity

Method

Remarks

Pipe Spool contd

Cross checking the post heating while
welding the job

17

Post heating

18

Cross check and sign on the PWHT

PWHT, number of thermocouples attachment time - temperature chart during PWHT.

19

No of runs on socket joints

20

Interpass Temperature

21

During Spool weld visual inspection the

followings are verified or not?:

Cross check while welding socket joints.

Cross check while welding the joint.

Line no

Verify the punching on spool as well as

on Aluminium tag
Verify the punching on spool as well as
on Aluminium tag

FCO no

Verify the punching on spool as well as

on Aluminium tag

Joint no

Verify the punching on spool weld joint

Welder no

Verify the punching on spool weld joint

STS no

Spool verification with ISO for no. of

joints and Spec break

Verify the punching on spool weld

joint
Verify the WPS number mentioned in
spool clearance report.

Weld process with WPS

Physical condition of the spool, especially
for pitting on ERW pipes.

Physical verification

Flange serration

Physical verification

Reinforcement of weld joint is within code

limit and not less than the thickness.

Complaints
Received
from site on this point

For dissimilar thickness or external

overlap, the weld shall be tapered to
suit the step.

Orifice flange internal grinding

Physical verification

Power brushing on joint internal wherever

accessible

Physical verification

Internal cleaning by air blowing

Physical verification

Aluminum tag verification

Ensuring proper gauge of GI wire is used for
tag and wooden blanks

Physical verification

Ensuring SS wire is used for tag n the case of

SS spools.
Flagging of the spools for the status:
Orange colour ribbon for readiness of the
spool for inspection
Green colour ribbon for NDE cleared spools
Red colour ribbon for repair spools

Complaints
Received
from site on this point

Physical verification
Physical verification

Physical verification

All spools are to be rotated to 360 and

inspected. All weld joints shall be inspected
from inside if open joints.
Inspection checklists for Fabrication Division Quality
Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Page 4 of 11

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

Sr. no.

Activity

Method

Remarks

Pipe Spool contd

22

Radiography testing

23

Whether the approved NDT procedures are

available or not?
Site approval from BARC is available or
not?

Document verification with NDE agency

24

Record of present strength of the camera is

available or not?

Document verification with NDE agency

25
26

Calibration for safe light, densitometer,

survey meter, IQI are available or not?

Document verification with NDE agency

27

Radiography camera operating system is in

good condition or not?

28

Qualified site incharge is in site or not?

29

Qualified personnel operating the camera or

not?

30

Availability of the procedures

Physical verification

Physical verification during testing

31

NDT Darkroom condition verified or not?

Work instruction of film processing
procedure is displayed in the dark room or
not?

32

Log book for humidity, room temperature ,

film process and chemical replenishing are
maintained or not?

33

Magnetic particle testing

34

Magnetic particle testing procedure and

qualified procedures are available with NDE
contractor or not?

Physical verification

35

Yoke calibrated, and Lifting capacity

verified or not?

Physical verification

36

Magnetic particle bath concentration is

verified with centrifuge or not? Log book for
the same is maintained or not?

Physical verification

37

Field indicator is being used during the test

or not?

Physical verification

38

Sprayer is in working condition or not?

Physical verification

39

During test surface contrast enhancement

properly being done or not?

Physical verification

40

NDT marking for random NDT pipe

classes

41

identification of lot (per day offering or as

per production manager)

42

minimum % of joints as per form 167A to be

covered

43

At least one joint per welder per lot shall be

marked for NDT

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Physical verification

Physical verification

Physical verification

2QA WIN ME 009

Page 5 of 11

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

Sr. no.

Activity

Method

Remarks

Pipe Spool contd

45

Spec wise minimum % as per form 167A per

welder shall be covered.
In case of repair, penalty shall be selected
from the same lot and shall not be carried
over to other lot.

46

Evaluation of welder performance are being

done on daily basis or not?

Daily welder performance reports

Issue repair memo and follow up

48

Status of repair joints are being moinitored or

not?
After RT interpretation, for repair joints
repair memo are issued to the contractor or
not?
Penalty joints offered on same group of
joints or not?

Issue repair memo and follow up

49

44

47

Issue repair memo and follow up

For Other Jobs like PP,

ASME B 31.3 table 341.3.2
the applicable
Project specification 22960-3PS-GAWspecification to be
004
followed

50

Whether the copies of acceptance criteria are

available or not?

51

Whether the fit-up is as per the requirement

or not?

Root gap, off-set if any

52

In case of Impact requirements, whether the

electrode weaving are controlled or not?

Applicable WPS

53

Whether DPT material is in stock or not?

The set is from single manufacturer or
not? DPT is carried out as required in
Form 167A or not?

54

The required weld fillet size of supports, RF

pads, branch connections are verified or not?

55

The PWHT procedure is available or not?.

PWHT procedure - 2QM 00 JEP ME 006
All the PWHT recorders and the
The chart is to be
WPS, Calibration records
thermocouples alongwith compensating leads
certified at 300 deg and
again at soaking temp.
are calibrated or not?
As per procedure required nos/locations of
thermocouples are installed or not?

PWHT procedure - 2QM 00 JEP ME 006

56

The heating band width is maintained as per

the PWHT procedure or not?

PWHT procedure - 2QM 00 JEP ME 006

57

58

After PWHT the butt weld joints Hardness is

checked or not as per specification?

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Coordination with stores

All
Temporary
attachment
including
thermocouple
attachment
shall
be
DP/MP tested

Physical verification

Project specification 22960-3PSGAW004 & Form 167A

Page 6 of 11

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

Sr. no.

Activity

Method

Remarks

Pipe Spool contd

Hydrotest

59

Verify the offer report with the spool

numbers and maximum permissible
pressure.

60

Physical verification of spools for any

damage etc.

61

Verification of the dressing of temporary

attachment, fill-up & NDT.

62

For alloy steel temp. joints, verify preheat,

postheat & PWHT as per WPS.

63

Verify the dummy used are rated as per the

pressure rating

Verify with the pipe class wise

maximum permissible pressure list.
Combination of SS to CS & LAS not
permitted.

Verify with the hard punch.

For Carbon Steel 300 ppm and for SS 30
ppm

64

Chloride content of hydrotest water is

verified or not?

65

The used pressure gauges for the hydrotest

are calibrated on daily basis with date
marking

66

Two gauges used or not?

Physical verification
Calibration record

67

Test pressure is within 1.5 to 4 times of the

gauge pressure or not?

Physical verification

68

Carry out inspection after min 30 min

holding time.

69

Verify whether pressure gauges are returning

to 0 after pressure test.

71

All NCR / MDR / FOR / SER are being

maintained or not?
Whether all stagewise inspection records are
prepared and signed by the concerned
persons.

72

The safety practices at work area being

maintained or not?.

70

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Problem faced. Be
careful.

Verify all flange for any leaks and all

joints & Long Seam Welds.

As per QAP: 2 QA QAP GE 001

Physical verification
Physical verification

Page 7 of 11

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

2.

CHECK LIST FOR STRUCTURAL STEEL INSPECTION AT

FABRICATION DIVISION
Method

Sr. no.

Activity

Verify and ensure the storage condition/stock status of

the customer supplied material.

Remarks
Stock register and propoer
storage methodology.

Applicable ITPs
2
Whether the approved copy of the ITP available?
3

Whether the copy of project / job specification is

available?
Whether applicable WPS is used?

4
5

Whether welders performing welding / tacking are

qualified? Are they do weld with in the qualified
ranges?
Whether the electrodes being used are approved
brands or not?

3PS SS 001 / applicable spec.

Availability of applicable
WPS
WPQ Certificate / Welder ID
card
List of approved brand,
Physical verification along
with batch test certificates
Reviewed batch test
certificates

Whether the batch test certificates are reviewed before

start use of the electrodes?
Whether all the low hydrogen electrodes are properly daily baking record
baked or not?

Whether the materials other than IS 2062 are verified

along with MTC?

PMI check on alloy steel / stainless steel material

prior to start use?

10

Whether the copies of acceptance criteria are

available?

11

Whether DPT material is of from single

manufacturer?

12

13

14

If welding electrodes are in

contractors scope
If welding electrodes are in
contractors scope

Document review and

physical verification

IS 7215, BS 5135, IS 3658,

Physical verification before
start of job

BS 5135 acceptance level for

Whether the surface defects on weldment is visually butt and fillet welds.
verified for 100% ?
Whether the required weld fillet size is verified for
Physical verification during
structural being inspected?
weld visual inspection along
with drawing
Whether the distortion occurred in the fabricated
structural is with in the acceptable limit?

IS 7215 / Applicable std or

code
IS 7215 / Applicable std or
code

15

Whether the camber/sweep in column or beam of the

fabricated structural is with in the acceptable limit ?

16

Whether the weld access holes are properly dressed /

shaped?

17

Verify the structural is have the correct identification

by hard punch.

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

As per drawing / AWS D 1.1

physycal verification

Page 8 of 11

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

Sr. no.

Activity

Method

Remarks

Structural Steel contd ..

physical verification
18

Confirm whether the structural are tied with duly hard

punched aluminium tag by 16 swg. GI wire.
physical verification

22

23

Verify the correctness of the description punched

in the tag including revision no
Whether any NDT requirement is shown in drawing? Arrange to perform require
NDE

24

Whether the specified NDE on the structural is carried Perform NDE and confirm its
out?
acceptance

25

Whether the relevant NDE reports are attached with

the Structural steel fabn. Report?

26

All NCR / MDR / FOR / SER are being maintained or

not?

3.

Mandatory Verification. Few

complaints received from site
on wrong punching.

Random NDT shall be carried

out on daily lot as per the %
given

Verify and confirm during

NDE clearence

CHECK LIST FOR WRAPPING & COATING INSPECTION

AT FABRICATION DIVISION

Sr. no.

Activity

Method

Whether the Project specification 22960-3PSGAW008 - latest revision available with contractor

Verify the inspection doc

file .

Whether Contractor is having the Thermometer,

coating thickness gauges and Holiday tester (2 nos)
with valid calibration certificates.

Correlate and Verify the

Equipment & Certificates.

Check whether ITP No. 2QAITPME013 is available.

Verify the inspection doc

file .

Consumables supplied in Steel Drum are properly

sealed & marked

Visual inspection

Co-relate the Material TC with the wrapping & coating

materials :
Verify with TC document
and batch number
1. Primer synthetic enamel paint
2. Coal tar enamel.

Check Coal tar enamel & Primer are of same

manufacturer.

Verify with TC document

Physical characteristics of wrapping & coating

materials to be verified.

Verify with TC document/as

per specification

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Page 9 of 11

Remarks

All tests as per 22960-3PSGAW008 - latest revision

shall be reported

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

Sr. no.

Activity

Method

Remarks

Wrapping & Coating contd ..

Check whether the Wrapping & reinforcing materials

are stored in dry place.

As per manufacturers
recommendation / as per
specification.

Check the outer surface of pipe is free from all lose

materials,dirt, grease or moisture etc before sand
blasting.

Surveillance

10

Check the sand blasting of external surface of pipe is

SA2-1/2. Finish

Physical verification

11

Check the primer is applied within 4hrs after sand

blasting is carried out.

Surveillance

12

Check while handling of prime coated & wrapped

pipes, Sling belts are used or not, to prevent damage to Surveillance
outer area of pipe.

13

Verify the temperature

Check whether the enamel heated in the appliance is
frequently during heating by
not exceeding the permissible temperature limit of 260 means of calibrated
deg C
temperature measuring
instrument

14

Visual examination of Wrapping for wrinkles, pockets,

Physical verification
tears & for thorough bonding to surface.

15

Whether the enamel applied have overall thickness

of 4 mm on the pipe body & 2.4 mm when
measured from top of the weldment.

Check frequently the

thickness by using
calibrated coat thickness
measurement instrument.

16

Whether the spot thickness test is being performed.

Sample shall be taken 25mm

x 25mm square for checking
the thickness and
adhesiveness.

17

Whether Coating & wrapping shall be trimmed off

150 mm from end of each pipe.

Physical verification

18

Whether all repairs identified in the coating during

visual inspection are rectified.

Visual inspection of the

repaired surface.

19

Whether the coated pipes are examined for holidays

(at 14KV) and the identified holidays are repaired and
reexamined.

Check by calibrated holiday

detector.

20

Whether Tag identification is marked on inner surface

As per Tag Identification as
of pipe before Wrapping & coating by Permanent
tied on spool.
marker.

21

Whether adhesion test has been conducted on the day's Adhesion test as per AWWA
lot (1 nos in 50 pipes with minimum 1 no)
C203

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Page 10 of 11

Visual Inspection shall be

carried out after the coating
is hard.
Check carefully,
complained received from
site for less thickness

Quality Management
Jamnagar

Fabrication Division
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

Sr. no.

Activity

Method

Remarks

Wrapping & Coating contd ..

22

Whether all inspection data are filled properly in the

Review of the reports before
latest revision format and signed by relevant personnel. final sign.

23

Whether the inspection reports are submitted to

planning department in time

Inspection checklists for Fabrication Division Quality

Management Department
Doc. No.: 2QMGUIGE001, Rev.00, Dt. 29/06/2005

Surveillance

Page 11 of 11

Verify once in a week

Quality Management
Jamnagar