SECTION 17.0
Quality Assurance Plan
Comprehensive QA/QC framework covering Inspection & Test Plans, welding procedure qualifications, NDE acceptance criteria, and document review workflow for the 3,000 MTPD Sulphuric Acid Plant EPC project.
Hold / Witness / Review Point Legend
HHold Point — Work stops until witnessed & approved
WWitness Point — Notified 24 hrs in advance, may proceed if not attended
RReview — Records reviewed, presence not required
—Not applicable
| # | Activity / Check | Reference | Acceptance Criteria | C | O | T | Records |
|---|---|---|---|---|---|---|---|
| 1 | Review of material test certificates (MTC) | ASME SA-516 Gr.70 / SA-240 | Chemical composition & mechanical properties per spec | R | R | R | MTC, Mill Certificates |
| 2 | Raw material inspection — plate UT scanning | ASME SA-578 / SA-435 | No lamination, UT acceptance per Level B | W | R | W | UT Report |
| 3 | Marking, cutting & edge preparation | Approved drawing | Dimensions within tolerance, bevel angle ±2.5° | R | — | R | Dimensional Report |
| 4 | Fit-up inspection before welding | WPS / Approved drawing | Root gap, alignment, tack weld quality per WPS | W | W | W | Fit-up Report |
| 5 | Welding — longitudinal & circumferential seams | Qualified WPS per ASME Sec. IX | Visual acceptance per ASME Sec. VIII UW-35 | W | R | W | Weld Log, WPS/PQR |
| 6 | NDE — 100% RT of all pressure seams | ASME Sec. V Art. 2 | RT acceptance per ASME Sec. VIII UW-51(b) | H | W | H | RT Film, Reader Sheet |
| 7 | NDE — UT of nozzle-to-shell welds | ASME Sec. V Art. 4 | UT acceptance per ASME Sec. VIII App. 12 | W | R | W | UT Report |
| 8 | Post-Weld Heat Treatment (PWHT) | ASME Sec. VIII UCS-56 | Holding temp 595–650°C, rate per thickness, chart recording | H | W | H | PWHT Chart, Thermocouple Layout |
| 9 | Hardness testing after PWHT | ASME Sec. VIII UCS-85 | ≤225 HBW for CS, per material spec | W | R | W | Hardness Report |
| 10 | Hydrostatic test | ASME Sec. VIII UG-99 | Test pressure = 1.3 × MAWP, 30-min hold, no leak/deformation | H | H | H | Hydrotest Report, Pressure Chart |
| 11 | Final dimensional inspection | Approved GA drawing | All dimensions within drawing tolerances | W | W | W | Dimensional Report |
| 12 | Painting & surface protection | Project painting spec | Sa 2.5 surface prep, DFT per spec | R | R | R | Painting Report, DFT Records |
| 13 | Final inspection & release | All above | All NCRs closed, documentation complete | H | H | H | Release Certificate, MDR |
Note: ITPs shown are proposal-stage templates (Rev 0). Detailed ITPs will be finalized post contract award in consultation with PPL QA/QC team and the appointed TPI agency. Additional ITPs will be developed for E&I equipment, rotating equipment, and site construction activities.