PMT MACHINES LTD

Inspection and Test Plan

For
Bogie Frame Fabrication
ATTACHMENTS

List of Referenced Forms:

No. Form No: Description:
1
2
3
4
NOTE: 1) Each specific ITP will have a revision number, which is individually changed as the ITP are revised. The referenced forms are included in and controlled by
the referenced document. Therefore, the latest revision of these forms, at the time of initiation of the ITP, will be utilized. The referenced forms will be included only
during ITP review cycles prior to issue for Production's.
2 ) This ITP shall be used as Inspection and Test Plan before Production of the Job, where as during and after job production
it shall be used as checklist.

Legend of Inspection Requirements:

H: Hold Point is a mandatory inspection point and work shall not proceed without the presence of
a representative of the cognizant organization. W: Witness Inspection Point: Designated Witness Points for the
Involved personnel, which are required to be signed off by Witnessed personnel. All activities, which have "W" point,will require a written notification of Client
Inspector, in the event that the Client Inspector does not attend within an agreed period the work may proceed. In such cases, the Client's/Contractor Inspectors will
record in the appropriate signature space on the forms " Not Witnessed", and shall sign and date such spaces.
W% : % Witness Inspection Point: Designated percentage Witness Point
assigned by the Client, which will require written notification from the Contractor/Client's. In the event Client Inspector does not attend within an agreed period the
work may proceed. The percentage shall mean a minimum of 10% inspection, if not otherwise agreed in the contract, however this may be increased at discretion of
the client Inspector. S: Surveillance/Monitoring:
Random observation of the controls of process activities. DR: Document
Review: This entails review of appropriate documentation.

MANF-1-QM00-BT-ITP-001

00 01.11.2017 Issued for Implementation AMIT SHAH

Rev Date Revision Prepared By Checked By Approved By
 ITP No : MANF-1-QM00-BT-ITP-001 Inspection and Test Plan
REV No : 00
Date : 01.11.2017 For
Sheet No : 1 of 5 Bogie Frame Fabrication
PMT MACHINES LTD
Projects:

Quality Acceptance Quality Inspection Responsibilty

Sr. No Activity Description Remarks
Procedure Criteria Records Contractor contractor Client's
Production QC QC

1.00 General Requirements & Documents

Review
Fabrication Shop Qualification &
1.1 H H H
Approval
Review of Technical Specification and
1.2 requirements for Bogie Frame DR DR DR
Fabrication
Review of Welder Qualification
1.3 DR DR DR
Procedure
Review of Welding Procedure
Specifications & Welding Procedure
1.4 DR DR DR
Qualification Record (WPS/WPQR)

1.5 Review of NDE Procedure DR DR DR

Review of Procedure for Control of
1.6 Welding Consumables DR DR DR

Check the availability of latest copy of

1.7 approved & relevant drawings with H S S
concerned engineer on shop
Legend:
S- Surveillance Only DR - Document Review
W - Witness Inspection Point
W% - Witness 10% min Point
H- Mandatory Hold Point

PMT PRODUCTION ENGINEER PMT QUALITY ENGINEER CLIENT

DATE
NAME
SIGNATURE
ITP No : MANF-1-QM00-BT-ITP-001 Inspection and Test Plan
 REV No : 00
Date : 01.11.2017 For
Sheet No : 2 of 5 Bogie Frame Fabrication
PMT MACHINES LTD
Projects:

Quality Acceptance Quality Inspection Responsibilty

Sr. No Activity Description Remarks
Procedure Criteria Records Contractor contractor Client's
Production QC QC

2.00 MATERIAL RECEIVING

Receiving Inspection & Verification of
2.1 Raw Material along with MTC as per H H S
PO.
check physical condition (free from
2.2 bends, twists and straightness, surface H H S
defects within limits)

Check the correctness of all primary

2.3 parts for bogie fabrication (Grade/Mat H H S
code, dimensional check & MTC, etc.;)

Ensure the proper Storage, Handling &

2.4 H H S
Preservation
Welding Equipment Calibration
Verification (like Welding Machines &
2.5 W W S
Electrode Ovens)

Legend:
S- Surveillance Only DR - Document Review
W - Witness Inspection Point
W% - Witness 10% min Point
H- Mandatory Hold Point

PMT PRODUCTION ENGINEER PMT QUALITY ENGINEER CLIENT

DATE
NAME
SIGNATURE
ITP No : MANF-1-QM00-BT-ITP-001 Inspection and Test Plan
REV No : 00
 REV No : 00
Date : 01.11.2017 For
Sheet No : 3 of 5 Bogie Frame Fabrication
PMT MACHINES LTD
Projects:

Quality Acceptance Quality Inspection Responsibilty

Sr. No Activity Description Remarks
Procedure Criteria Records Contractor contractor Client's QC
Production QC
3.00 Fit-up Clearance

Check whether cutting/drilling/

3.1 beveling is as per the requirements and H H S
dimensions are complying

Check the Fit-up Inspection and ensure

3.2 H H S
its cleanliness

4.00 Welding

check & ensure the availability of

4.1 H H S
applicable WPS
Verify the Welder Qualification &
4.2 H H S
Certification
check the qualified welder are
4.3 H H S
performing welding/tacking
check proper baking of electrode, if low
4.4 H H S
hydrogen electrode are used
check the preheat and interpass
4.5 W% W% S
temperature (as applicable)
Monitor the In process welding as per
4.6 W W S
WPS
Legend:
S - Surveillance Only DR - Document Review
W - Witness Inspection Point
W% - Witness 10% min Point H - Mandatory Hold Point
PMT PRODUCTION ENGINEER PMT QUALITY ENGINEER CLIENT

DATE
NAME
SIGNATURE
ITP No : MANF-1-QM00-BT-ITP-001 Inspection and Test Plan
REV No : 00
 REV No : 00
Date : 01.11.2017 For
Sheet No : 4 of 5 Bogie Frame Fabrication
PMT MACHINES LTD
Projects:

Quality Acceptance Quality Inspection Responsibilty

Sr. No Activity Description Remarks
Procedure Criteria Records Contractor contractor Client's
Production QC QC

5.00 Inspection and NDE Clearance

Check the Visual Inspection of Welds

5.1 and ensure no defect on surface, H H H
dressing of sharp edges etc.

check % of NDE requirements for weld

5.2 H H S
joints
Carry out relevant NDE on selected
5.3 H H W
Butt/Fillet ( RT/UT/PT/MT)

Check dye penetrant test on the

5.4 temporary attachments & weld joints, H H W
as required

5.5 Hardness check, as applicable H H W

NDE Clearance - verify all relevant test

5.6 DR DR DR
reports
check the final dimensions of fabricated
5.7 H H H
items/ assembly
check the fabrication clearance and
5.8 H H H
release the bogie for Painting
Legend:
S - Surveillance Only DR - Document Review
W - Witness Inspection Point
W% - Witness 10% min Point H - Mandatory Hold Point
PMT PRODUCTION ENGINEER PMT QUALITY ENGINEER CLIENT

DATE
NAME
SIGNATURE
ITP No : MANF-1-QM00-BT-ITP-001 Inspection and Test Plan
REV No : 00
Date : 01.11.2017 For
 Date : 01.11.2017
Sheet No : 5 of 5 Bogie Frame Fabrication
PMT MACHINES LTD
Projects:

Quality Acceptance Quality Inspection Responsibilty

Sr. No Activity Description Remarks
Procedure Criteria Records Contractor contractor Client's
Production QC QC

6.00 Records

6.1 compilation of all quality records H H DR

check whether copy of release note of

6.2 finished bogie handed over to H H DR
concerned painting supervisor

Legend:
S- Surveillance Only DR - Document
Review W-
Witness Inspection Point W% - Witness 10% min Point
H- Mandatory Hold Point
PMT PRODUCTION ENGINEER PMT QUALITY ENGINEER CLIENT

DATE
NAME
SIGNATURE