QUALITY ASSURANCE PLAN - DOC

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					QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007




                   FOR



PAINT EPOXY ALUMINIUM PRIMER

        DS CAT NO. : 8010 – 000987

SPECIFICATION : NCD 1467 ISSUE I/DEC 1997



               APPROVED BY




DIRECTORATE OF QUALITY ASSURANCE (NAVAL)
WEST BLOCK NO. 5, R.K. PURAM, NEW DELHI – 66
                                      -2-

              QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007

                                   INDEX


SL.NO.                  DESCRIPTION                   PAGE NO.
1.       Record of amendments                            3

2.       Related Documents and Specifications            4

3.       List of abbreviation                            5
4.       Chapter – 1: Introduction                       6
5.       Chapter – 2: Quality Assurance Plan            7-8

         Acceptance Physical Parameter: Part –I
6.       Acceptance of Paint Epoxy Aluminium Primer     9-10
         (Laboratory Test) Part 2




                                                              Contd……..3
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             QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007
                    RECORDS OF AMENDMENTS


SL.NO.   AMENDMENT NO.      AUTHORITY     DATE    SIGN




                                                    Contd…….4
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             QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007


         RELATED DOCUMENTS AND SPECIFICATIONS


SL.NO.    SPECIFICATION                      DESCRIPTION
   1.     IS-101/1986(Part-1/Sec-1)          Sampling
   2.     IS-101/ 1986(Part-1/Sec-3)         Preparation of panels
   3.     IS-101/1987(Part-1/Sec-4)          Brushing test
   4.     IS-101/1989(Part-1/Sec-5)          Consistency
   5.     IS-101/1987(Part-1/Sec-6)          Flash point
   6.     IS-101/1986(Part-2/Sec-2)          Volatile matter
   7.     IS-101/1986(Part-3/Sec-1)          Drying Time
   8.     IS-101/1989(Part-3/Sec-2)          Film thickness
   9.     IS-101/1988(Part-5/Sec-1)          Hardness test
  10.     IS-101/1988(Part-5/Sec-2)          Flexibility and adhesion
  11.     IS-101/1988(Part-6/Sec-1)          Resistance to humidity
  12.     IS-101/1989(Part-6/Sec-2)          Keeping properties
  13.     IS-101/1990(Part-8/Sec-2)          Pigments and Non-Volatile
                                             Matter
  14.     IS-101/1993(Part-8/Sec-6)          Volume solids
  15.     IS-354/1986                        Test method for Epoxy Resins
  16.     IS-513/1994                        Cold Rolled low Carbon steel
                                             sheets and strips
  17.     IS-1070/1992                       Water for general laboratory
                                             use
  18.     IS-1303/1983                       Glossary of terms relating to
                                             paints
  19.     IS-2552/1989                       Steel drums (galvanized and
                                             ungalvanized)
  20.     IS-4683/1968                       Chilled iron shots and grits
  21.     CQAE(M)/GEN/PAINT                  Packing schedule for paints
                                             and varnish
  22.     SIS 05 5900/1967(Swedish           Pictorial standard for surface
          standard)                          preparation for painting steel
                                             surfaces.




                                                                      Contd…..5
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         QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007


           LIST OF ABBREVIATIONS



SL.NO.           ABBREVIATION         MEANING

1.               W                    Witness

2.               TC                   Test Certificate

3.               S.O.                 Sampling Officer




                                                         Contd……6
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             QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007

                            CHAPTER – 1


                          INTRODUCTION
1.   This Quality Assurance Plan is related to Paint Epoxy Aluminium
     Primer required for protection of Steel and Aluminium structure
     including weather, helo and flight decks of naval ships. The primer
     comprises aluminium pigmented epoxy resin composition (Base)
     and a hardner packed separately. Base and hardner when mixed in
     specified proportion will produce a ready mixed paint suitable for
     application by brushing.

2.   Two coats of this primer shall be applied to provide a total dry film
     thickness of 150 – 200 microns for adequate corrosion protection.
     The primer coats are followed by required number of top coats.

3.   Steel surface before application of the primer shall be cleaned by
     abrasive blasting to obtain a finish of Sa 2.5 quality of Swedish
     Standard SIS 05-5900 -1967. Aluminium surface must be
     degreased using a suitable detergent followed by washing with
     fresh water and drying prior to primer application.

4.   Coating interval between two coats of primer as well as primer and
     finish paint shall not be less than 16 hrs and not more than 72 hrs.

5.   Any deviation from the laid down and prescribed parameters/test
     methods is to be referred back to DQA (N) by the Inspecting Agency
     for consideration prior to acceptance of the stores.




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               QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007

                                   CHAPTER-2

PART-I: Acceptance Physical Parameters

SL.    PARAMETERS        TYPE OF CHECK                  QUANTUM         REMARK
NO.       TO BE                                             OF
        CHECKED                                           CHECK
1.    Mandatory Check  Prior to commencing the QA 100        %     of    S.O.
                       Checks, the pre-inspection offered store
                       test report submitted by the (Batch wise)
                       firm for offered batch shall
                       be thoroughly scrutinized
                       and all parameters should
                       be fully meeting the specs
                       requirements.
                       In case any parameter is
                       found not meeting the
                       specified requirements, the
                       call letter may be cancelled
                       with intimation to inspection
                       authority and order placing
                       authority without any delay.
2.    Packing          Paint should be packed in 100         %     of    S.O.
                       new clean and rust free MS offered store
                       drum of 20 Ltrs capacity (Batch wise)
                       conforming to Gr-B2 of IS-
                       2552.
3.    Condition of the a) The inspected lot shall be 100     %     of    S.O.
      store            kept in a well ventilated and offered store
                       locked bond room.              (Batch wise)
                       b) The drums are to be kept
                       on a wooden pellet.
                       c) Not more than three
                       drums shall be stacked on
                       one another.
4.    Sampling         Random sampling                IS : 101 (Part     S.O.
                                                      1/Sec 1) -
                                                      1986
5.    Marking on the Each container shall be 100             %     of    S.O.
      container        legibly and indelibly marked offered store
                       with:-                         (Batch wise)
                        P.O. number & date
                        Description     of     store
                          exactly as per P.O.
                        D.S. Cat./Patt No.
                        Specification No.
                                                                        Contd……7
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                QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007

SL.    PARAMETERS              TYPE OF CHECK                 QUANTUM           REMARK
NO.       TO BE                                                 OF
        CHECKED                                               CHECK
                           Batch No. & Mfg.Date
                           Net quantity (in terms of
                             liters)
                           Gross weight & Net
                             weight
                           Tare weight of drum
                           Weight /Litre
                           Consignee’s name and
                             address as per P.O.
                           Manufacture’s name &
                             address or recognized
                             trade mark.
                           Expiry date of store
                           Sl.No. of drum together
                             with total no. of drums in
                             the same batch(i.e. n/N)
                           All drums shall be marked
                             with                   term
                             “INFLAMMABLE”
                           Each       Hardner     drum
                             should be marked with
                             “TOXIC       VAPOUR        –
                             HANDLE WITH CARE”
                           Stowage Instruction
6.    Preliminary         The paint shall not show          100    %      of     S.O.
      Examination         hard settling, objectionable      offered store
                          skinning or tendency to gel       (Batch wise)
                          in the original container.
7.    Batch               Batch       confirmatory      /   100    %      of     S.O.
      confirmatory test   uniformity      is   to     be    offered store
                          ascertained by checking the        (Batch wise)
                          wt/ ltr of samples randomly
                          selected from the lot.
                          If result of wt/ltr is found
                          uniform      the   batch     is
                          assumed to be uniform.
8.    Sealing Plan        All drums of store and            100 % of             S.O.
                          samples drawn should be
                          sealed with QA Estt’s seal        offered store
                          as Barcode stickers or
                          Rubber Stamped stickers           (Batch wise)
                          after approval.

                                                                               Contd……..9
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                    QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007

      Part-II: Acceptance of Paint Epoxy Aluminium Primer as per NCD 1467
  Issue 1 of Dec 1997 (Lab Testing)
  Quantum of check – 100 % of samples selected


SL.   PARAMETERS            SPECIFICATION                TEST METHOD        REMARK
NO.                         REQUIREMENTS
 1.   Consistency           The base paint and           IS : 101 (Part 1   TC – Unit’s
                            hardner each shall be in     /Sec 5) - 1989     Lab/NABL
                            such a condition that                           Approved
                            these on mixing in given                        Lab/Approved
                            ratio produce uniform                           Govt. Lab
                            thixotropic paint suitable
                            for application by brush.
 2.   Application           The paint when applied       IS : 101 (Part 1       -do-
      Properties            by brush, on drying give     /Sec 4) - 1987
                            uniform film free from
                            sagging and wrinkling.
 3.   Flash point, base     25                           IS : 101 (Part 1       -do-
      and hardner, C,                                   /Sec 6) - 1987
      minimum
 4.   Pot life of mixed     6                            Appendix B to          -do-
      paint, minimum,                                    NCD 1467
      hour
 5.   Volatile matter, in   35                           IS : 101 (Part 2       -do-
      the mixed paint                                    /Sec 2) – 1986
      percent by mass,
      Maximum
 6.   Pigment content in    32  2%                      IS : 101 (Part 8       -do-
      the mixed paint                                    /Sec 2) – 1990
      percent by mass
 7.   Dry film thickness    75 – 100 microns             IS : 101 (Part         -do-
      on burnished MS                                    3/Sec 2) – 1989
      panel minimum 1.5
      mm thick, one coat,
      microns
 8.   Bend test, one coat   No cracking or flaking of    IS : 101 (Part         -do-
      of primer on tinned   the primer film              5/Sec 2) – 1988
      MS panel using
      type 1 apparatus
      and 6 mm dia
      mandrel, 7 days
      drying of primer

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                   QAP NO. : DQAN/QAP/NS/2007/306 DATED 15 MAY 2007


SL.    PARAMETERS             SPECIFICATION               TEST METHOD        REMARK
NO.                           REQUIREMENTS

 9.    Scratch hardness       No such scratch as to       IS : 101 (Part 5   TC – Unit’s
       one coat of primer     show bare metal with a      /Sec1) – 1988      Lab/NABL
       on tinned MS panel     load of 1500 gms                               Approved
       ( 7 days drying)                                                      Lab/Approved
                                                                             Govt. Lab
 10.   Drying time, hrs.                                  IS : 101 (Part 3        -do-
       maximum                                            /Sec1) – 1988
           (a) Surface dry    02 hrs
           (b) Hard dry       16 hrs
 11.   Percent Volume         50%                         IS : 101 (Part 8        -do-
       Solids, minimum                                    /Sec6) – 1993
 12.   Resistance to          No deterioration of the     IS : 101 (Part 6        -do-
       artificial sea water   coating and corrosion of    /Sec1) – 1988
       spray, 28 days         underneath substrate
                              (Preparation of panels
                              as per Appendix C of
                              Spec)
 13.   Epoxide equivalent     350 – 500                   Annex C of IS :         -do-
       of base component                                    14948/2001
 14.   Aluminium content      75 %                        Appendix A to           -do-
       in the pigment,                                    NCD 1467
       percent , minimum
 15.   Compatibility with     The primer coat will be     Clause 6.2.1 of         -do-
       epoxy finishing        compatible with the         NCD 1467
       paint                  epoxy finishing paint
                              including “HEAVY-DUTY
                              NON SKID PAINT”
 16.   Keeping Quality        The material shall retain   Guarantee /        S.O. to obtain
                              its property for a period   Warranty           Guarantee /
                              of not less than 12         Certificate from   Warranty
                              months from the date of     the                Certificate
                              manufacture.                manufacturer


NOTE : QAP REFERENCE MUST BE INDICATED IN THE INSPECTION AND TEST
       REPORTS.


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