Endorsement Sheet For QP: Reference / Standard / Field Quality Plan (RQP / SQP/RFQP/SFQP) To Be Filled in by NTPC

ENDORSEMENT SHEET FOR QP
REFERENCE / STANDARD / FIELD QUALITY PLAN (RQP / SQP/RFQP/SFQP) TO BE FILLED IN BY SUPPLIER AT TIME OF SUBMISSION
PROJECT NAME CONTRACT NO.: MAIN SUPPLIER MANUFACTURER WORKS & ADDRESS ITEM /EQUIPMENT / SYSTEM/ SUB-SYSTEM DETAILS i.e. MODEL TYPE / SIZE /RATING etc. APPROVED QP NO.: RQP/SQP/RFQP/SFQP DADRI CS-6130-108-2-FC-NOA-4722 BHEL M/S BHEL TRICHY BOILER STRUCTURE
To be filled in by NTPC
REVIEW & ENDORSEMENT BY NTPC PROJECT SPECIFIC QP NUMBER ALLOTTED QP NO.: 6130-108-QVM-G-003-01 REV 01 REV. NO.: DATE:
** The RQP/SQP/RFQP/SFQP once endorsed for a particular contract shall remain valid even though the original QP may have expired or revised, unless / otherwise mutually agreed with the supplier.
(TICK APPLICABLE)
0000-999-QV M-T273
REV. NO.: 00
DATED**:29/07/2003
Confirmation by Main Supplier (TICK WHICHEVER APPLICABLE) I. That the item/ component is identical to that considered for QP approval. OR. II. That there are minor changes in the item/ component with respect to that considered for QP approval, however the same do not affect the contents of QP. OR III. That there are minor changes in the item/ component with respect to that considered for QP approval, however the same affect the QP slightly, as indicated BELOW. 1. Log-sheet no. 01 revised as per boiler layout plan drg. For Dadri 2. Log-sheet no. 02 revised as per boiler layout plan drg. For Dadri 3. Log-sheet no. 08 revised as per Trichy instruction of minimum structure required for Lifting boiler Drum .
Revised Log sheets noted. However, BHEL to ensure that the requirements of Erection manual and Erection drawings are completely converted into Log-sheets.
The QP is endorsed for this project without any change The QP is endorsed for this project with changes as indicated. DISTRIBUTION OF ENDORSEMENT OF A) RQP/SQP: 1. MAIN SUPPLIER (WITH A COPY OF QP) 2. MANUFACTURER 3. RIO 4. CQA-SPL 5. CQA-O/C B) RFQP/SFQP: 1. MAIN SUPPLIER (with a copy of QP) 2. MANUFACTURER 3. NTPC FQA (with a copy of QP) 4. NTPC Erection (with a copy of QP) 5. CQA-SPL 2007.05.2 6. CQA-O/C
( H.M.NAGDHAR ) DGM/Quality SIGN.: (Main Supplier) DATE BHEL/PSNR
3 14:25:42 +05'30'
SIGN.: (Manufacturer) DATE: NTPC (Reviewed /Approved by/ Date & Seal)
FORMAT NO.: QS-01-QAI-P-10/ F5-R1
1/1
ENGG. DIV./ QA&I
FIELD QUALITY PLAN

FOR
BOILER STRUCTURES
(Erection) FOR
DADRI TPP - 2 x 490 MW (M/s. National Thermal Power Corporation Ltd.)
BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR NORTHERN REGION NOIDA
QP NO. : PN-QPE-BR-100 REV.NO.: R00

FMT-QP-001 Rev.01
FIELD QUALITY PLAN FOR

BOILER STRUCTURES (Erection) DADRI TPP 2 x 490 MW (M/s. National Thermal Power Corporation Ltd.)
APPROVED BY QUALITY PLAN NO. ORIGINAL DATE OF ISSUE REVISION NO. & DATE COPY NO. ISSUED TO DATE OF ISSUE
AGM PSNR Q NOIDA
(S K DUTTA) PN-QPE-BR-100 24-04-2007 R00 Dt. 24-04-2007
CONTROLLED / INFORMATION COPY ISSUED BY (SIGNATURE & DESIGNATION)

( H.M.NAGDHAR ) DGM/Quality BHEL/PSNR
H M NAGDHAR/DGM/QUALITY
BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR NORTHERN REGION

FMT-QP-002 Rev. 01
QP NO. : PN-QPE-BR-100
CONTENTS
PSNR - Quality
REV.NO.: PAGE 1
R00 OF 1
Sl.No. 1.0 2.0 3.0
Description Status of amendments Authorisation for different categories of checks Field Quality Plan for BOILER STRUCTURES (Erection) For DADRI TPP 2 x 490 MW (M/s. National Thermal Power Corporation Ltd.)
No. of Pages 01 01
3.1 3.2 3.3
Statement of checks Documents referred in Quality Plan Log Sheets : L-00 to L-08
10 01 15
******
FMT-QP-003 Rev.00
QP NO. : PN-QPE-BR-100 STATUS OF AMENDMENTS

PSNR Quality
REV.No.: PAGE 1
R00 OF 1 Remarks
Sl.No.
Reference of Sheet(s) Amended

NIL
Amendment No. & Date
FMT-QP-016 Rev. 00
PSNR - Quality
AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECK
Classification of Check Symbol Description BHEL A Critical NTPC BHEL B Major NTPC BHEL C Minor NTPC -----Erection / Commissioning Head of Section Quality Assurance Engineer Erection / Commissioning Inspection Agency Task performer & surveillance by QAE FQA Task performer Erection / Commissioning Task performer Clearing Agency HOS FQA HOS Erection / Commissioning Incharge Task performer Dispositioning Authority Engg. centre / Head Quality - Region CQA Engg. centre / Head Quality - Region FQA Engg. centre / Head Quality - Region
Legend
HOS QAE
NOTE : 1. Dispositioning Authority in A, B & C classes of checks shall be as under : Product non-conformities Process / system non-conformities 2. : Engineering Centre : Head / Quality - Region
QAE shall witness A Category checks. He is also authorised to carry out surveillance in any of theB and C category of checks at his discretion. In case of non-conformity, before accepting, clearing agency shall ensure dispositioning and the same shall be reflected in log sheets / protocols. Non-conformance Procedure, apart from above shall be in line with clause No. 4.7 of QA co-ordination procedure.
3.
4.
FMT QP 004 REV. 00
QP NO. : PN-QPE-BR-100 STATEMENT OF CHECKS

PSNR Quality
REV.No.: PAGE 1
R00 OF 10
Capacity / Type System Sub-System Area

*
: : : :
2 x 490 MW BOILER STRUCTURES ERECTION
For checks where log sheets are not called for, suitable records shall be maintained in the form of log book / protocols. As an evidence of having carried out the work satisfactorily, a general purpose log sheet L-00 shall be maintained for all the checks. The above sub-system covers Foundations, Boiler supporting structures including ceiling structures and welding. NTPC Technical specification and NTPC approved documents relevant to this product shall be binding and any Non-conformation to this shall be referred to NTPC for disposal as per NTPC-CQA non-conformance disposal procedure. Abbreviations used in the column Type of Check are : R M V : Record Verification
* *
: Measurement : Visual
FMT-QP-005 Rev. 00
FIELD QUALITY PLAN

MANUFACTURERS NAME & ADDRESS
PREPARED BY : PSNR-QUALITY, NOIDA
PROJECT : DADRI 2 x 490 MW

PACKAGE : SG CONTRACT NO. : CS-6130-108-2FC-NOA-4722 CONTRACTOR : BHEL, PS-NR
FORMAT OF RECORD REMARKS
BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
SUB-SYSTEM : STRUCTURES
TYPE OF CHECK INSTRUMENT
QP NO. : PN-QPE-BR-100 REV. : R00 DATE : 24-04-2007 PAGE 2 OF 10

CLASS QUANTUM / FREQUENCY OF CHECK
SL. NO.
CHARACTERISTICS / ITEM
REFERENCE DOCUMENT/ ACCETANCE STANDARD
FOUNDATION : 1. Availability of identified & protected permanent bench mark. Elevation of top of foundation pedestals with reference to permanent bench mark. V B 100%
2.
Dumpy level / Water level / Tape Tape
100%
Drawing / Guidelines for erection
L - 01
3.
Disposition of foundation pedestals with reference to longitudinal axis of boiler and reference axis. Spacing between the foundation pedestals.
100%
-do-
L - 02
4.
Tape
100% -do-
L - 02
5. 6.
Diagonals of the main column foundation pedestals. Pitch distance of foundation pedestal bolts on both the axes and its diagonals.
M M
Tape Tape
B C
100% 100% -do-
L - 03 L - 04
FOR NTPC USE BHEL, PSNR-QUALITY BHEL, PS-NR MANUFACTURER / SUBCONTRACTOR CONTRACTOR SIGNATURE
DOC. NO.
ERECTION
AREA REVIEWED BY NAME & SIGNATURE, OF APPROVING AUTHORITY & SEAL
FMT-QP-015 REV.02
FIELD QUALITY PLAN

BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
TYPE OF CHECK INSTRUMENT
: SG QP NO. : PN-QPE-BR-100 PACKAGE REV. : R00 CONTRACT NO. : CS-6130-108-2DATE : 24-04-2007 FC-NOA-4722 PAGE 3 OF 10 CONTRACTOR : BHEL, PS-NR
FORMAT OF RECORD CLASS QUANTUM / FREQUENCY OF CHECK REFERENCE DOCUMENT/ ACCETANCE STANDARD REMARKS
SL. NO.
CHARACTERISTICS / ITEM
STRUCTURES : 1. Preassembly of columns before erection, wherever applicable. V/M Tape / Piano wire / Water level - do C 100% Drawing
2.
Individual column piece camber and sweep (Tolerance : 1 mm / M ; 10 mm max.). Camber and sweep for assembled columns (Tolerance : 1 mm / M ; 18 mm max.). Total length of column before erection (Tolerance : 15 mm max.). Orientation of columns. Check for match mark, elevation mark, column No., splice size etc. Ensure matching of centre line of base plate with pedestal axes.
100%
Drawing / Guidelines for Erection - do -
3.
- do -
100%
4.
Tape
100%
- do -
5.
100%
- do -
6.
100%
- do -
FOR NTPC USE BHEL, PSNR-QUALITY BHEL, PS-NR MANUFACTURER / SUBCONTRACTOR CONTRACTOR SIGNATURE
DOC. NO.
ERECTION
FMT-QP-015 REV.02
FIELD QUALITY PLAN

BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
CHARACTERISTICS / ITEM TYPE OF CHECK INSTRUMENT
: SG QP NO. : PN-QPE-BR-100 PACKAGE REV. : R00 CONTRACT NO.: CS-6130-108-2-FC-NOA-4722 DATE : 24-04-2007 CONTRACTOR : BHEL, PS-NR PAGE 4 OF 10
CLASS QUANTUM / FREQUENCY OF CHECK REFERENCE DOCUMENT/ ACCETANCE STANDARD FORMAT OF RECORD REMARKS
SL. NO.
7.
Elevation of column at 1 metre level with reference to bench mark (Tolerance : 5 mm ). Alignment of first piece of column with horizontal beams and vertical bracings (Tolerance : Position w.r.t. reference axis : 5 mm ; elevation : 5 mm). Completion of boxes with main brace level members (MBL). Grouting gap below the column base (Min. 20 mm ; max. 70 mm ). Verification of test certificates and batch certificates of grout material.
Water level / Tape
100%
Drawing / Guidelines for Erection - do L 06
8.
Theodolite / Tape / Plumb bob
100%
9.
100%
- do -
10.
Tape
100%
- do -
11.
100%
Work Instruction for Grouting
12.
Grouting of column bases.
V/R
100%
Drawing / Grout Manufacturers Recommendation
L - 05
FOR NTPC USE BHEL, PSNR-QUALITY BHEL, PS-NR MANUFACTURER / SUBCONTRACTOR CONTRACTOR SIGNATURE FMT-QP-015 REV.02
DOC. NO.
ERECTION
FIELD QUALITY PLAN

BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
: SG QP NO. : PN-QPE-BR-100 PACKAGE REV. : R00 CONTRACT NO. : CS-6130-108-2-FC-NOA-4722 DATE : 24-04-2007 CONTRACTOR : BHEL, PS-NR PAGE 5 OF 10
SL. NO.
13.
Alignment of columns at every stage of erection.
Theodolite / Tape / Plumb bob Bolt Tension Calibrator / Torque wrench Piano wire / Tape / Water level - do -
100%
Drawing / Guidelines for Erection Drg. / Guidelines for Erection / HSFG Bolt Tightening Procedure Drawing / Guidelines for Erection
L - 06
14.
Tightening of HSFG bolts for column joints, horizontal beams and vertical bracings.
M/V
100%
15.
Camber and sweep of the individual ceiling girder pieces (Tolerance : 1 mm / M, max. 5 mm).
100%
16.
Camber, sweep, diagonal and overall length before and after welding (Tolerance : 1 mm / M, max. 15 mm). Alignment of ceiling girders.
100%
- do -
17.
Tape / Plumb bob / Water level Bolt Tension Calibrator / Torque wrench
100%
- do -
L - 07
18.
Tightening of HSFG bolts between ceiling girders and welded beams (WBs).
100%
Drawing / Guidelines for Erection / HSFG Bolt Tightening Procedure
DOC. NO.
ERECTION
FIELD QUALITY PLAN

BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
: SG QP NO. : PN-QPE-BR-100 PACKAGE REV. : R00 CONTRACT NO : CS-6130-108-2-FC-NOA-4722 DATE : 24-04-2007 CONTRACTOR : BHEL, PS-NR PAGE 6 OF 10
SL. NO.
19.
Verticality of columns before and after ceiling girder erection, at every 5M and at column erection joints.
Theodolite / Plumb bob / Tape Theodolite / Tape
100 %
Drawing / Guidelines for Erection - do -
L-06
20.
Centre line of ceiling girders marked w.r.t. the longitudinal axis of boiler transferred from ground level to top. Readiness of structure for drum erection. Clearance of mile-stone activity. Verticality of all main columns (wherever possible) immediately after drum lifting and compare with previous values. Removal of temporary supports.
100%
L 07
21. 22. 23.
V V M Theodolite / Plumb bob / Tape
A A A
100% 100% 100%
- do -
L 08
Drawing / Guidelines for Erection
L 06
24.
100%
DOC. NO.
ERECTION
FIELD QUALITY PLAN

PREPARED BY : BHEL, PSNR -QUALITY, NOIDA
BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
: SG QP NO. : PN-QPE-BR-100 PACKAGE REV. : R00 CONTRACT NO.: CS-6130-108-2-FC-NOA-4722 DATE : 24-04-2007 CONTRACTOR : BHEL, PS-NR PAGE 7 OF 10
SL. NO.
WELDING & NDE : 1. 2. Qualification of welders. Availability of approved WPS, Heat Treatment Schedule, Erection Manual, Storage Manual, Calibration test certificates of instruments used. Adoption of correct procedure, approved electrodes and methods. V/R R A A 100% 100% Welding Manual
3.
V/R
100%
Drawing / Welding Manual / Heat Treatment Manual Drawing / Guidelines for Erection / Heat Treatment Manual
4.
Pre heating and Post Weld Heat Treatment of weld joints.
V/M
Time Temperature Recorder / Thermal Chalk
As per Reference Document
5.
NDE for welds of structural members : a) Edge Preparation : MPI / LPI for new edges prepared at site after flame cutting / trimming of respective member where t 32 mm. V C 100% NDE Manual
FOR NTPC USE BHEL, PS-NR BHEL, PS-QUALITY MANUFACTURER / SUBCONTRACTOR CONTRACTOR SIGNATURE FMT-QP-015 REV.02
DOC. NO.
ERECTION
FIELD QUALITY PLAN

BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
SL. NO.
b) Butt Welds : i. MPI / LPI on all back gouged / ground grooves prior to welding from second side. ii. RT for t 32 mm. iii. MPI / LPI on finished welds for t 25 mm < 32 mm. iv. MPI / LPI on finished welds for t < 25 mm. c) Groove Welds : i. MPI / LPI for back gouged / ground area before second side welding in case of double side welding in case of double side groove joint. ii. MPI / LPI on finished welds for t > 25 mm. iii. MPI / LPI on finished welds for 25 mm. V B 100% NDE Manual V B 100% NDE Manual
V V V
B B B
100% 100% 10% of weld length at random
- do - do - do -
V V
B B
100% 10% of weld length at random

DOC. NO.
- do - do -
ERECTION
FIELD QUALITY PLAN

BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
SL. NO.
d) Fillet Welds : i. LPI / MPI for welds between flange and web. ii. LPI / MPI for other welds joining plate members in which both plate members are over 25 mm thick. iii. All other welds. 6. NDE FOR CEILING GIRDERS : a) Butt welds : i. MPI / LPI for back gouged / ground area before second side welding. ii. MPI on all butt welds for ceiling girders. iii. For flange - RT iv. For web spot RT of joints, including T / + joints. V B 100% - do V V B B 100% 10% of weld length 100% NDE Manual - do -
- do -
V V V
B B B
100% 100% 10% of weld length

DOC. NO.
- do - do - do -
ERECTION
FIELD QUALITY PLAN

BHEL, PS-NR,
Noida
PSNR - Quality
ITEM
: BOILER
SL. NO.
b) Fillet welds : MPI on fillet welds joining web tension flange. V B 100% NDE Manual
DOC. NO.
ERECTION
QP NO. : PN-QPE-BR-100 DOCUMENTS REFERRED IN QUALITY PLAN

PSNR Quality
REV.NO.: R00 PAGE 1 OF 1
SL.NO.
1.
Reference Document
Guidelines for the Erection of Boiler Supporting Structures Tightening Procedure for HSFG Bolts (Pub. No. 2302-82) Welding Manual (Doc. No. :PS:CMX:001 Rev.No.: 01/12-98) NDE Manual (Doc. No. :PS:CMX:002 Rev.No.: 01/12-98) Heat Treatment Manual (Doc. No. :PS:CMX:003 Rev.No.: 01/12-98) Storage & Preservation Instructions for Boiler & Auxiliaries (Doc. No. : PS:CMX:005 Rev. 00 / 93 )
Issuing Authority
BHEL, Trichy
2.
BHEL, Trichy
3.
BHEL, PS-NR, Noida
4.
BHEL, PS-NR, Noida
5.
BHEL, PS-NR, Noida
6.
BHEL, PS-NR, Noida
FMT-QP-017 REV.00
RECORD OF QUALITY CHECKS

PSNR - Quality
SHEET NO. OF QPI
CHECK NO.
RESULTS ACHIEVED OK / NOT OK
DRAWING / DOCUMENT REFERENCE
FORMAT OF RECORD
CHECKED BY SIGN. & DATE
ACCEPTED BY SIGN. & DATE
REMARKS
Note : Any protocol made is to be numbered & mentioned in Format of Record column. SYSTEM SUB-SYSTEM AREA QP NO. : PN-QPE-BR-100 REV. NO. : R00 LOG SHEET NO. : L-00 PAGE 1 OF 1
PROJECT UNIT NO. RATING

FMT-QP-007 REV. 00
INSTRUMENT REGN.NO. DATE OF INSPECTION

PSNR - Quality
DRAWING / DOCUMENT REF.
BOILER FOUNDATIONS TOP OF PEDESTAL

Top elevation of pedestals as per drawing _______ mm Tolerance : + 30 mm - 20 mm Pedestal Sl, No. Designation
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. 26. 27. 28. 29.
PROJECT UNIT NO. RATING FMT-QP-008 REV.00
Top Elevation
Sl. No.
30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56.
All dimensions are in mm Pedestal Top Designation Elevation

S1R S2R S3R S4R S5R S6R S7R S8R S9R S10R S11R S12R S13R S14R S15R S16R S19R S20R S21R S22R S23R S24R S25R S26R S27R LC1R LC2R
S1L S2L S3L S4L S5L S6L S7L S8L S9L S10L S11L S12L S13L S14L S15L S16L S17 S18 S19L S20L S21L S22L S23L S24L S25L S26L S27L LC1L LC2L
NAME CHECKED BY ACCEPTED BY CUSTOMER
SIGNATURE & DATE
QP NO.:PN-QPE-BR-100 REV.NO.: R00 LOG SHEET NO.: L-01 PAGE
OF
INSTRUMENT REGN.NO. DATE OF INSPECTION DRAWING / DOCUMENT NO. Power Sector - Quality
BOILER COLUMN FOUNDATION PEDESTALS - SPACING

B 1
S22L
2
S23L
3
S1L S2L
4
S3L
5
S4L
6
S5L
7
S6L S21L
S28L
S27L S24L
8 49 50 A
61
44
S7L S8L
9 45 17
S14L
10 46
S9L
11 47
S10L
12 48
S11L
13
S12L
14
S20L
15 60 C
16 51
S13L
52
18
S15L S16L
53 22
S17
57
58
59 S18 S25R
S21L S25R
64 S19
62 LONGITUDINAL AXIS OF BOILER
19
S13R S14R
20
63
21
64 S15R S16R
65 72
26 66
S7R
67
S8R
27 68 74
69
S9R S3R
28 70 75
S4R
29 71
S10R
30
S11R
31 S21 R
S12R S20R
73
S1R S2R
76
S5R
77
S6R
78
S21R 42 S27R 43 S24R
32
33
34 D
35 38
79
S22R
80
S28R
81
S23R
39
40
41
NAME PROJECT UNIT NO. RATING FMT-QP-007 REV.00 CHECKED BY ACCEPTED BY CUSTOMER
SIGNATURE / DATE
PN-QPE-BR-100 REV. NO.: R00 LOG SHEET NO.: L-02 PAGE 1 OF 3
QP NO.:

PSNR - Quality

Sl.No. 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. Location 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 As per drawing Actual Sl.No. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. Location 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 1 mm / M, 5 mm max. 1 mm / M, 15 mm max.
SIGNATURE & DATE QP NO.:PN-QPE-BR-100 REV.NO.: R00 LOG SHEET NO.: L-02 PAGE
As per drawing
Actual
26. 26 53. 27. 27 54. Tolerances : 1. Between adjacent foundation pedestals centres : 2. Spacing between first and last row of foundation : All dimensions are in mm.
OF

PSNR - Quality

Sl.No.
55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81.
Location
55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
As per drawing
Actual
Sl.No.
82. 83. 84. 85.
Location
A B C D
As per drawing
Actual
SIGNATURE & DATE
OF
INSTRUMENT REGN.NO. DATE OF INSPECTION DRAWING / DOCUMENT NO. Power Sector - Quality

B
S22L S23L
S28L
S1L S2L S3L S4L S5L S6L S21L S27L S24L
S7L
S8L
S9L
S10L
S11L
S12L
S20L
S21L
S13L S14L LONGITUDINAL AXIS OF BOILER 63 S13R S14R 64 S15R S15L S16L
A
S17 S18 S25R S16R
S25R
S19
S21 R
S7R S1R S8R S2R S9R S3R S10R S4R S11R S5R S12R S6R S20R S21R S27R S24R
S22R
S28R
S23R
SIGNATURE / DATE
PN-QPE-BR-100 REV. NO.: R00 LOG SHEET NO.: L-03 PAGE 1 OF 2
QP NO.:

PSNR - Quality
DIAGONAL CHECK BETWEEN MAIN COLUMN FOUNDATION PEDESTALS

Diagonal between
S7L & S8R S7R & S8L S13L & S14R S13R & S14L S8L & S9R S8R & S9L S9L & S10R S9R & S10L S15L & S16R S15R & S16L S10L & S11R S10R & S11L S11L & S18 S17 & S12L S17 & S12R S11R & S18 S11L & S12R S11R & S12L
Sl.No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Measurement
Difference
Sl.No.
Diagonal between
Measurement
Difference
Tolerances : 1. Foundation pedestals diagonal difference 2. Cumulative diagonal difference All dimensions are in mm.
: :
1 mm / M, 10 mm max. 1 mm / M, 25 mm max.
SIGNATURE & DATE QP NO.:PN-QPE-BR-100 REV.NO.: R00 LOG SHEET NO.: L-03 PAGE
OF

PSNR - Quality
PITCH DISTANCE OF FOUNDATION BOLTS AND DIAGONALS

b3 b4
a2 A a1 D1
D2
a4
a3
b1 B
AS PER DRAWING PEDESTAL DESIGNATION L R L R L R L R L R A B a1 a2 a3
b2
a4
b1
b2
b3
b4
D1
D2
Tolerances: 1. Pitch Distances 2. Diagonal Difference

PROJECT UNIT NO. RATING FMT-QP-008 REV.00 CHECKED BY ACCEPTED BY CUSTOMER
: 3 mm All dimensions are in mm : 5 mm max.

NAME SIGNATURE & DATE QP NO.:PN-QPE-BR-100 REV.NO.: R00 LOG SHEET NO.: L-04 PAGE
OF

PSNR - Quality
GROUTING OF COLUMN BASES
1.
Column Numbers
2.
Grout Material Specification
3.
Ratio of proportion of grout mix
4.
Whether any additives added
Yes / No
If yes, details
5.
Date of grouting
6.
Whether test cubes have been taken
Yes / No
If yes, test results
7.
Remarks
The following column bases________________________________________are cleared for further erection after ________ days of curing.
SIGNATURE & DATE
OF

PSNR - Quality
VERTICALITY OF COLUMNS
Tolerance: 1mm / M, 25 mm Max. Column Number All dimensions are in mm Inclined towards East West North South
Elevation
SIGNATURE & DATE
OF

PSNR - Quality
CEILING STRUCTURES ALIGNMENT

P S7L S8L Q S9L R S S10L T S11L S12L
GIRDER A GIRDER B GIRDER C GIRDER D GIRDER E C. L. of boiler axis marked on girders
GIRDER F
S7R P1
S8R Q1
S9R R1
S10R S1
S11R T1
S12R
SPACING BETWEEN CEILING GIRDERS: As per drawing
Tolerance :
5 mm Max.
Location P Q R S T
Actual
Location P1 Q1 R1 S1 T1
As per drawing
Actual
All dimensions are in mm
SIGNATURE & DATE
OF

PSNR - Quality
CEILING STRUCTURES ALIGNMENT

DIAGONAL DIFFERENCE BETWEEN ADJACENT CEILING GIRDERS Tolerance : 25 mm Max. Between Girders AB BC CD DE E-F D1 D2 D1~D2
CEILING GIRDER C. L. VARIATION W.R.T. BOILER AXIS : Tolerance : 12 mm Max. All dimensions are in mm
Girder Designation Girder - A Girder B Girder C Girder D Girder E Girder F
Variation w.r.t. boiler axis Towards Left Towards Right
SIGNATURE & DATE
OF

PSNR - Quality
JOINT INSPECTION PROTOCOL FOR COMPLETION OF STRUCTURE PRIOR TO DRUM ERECTION

Sl.No. 1 2 Activity Completion and verification of all log sheets / records of erection. Erection completion of : a) All columns b) Horizontal beams between columns c) Vertical bracings and tie members d) Horizontal bracing on all main brace levels (MBLs) e) Ceiling girders, welded beams (WBs) & ceiling bracings. 3. 4. 5. 6. 7. Welding completion Completion of HSFG bolts tightening. NDE completion Heat treatment completion Remarks : Observation
Note : Minimum structures required for drum erection are listed in sheets 2 / 3 and 3 / 3. Boiler supporting structure is cleared for drum erection.
NAME PROJECT UNIT NO. RATING FMT-QP-008 REV.00 CHECKED BY ACCEPTED BY CUSTOMER SIGNATURE & DATE QP NO.:PN-QPE-BR-100 REV.NO.: R00 LOG SHEET NO.: L-08 PAGE
OF

PSNR - Quality
MINIMUM STRUCTURES REQUIREMENT FOR DRUMERECTION (LIST OF REVAMPED PG - MA UNDER PG - 35

Sl.No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
PROJECT UNIT NO. RATING FMT-QP-008 REV.00 ACCEPTED BY CUSTOMER
MA 4 146 4 196 24 335 010 111 112 121 122 130 140 150 190 211 212 213 214 221 222 231 232 311 312 321 322 331 332 341 342 351 352 361 362
Description Upper Drum Sspn Id 6 17300 DL Upper Drum trans Str 4483 DL Slncr & support starting 3320 DL Foundation Materials Main Columns Left Main Columns Left Main Columns Right Main Columns Right Main Columns Middle, except S14 L & S14 R and S17 Auxiliary Columns Left Auxiliary Columns Right Girder Pin Connection Ceiling Girder (fabricated) Ceiling Girder (fabricated) Cross Girder Cross Girder Ceiling Rolled shapes Ceiling Rolled shapes Ceiling Bracing Ceiling Bracing Floor Bracing I MBL Floor Bracing I MBL Floor Bracing II MBL Floor Bracing II MBL Floor Bracing III MBL Floor Bracing III MBL Floor Bracing IV MBL Floor Bracing IV MBL Floor Bracing V MBL Floor Bracing V MBL Floor Bracing VI MBL Floor Bracing VI MBL
1st Pass 2nd Pass 1st Pass 2nd Pass
1st Pass 2nd Pass 1st Pass 2nd Pass 1st Pass @ 2nd Pass @ 1st Pass 2nd Pass 1st Pass 2nd Pass 1st Pass 2nd Pass 1st Pass 2nd Pass 1st Pass 2nd Pass 1st Pass 2nd Pass 1st Pass 2nd Pass
OF

PSNR - Quality
MINIMUM STRUCTURES REQUIREMENT FOR DRUMERECTION (LIST OF REVAMPED PG - MA UNDER PG - 35

Sl.No. MA Description
33 381 Landing Platforms - 1st tier * 34 382 Landing Platforms - 2nd tier * 35 383 Landing Platforms - 3rd tier * 36 390 Drum Floor * 37 441 Main Beams - Lower - 1st Pass 38 442 Main Beams - Middle - 1st Pass 39 443 Main Beams - Upper - 1st Pass 40 451 Main Beams - Lower - 2nd Pass 41 452 Main Beams - Middle - 2nd Pass 42 453 Main Beam - Upper - 2nd Pass 43 511 Front Bracing - Lower 44 512 Front Bracing - Middle 45 513 Front Bracing - Upper 46 521 Side Bracing - Lower 47 522 Side Bracing - Middle 48 523 Side Bracing - Upper 50 531 Rear Bracing - Lower 51 532 Rear Bracing - Middle 52 533 Rear Bracing - Upper 53 700 Fasteners 54 811 Floor grills & Guard Plate * 55 821 Main Stairs - Lower 56 822 Main Stairs - Middle 57 823 Main Stairs - Upper 58 851 Handrails & Posts * @ - Rolled shapes which are required for drum lifting are to be erected and others as and when requirements arises. - These items are not mandatory for drum lift, but may be important from statutory regulation, operation / erection and health / safety point of views.
NOTE : For details refer applicable PGMA list.
SIGNATURE & DATE
OF

Endorsement Sheet For QP: Reference / Standard / Field Quality Plan (RQP / SQP/RFQP/SFQP) To Be Filled in by NTPC

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Endorsement Sheet For QP: Reference / Standard / Field Quality Plan (RQP / SQP/RFQP/SFQP) To Be Filled in by NTPC

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ENDORSEMENT SHEET FOR QP

( H.M.NAGDHAR ) DGM/Quality SIGN.: (Main Supplier) DATE BHEL/PSNR

FORMAT NO.: QS-01-QAI-P-10/ F5-R1

ENGG. DIV./ QA&I

FIELD QUALITY PLAN

DADRI TPP - 2 x 490 MW (M/s. National Thermal Power Corporation Ltd.)

BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR NORTHERN REGION NOIDA

QP NO. : PN-QPE-BR-100 REV.NO.: R00

FIELD QUALITY PLAN FOR

AGM PSNR Q NOIDA

(S K DUTTA) PN-QPE-BR-100 24-04-2007 R00 Dt. 24-04-2007

CONTROLLED / INFORMATION COPY ISSUED BY (SIGNATURE & DESIGNATION)

BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR NORTHERN REGION

Sl.No. 1.0 2.0 3.0

3.1 3.2 3.3

QP NO. : PN-QPE-BR-100 STATUS OF AMENDMENTS

Reference of Sheet(s) Amended

Amendment No. & Date

AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECK

FMT QP 004 REV. 00

QP NO. : PN-QPE-BR-100 STATEMENT OF CHECKS

Capacity / Type System Sub-System Area

2 x 490 MW BOILER STRUCTURES ERECTION

FIELD QUALITY PLAN

PREPARED BY : PSNR-QUALITY, NOIDA

PROJECT : DADRI 2 x 490 MW

QP NO. : PN-QPE-BR-100 REV. : R00 DATE : 24-04-2007 PAGE 2 OF 10

REFERENCE DOCUMENT/ ACCETANCE STANDARD

Dumpy level / Water level / Tape Tape

Drawing / Guidelines for erection

100% 100% -do-

FIELD QUALITY PLAN

PREPARED BY : PSNR-QUALITY, NOIDA

PROJECT : DADRI 2 x 500 MW

Drawing / Guidelines for Erection - do -

FIELD QUALITY PLAN

PREPARED BY : PSNR-QUALITY, NOIDA

PROJECT : DADRI 2 x 500 MW

Water level / Tape

Drawing / Guidelines for Erection - do L 06

Theodolite / Tape / Plumb bob

Work Instruction for Grouting

Grouting of column bases.

Drawing / Grout Manufacturers Recommendation

FIELD QUALITY PLAN

PREPARED BY : PSNR-QUALITY, NOIDA

PROJECT : DADRI 2 x 500 MW

Alignment of columns at every stage of erection.

Drawing / Guidelines for Erection / HSFG Bolt Tightening Procedure

FIELD QUALITY PLAN

PREPARED BY : PSNR-QUALITY, NOIDA

PROJECT : DADRI 2 x 500 MW

Theodolite / Plumb bob / Tape Theodolite / Tape

Drawing / Guidelines for Erection - do -

21. 22. 23.

V V M Theodolite / Plumb bob / Tape

100% 100% 100%

Drawing / Guidelines for Erection

FIELD QUALITY PLAN

PREPARED BY : BHEL, PSNR -QUALITY, NOIDA

PROJECT : DADRI 2 x 500 MW

Pre heating and Post Weld Heat Treatment of weld joints.