A.K.

Banerjee
2015.03.13 11:47:40
+05'30'

DEVELOPMENT CONSULTANTS
PRIVATE LIMITED
Reviewed for general conformance with Contract
drawings and specifications.
ACTION :

1 Approved

Disapproved.

For information/reference
only.

Information category with

comments. Resubmission
required.

Approved except as

2 noted. Forward final

drawing.
Approved except as

3 noted. Resubmission

BGR ENERGY SYSTEMS LIMITED

required.

POWER PROJECTS DIVISION

Approval of Contract documents by the Consultant shall
not relieve the Seller of his responsibility for any errors
and fulfilment of Contract requirements.

443, ANNA SALAI, TEYNAMPET

CHENNAI - 600 018
PROJECT: 2 X 660 MW IB TPS , ODISHA POWER GENERATION CORPORATION LTD

MANUFACTURING INSPECTION AND TEST PLAN

for structural materials for Equipment Mounting and Towers

PREPARED BY

REVIEWED BY

APPROVED BY

R.SHREEVATSAN

S.CHANDRASEKAR

K.KALYANARAMAN

LEGEND:
P-Perform

MTC-Manufacturer test certificate

WPS-Welding procedure Specification

R-Review

DPT- Dye Penetrant Testing

PQR-Procedure Qualification Record

W-Witness

NDT- Non Destructive Testing

WPQ-Welder Performance Qualification

RW-Random witness

BGR Doc. No.: BGR-PPD-0208-EL-MQP-0494, REV 02, DATED: 12.03.15

VENDOR Doc. No.: RPECPL/BGR/OPGCL/QAP/STR/001, REV 02, DATED: 11.02.15
Page 1 of 4

QUALITY ASSURANCE PLAN

Package/Equipment :
SWITCHYARD TOWERS & SUPPORTING STEEL STRUCTURALS

RATAN PROJECTS & ENGG. CO. PVT. LTD.

26, PRASANNA KUMAR TAGORE STREET,
KOLKATA 700 006

Rev. No : 02

CLIENT : ODISHA POWER GENARATION CORPORATION LTD.

Date : 11.02.2015

P.O. NO. 3500006202, Date : 09.12.2014

Quantum/
Type of check Frequency of
check

Ref documents &

Acceptance std

Major

Visual/
Measurement

Random

Mechanical Properties

Major

Verification

Chemical Properties

Major

Ultrasonic Test of Plate thickness

25mm

Item/Component &
Operation

S.NO

1.0

Doc. No: RPECPL/BGR/OPGCL/QAP/STR/001

Project: 2X660 MW, IB TPS, BANAHARPALLI

CONTRACTOR: BGR ENERGY SYSTEMS LTD

Characteristics

Class of
Check

Visuals & Dimensions

Format of
Record

Inspecting Agency
Remarks

Contractor

BGR

Customer

Appvd. Drg./GTP

Mfg. TR/LAB TC

2/heat

IS: 2062

Mfg. TR/LAB TC

Verification

1/heat

IS: 2062

Mfg. TR/LAB TC

Major

Verification

100%

ASTM A 435

Visuals & Dimensions

Major

Visual/
Measurement

Random

Appvd. Drg./GTP

Mfg. TR/LAB TC

Mechanical Properties, Chemical

Properties and Hardness

Major

Verification

Sample

IS:1367-3 /IS:13676

Mfg. TR/LAB TC

Hot Dip galvanizing

Major

Verification

Sample

IS:1367-13

Mfg. TR/LAB TC

Visuals & Dimensions

Major

Visual/
Measurement

Random

Appvd. Drg./GTP

Mechanical Properties

Major

Verification

Sample

IS 4072/ IS 1079

Chemical Properties

Major

Verification

Sample

IS 4072/ IS 1079

Electro Galvanised ( Only for Spring

Washer )

Major

Verification

Sample

IS 1573

Visuals & Dimensions

Major

Visual/
Measurement

Random

Appvd. Drg./GTP

Mfg. TR/LAB TC

Mechanical Properties

Major

Verification

Sample

IS:2062

Mfg. TR/LAB TC

Chemical Properties

Major

Verification

Sample

IS:2062

Mfg. TR/LAB TC

Hot Dip galvanizing

Major

Verification

Sample

Appvd. Drg./IS:
2629

Mfg. TR/LAB TC

Raw Material / Equipment Items

1.1

1.2

1.3

1.4

Structural/plates

Bolts, Nuts

Supplier TC
/ Internal
Test Report

Washers

Foundation Bolts

VENDOR: RATAN PROJECTS & ENGG.CO.(P) LTD.

BGRESL

CUSTOMER

SIGNATURE :

SIGNATURE :

SIGNATURE :

NAME :

NAME :

NAME :

Page 2 of 4

QUALITY ASSURANCE PLAN

Package/Equipment :
SWITCHYARD TOWERS & SUPPORTING STEEL STRUCTURALS

RATAN PROJECTS & ENGG. CO. PVT. LTD.

26, PRASANNA KUMAR TAGORE STREET,
KOLKATA 700 006

Doc. No: RPECPL/BGR/OPGCL/QAP/STR/001

Rev. No : 02

CLIENT : ODISHA POWER GENARATION CORPORATION LTD.

Date : 11.02.2015

P.O. NO. 3500006202, Date : 09.12.2014

Quantum/
Type of check Frequency of
check

S.NO

Item/Component &
Operation

Characteristics

Class of
Check

1.5

Welding Electrode (batch

certificate)

Verification of batch certificate

Major

Verification

1.6

Zinc Ingot

Quality of Zinc

Major

Verification

Project: 2X660 MW, IB TPS, BANAHARPALLI

CONTRACTOR: BGR ENERGY SYSTEMS LTD

Sample

Ref documents &

Acceptance std

Format of
Record

Apprd. Drwg/
Related std

Sample per IS:2629/IS:209/IS:1

Lot/Batch
3229

Inspecting Agency
Remarks

Contractor

BGR

Customer

Supplier
TC/Internal
Test Report

MTC

Match Marking will be done

in black Condition

IF already approved
established procedure is
available, then review or
else witnessed by customer

In Process

2.1

Materials Marking, Cutting,

Drilling, Punching

Visual & Dimensions

Major

Visual/Measur
ement

100%

Appvd. Drg./GTP

2.2

Welding Control

Verification of WPS/PQR/WPQ

Major

Visual

100%

ASME SEC IX

2.3

Final Welding

Visual & Dimensions

Major

Visual

10%
Random

Mfg. Drg/ Data

Sheet

2.4

NDT

DPT on Welds

Major

Visual

100%

ASTM E165

Report

2.4

Trial Assembly

Visual & Dimensions

Major

Measurement

1/ Type

Appvd. Drg./GTP

Mfg.
record/In
process
Report

VENDOR: RATAN PROJECTS & ENGG.CO.(P) LTD.

Mfg.
Record/In
process
Report

Note - 1

BGR ESL

dimension 5mm

OPGCL

SIGNATURE :

SIGNATURE :

SIGNATURE :

NAME :

NAME :

NAME :

Note: 1. During the course of execution if in any Butt joint is made in the load bearing section the same shall be checked with 100% RT/UT

Page 3 of 4

Tolerance for part

dimension 2mm and full

QUALITY ASSURANCE PLAN

Package/Equipment :
SWITCHYARD TOWERS & SUPPORTING STEEL STRUCTURALS

RATAN PROJECTS & ENGG. CO. PVT. LTD.

26, PRASANNA KUMAR TAGORE STREET,
KOLKATA 700 006

Item/Component &
Operation

S.NO

2.5

3
3.1

3.2

Hot Dip Galvanizing

Doc. No: RPECPL/BGR/OPGCL/QAP/STR/001

Project: 2X660 MW, IB TPS, BANAHARPALLI

CONTRACTOR: BGR ENERGY SYSTEMS LTD

Rev. No : 02

CLIENT : ODISHA POWER GENARATION CORPORATION LTD.

Date : 11.02.2015

P.O. NO. 3500006202, Date : 09.12.2014

Quantum/
Type of check Frequency of
check

Characteristics

Class of
Check

Surface preparation (DegreasingPickling)

Major

Mechanical

Quality of Zinc Material

Major

Temperature of Zinc Bath

Inspecting Agency

Ref documents &

Acceptance std

Format of
Record

Contractor

BGR

Customer

100%

Appvd. Drg./IS:
2629

Log Book

Verification

Sample per
Lot

Appvd. Drg./IS:
2629

MTC

Major

Visual

Continuous

Appvd. Drg./IS:
2629

Log Book

Surface Finish

Major

Visual

100%

Appvd. Drg./IS:
2629

Log Book

Zinc Coating Thickness

Major

Measurement

Process
Check

Appvd. Drg./IS:
2629

Log Book

Visual & Dimensions

Major

Visual/
Measurement

Random

Appvd. Drg./GTP

Report

Visual & Dimensions, Marking &

Rectification

Major

Visual/
Measurement

Random

Appvd. Drg./GTP

Report

Surface Finish, Distortion

Major

Visual

Random

Appvd. Drg./IS:
2629

Report

Adhesion Test

Major

Pivoted
Hammer Test/
Knife Test

2 Sample
Per Lot

IS: 2629

Report

Zinc Coating Thickness

Major

Measurement

2 Sample
Per Lot

IS: 6745

Report

Mass of Zinc Coating

Major

Measurement

2 Sample
Per Lot

IS: 2629

Report

Uniformity of Zinc Coating

Major

Measurement

2 Sample
Per Lot

IS: 2629 / IS: 2633

Report

Final Inspection
Individual Members of
Towers/Structures

Hot Dip Galvanizing

Packing and Transport

Final Documentation

Included in the supplier Scope

Review of documents

Major

VENDOR: RATAN PROJECTS & ENGG.CO.(P) LTD.

Verification

100%

As per approved
QAP

Document
Package

BGR ESL

OPGCL

SIGNATURE :

SIGNATURE :

SIGNATURE :

NAME :

NAME :

NAME :
Page 4 of 4

Remarks