FQP - Fuel Handling System

ID NO.
FIELD QUALITY PLAN

FOR
FUEL HANDLING SYSTEM

FOR
SHREE MEGA POWER (2x150MW)
CETHAR VESSELS LIMITED

TIRUCHIRAPPALLI
FIELD QUALITY ASSURANCE DEPARTMENT
DOC. No: QPE-FHS-001 REV. No : R00 / Oct-2010

FRT-FQP-001-REV 00
FIELD QUALITY PLAN

FOR
BOILER STRUCTURES
FOR
SHREE MEGA POWER

PREPARED BY (P.Vijayaragavan, Engineer / QA) REVIEWED BY (N.Narayanasamy,VP /UB& UPP ) APPROVED BY (V. Kandhsamy, Chief / FQA) DOCUMENT No. QPE-FHS-002 R00 / OCT-2010 CONTROLLED / INFORMATION COPY ID No. NO. OF PAGES: 30 DATE OF ISSUE ISSUED BY
COPY No:
ISSUED TO:
CETHAR VESSELS LIMITED

TIRUCHIRAPPALLI
FIELD QUALITY ASSURANCE DEPARTMENT
FRT-FQA-002-REV 00
DOC. NO. : QPE-FHS-001
CONTENTS
REV. NO. : R00 SHEET: 1 / 1
Sl. No
DESCRIPTION
NO. OF SHEETS
1 2. 3. 4. 5. 6
STATUS OF AMENDMENTS AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECKS STATEMENT OF CHECKS DOCUMENTS REFERRED IN QUALITY PLAN LOGSHEETS : L-00 TO L-04 FEEDBACK ON FIELD QUALITY PLAN
1 1 9 1 5 1
FRT-FQP-003-REV 00
STATUS OF AMENDMENTS
REV. NO. : RO0 SHEET : 1 / 1
SL. NO.
REFERENCE OF SHEETS AMENDED
AMENDMENT NO. & DATE
REMARKS
NIL
FRT-FQP-004-REV 00
AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECKS
REV. NO. : RO0 SHEET : 1 / 1
CLASSIFICATION OF CHECKS
CHECKING / WITNESSING AUTHORITY

CVL QAE
ACCEPTING AUTHORITY
HEAD/FQA
CRITICAL SCL
CONSTRUCTION
SCL
CVL B MAJOR SCL
ERECTION
QAE
CONSTRUCTION
SCL
CVL C MINOR SCL
ERECTION
HOS
---
SCL
LEGNDS:
QAE -QUALITY ASSURANCE ENGINEER HOS-HEAD OF SECTION
NOTE 1.QAE shall witness 'A' category checks. He is also authorised to carry out surveillance in any of B and C category of checks at his discretion. 2. In case of non-conformity, accepting authority shall ensure disposition before accepting and the dis-positioning shall be reflected on log sheets / protocols. 3. QAE shall ensure that only calibrated instruments are used for all measurements.
FRT-FQP-005-REV 00
STATEMENT OF CHECKS
REV. NO. : RO0 SHEET: 01 / 09
Capacity / Type: System: Sub-system: Area:
: 2 X 150MW : BOILER : FUEL HANDLING SYSTEM : ERECTION
NOTES: 1. For checks where log sheets are not called for, suitable records should be maintained in the form of log book / protocols. 2. As an evidence of having carried out the work satisfactorily, a general purpose log sheet, L-00 shall be maintained for all the checks. 3. The above sub-system covers Foundation and erection of structures, truck tippler,gantry,l conveyors, transfer tower,vibrating feeder,vibrating screen & Crushers with house,metal detectors, magnetic separators and belt weigher
FRT-FQP-006-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
FIELD QUALITY PLAN

SYSTEM: BOILER Sub system: Fuel handling system
TYPE OF CHECK INSTRUMENT
CUSTOMER: M/S.SHREE CEMENT LTD. PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-FHS-001 PACKAGE: EPC REV. No. : R00 PAGE No.: 02 / 09 CONTRACT No.: EBJ 072 & 087
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS/ITEM
1.0 1.1 1.2
FOUNDATION Availability of identified & protected permanent bench mark Elevation of top of foundation pedestals with reference to permanent bench mark Disposition of foundation pedestals with reference to M longitudinal axis of boiler and reference axis Spacing between the foundation pedestals Diagonals of the main column foundation pedestals Pitch distance of foundation pedestal bolts on both the axes and its diagonals STRUCTURES
Material Receipt Verification &Identification Check Check for cleanliness of structures before erection.
V M Dumpy level / Water level / Tape Tape M M M Tape Tape Tape
B B Drawing / erection manual -do-do-do-do-
100% 100% L - 01
1.3 1.4 1.5 1.6 2.0 2.1 2.2 2.3
A B B C
100% 100% 100% 100%
L - 01 L - 01 L - 01 L - 01
V V V/M
Nil Nil Tape / Piano wire / Water level
B B B
Transport/ packing Doc. Nil Drawing
100% 100% 100%

FOR CUSTOMER USE
Pre-assembly of columns before erection , wherever applicable.
MAIN SUPPLIER :CVL SIGNATURE
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QA E OF CVL & CUSTOMER, B SHALL BE WITNESSED BY ERECTION OF CVL & CUSTOMER AND C SHALL BE WITNESSED BY ERECTION OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SL. NO
FIELD QUALITY PLAN

TYPE OF CHECK
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
2.4
Individual column piece camber and sweep (Tolerance :1mm/M : 10 mm max.). Camber and sweep for assembled columns (Tolerance :1mm/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 center line of base plate with pedestal axes. Elevation of column at 1 meter level with reference to benchmark (Tolerance : 5 mm). Alignment of first piece of column with horizontal beams and vertical bracings (Tolerance :Position w.r.t. reference axis : 5mm; elevation: 5 mm).
-do-do-
B B B
Drawing / erection manual -do-do-
100%
2.5 2.6
M M
100% 100%
Tape
2.7
-do-
100%
2.8
V Water level / Tape Theodolite / Tape / Plumb bob
-doDrawing / erection manual -do-
100%
2.9
100%
2.10
100%
FOR CUSTOMER USE
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY ERECTION OF CVL & CUSTOMER AND C SHALL BE WITNESSED BY ERECTION OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SL. NO
FIELD QUALITY PLAN

TYPE OF CHECK
FQP No. : QPE-FHS-001 REV. No. : R00 PAGE No.: 04 / 09

INSTRUMENT CLASS
CUSTOMER: M/S.SHREE CEMENT LTD. PROJECT: SHREE MEGA POWER 2X150MW PACKAGE: EPC CONTRACT No.: EBJ 072 & 073
QUANTUM/ FORMAT FREQUENCY OF OF CHECK RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD
2.11 2.12
Completion of boxes with main brace level members ( MBL). Grouting gap below the column base (Min. 20mm ; max. 70 mm). Verification of test certificates and batch certificates of grout material.
V M Tape
B B A
-doDrawing Procedure for grouting Drawing / Grout manufactures Recommendation
100% 100%
2.13
100%
2.14
Grouting of column bases.
V/R
100%
L - 04
2.16
Alignment of columns at every stage of erection.
Theodolite / Tape / Plumb bob
Drawing / erection manual
100%
L - 05
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY ERECTIONOF CVL & CUSTOMER AND C SHALL BE WITNESSED BY ERECTION OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
FOR CUSTOMER USE
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SL. NO CHARACTERISTICS
CUSTOMER: M/S.SHREE CEMENT LTD. PROJECT: SHREE MEGA POWER 2X150MW SYSTEM: BOILER FQP No. : QPE-FHS-001 REV. No. : R00 PACKAGE: EPC Sub system: Fuel handling system PAGE No.: 05/ 09 CONTRACT No.: EBJ 072 & 073
TYPE OF CHECK INSTRUMENT CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
FIELD QUALITY PLAN
WELDING Procedure for structural welder / welding operator qualification at site
4.1
Qualification of welders
V/R
100%
4.2
Availability of approved WPS , Heat Treatment Schedule,Erection Manual, Calibration test certificates of instruments used. Adoption of correct procedure , approved electrodes and methods.
A Drawings / Procedure for receipt inspection and control of welding consumable at site / Heat Treatment Parameters Drawing / Guidelines for Erection / Heat Treatment Parameters
100%
4.3
V/R Time temperatur e Recorder / Thermal Chalk
100%
4.4
Pre heating and interpass temperature.
V/R
As per Reference Document

FOR CUSTOMER USE
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY ERECTIONOF CVL & CUSTOMER AND C SHALL BE WITNESSED BY ERECTION OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SL. NO
FIELD QUALITY PLAN

TYPE OF CHECK
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECOR D REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
5.0
NDE a) Edge preparation i .MPI for new edges prepared at site after flame cutting / trimming of respective member where t 38mm. ii . MPI/LPI for all gas cut edges for t 20mm and below 38mm. iii . MPI/LPI for all bevel edges for t 20mm prior to welding b) Butt welds MPI/ LPI on all back gouged / ground grooves prior to welding from second side.
CVL/PR/014 Rev.04 CVL/PR/006 Rev.03 -do-do-
100% 10% 100%
i.
V V V V
B A B B
CVL/PR/014 Rev.04 CVL/PR/006 Rev.03 CVL/PR/095 Rev.00 CVL/PR/014 Rev.04 CVL/PR/006 Rev.03
100% 100% 100% 10.00% For Customer Use
ii. RT for t 32mm. Iii. MPI/LPI on finished welds for t > 25mm to t < 32 mm. Iv. MPI/LPI on finished welds up to 25 mm thick.
-do-
Main Supplier: CVL Signature
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY ERECTION OF CVL & CUSTOMER AND C SHALL BE WITNESSED BY ERECTION OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, PPHYSICAL & T- TEST.
Reviewed By
Approved By
Approval Seal
SL. NO
FIELD QUALITY PLAN

TYPE OF CHECK

CLASS
QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
d) Fillet welds I.)LPI/MPI For welds between flange and web and bearing stiffeners. ii.) LPI/MPI For other welds joining plate members in which both plate members are over 25 mm thick. iii.) LPI for All other welds
V V V V V M V M M
Tape
CVL/PR/006 Rev.03 CVL/PR/014 Rev.04 -doCVL/PR/006 Rev.03
100%
B B
100% 10% of weld length
6.0
7 8
Gantry construction i) Provision of Stool Support ii) Provision of Deck sheet at fuel point iii) Idlers location & alignment iv) Provision of mounting bracket v) Provision of floor grills vi) Individual piece Dimension, holes location, bend & twist Vii) Gantry assembly dimension, holes location , bend & Twist . Head End & Tail End with pulleys Stringer arrangement i) Alignment ii) Centre to Centre Distance Drive Arrangement i) Alignment ( Axial & radial)
Tape
A B
Drawing Do--
100%
Do- Do--
Dial Micrometer
Drawing
100.00%
FOR CUSTOMER USE
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SL. NO
FIELD QUALITY PLAN

TYPE OF CHECK

CLASS
CHARACTERISTICS
INSTRUMENT
9 10
Skirt Board arragement at Fuel feeding point Grizzly hopper with Vibrating feeder I) Hopper orientation , dimensions & Alignment ii) Vibratory feeder location & Alignment Crusher , Screen & Vibrating feeder I) Orientation ii) Location iii)Alignment Inter connecting Chute I) Dimension , ii) Welding Soundness iii) location Laying of Belt I) Splicing ii) Hardness at the joint Provision of Scrapper
V M M
Tape -Do-
Drawing
100.00%
A A
Drawing Drawing
100.00% 100.00%
11
Tape
Drawing
100%
12
M Visual M V V M V
Tape Tape
A B A
Drawing
100%
Drawing
100.00% 100% 100% 100.00%

FOR CUSTOMER USE
13 14 15
B Hardness tester A A
Drawing 70 5 Deg Shore A Drawing
MAIN SUPPLIER :CVL
REVIEWED BY
APPROVED BY
APPROVAL SEAL
SL. NO
FIELD QUALITY PLAN

TYPE OF CHECK
FQP No. : QPE-FHS-001 REV. No. : R00 PAGE No.: 09/ 09

CLASS
CHARACTERISTICS
INSTRUMENT
16
Trial run with all Safety accessories i) Provision of pull chord Switches ii) Smooth operation iii) Vibration & Noise level of Drives
Drawing /Equipment manual
100%
17 18 19 20 21
Provision of Guard Provision of Fire fighting system Assembly of Conveyor hood Erection of Dust extraction system , Dust suppression system & Ducting Cladding
V V V V
A A A B
Drawing Drawing Drawing Drawing
100% 100% 100% 100%
MAIN SUPPLIER :CVL
FOR CUSTOMER USE APPROVAL SEAL
REVIEWED BY
APPROVED BY
DOC. NO. : QPE--002
DOCUMENTS REFERRED IN QUALITY PLAN

SL. NO 1 2
REV. NO.: RO0 SHEET :1/1
Reference Document
Erection Manual-Boiler supporting structures Quality Plan - Structural
Document / Procedure No
SMP/Erec/002 BI079/012
Issuing Authority
Construction QA&C
3 4 5 6
Procedure for Liquid Penetrent Examination Procedure for Radiographic Examination Procedure for Magnetic Particles Examination Procedure for Post Weld Heat treatment
CVL/PR/006 CVL/PR/095
QA&C QA&C
CVL/PR/014 CVL/PR/002A
QA&C QA&C
7 8 9
10
Procedure for grouting Procedure for visual inspection Procedure for Structural welder / welding operator qualification at site
CVL/FQA/PR/003 CVL/PR/029 CVL/FQA/PR/002
FQA QA&C FQA
Welding Consumable Selection Chart

List of Approved Welding Consumables
BGS-2-24 to BSG-2-027
CVL/AWCL/001
Engineering
QA&C
11
Notes: QA&C Quality Assurance & control
FQA Field Quality Assurance

FRT-FQP-009-REV 00
RECORD OF QUALITY CHECKS

RESULTS ACHIEVED OK / NOT OK DRAWING / DOCUMENT REFERENCE CLEARED BY SIGN. & DATE
SHEET NO. OF. FQP
CHECK NO.
FORMAT OF RECORD
INSPECTED BY SIGN. & DATE
REMARKS
Note: Any protocol made is to be numbered & mentioned in Format of Record column.
PROJECT UNIT NO. RATING FRT-FQP-010-REV 0 SYSTEM SUB - SYSTEM AREA DOC. NO. : QPE-FHS-001 REV. NO. : RO0 LOG SHEET NO. : L - 00 SHEET : 1/1
INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.
PITCH AND DIAGONAL DISTANCE OF FOUNDATION BOLTS
AS PER DRAWING PEDESTAL DESIGNATION L R L R L R L R L R Tolerances: 1. Pitch Distances 2. Diagonal Difference : 3mm : 5mm max
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE
a1
a2
a3
a4
b1
b2
b3
b4
D1
D2
All dimension are in mm

DOC. NO. : QPE-FHS-001 REV. NO. : RO0 LOG SHEET NO. : L - 01 SHEET : 1 / 1
GROUTING OF COLUMN BASES

1. Column number ( identification) 2. Grout material Specification 3. Ratio of proportion of grout mix 4. Whether any additives added If yes ,details : : : : : Yes / No
5. Date of grouting
: Yes / No
6. Whether test cubes have been taken : If yes ,details :
7. Remarks
The following column bases _____________________________ are cleared for further erection after _______days of curing.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER
SIGN. &DATE
DOC. NO. : QPE-FHS-001 REV. NO. : RO0 LOG SHEET NO. : L - 02 SHEET: 1 / 1
VERTICALITY OF COLUMNS
Column Number Elevation in metres Inclined towards (mm) East West North South
Tolerance : 1mm / M, 25 mm Max.

NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-FHS-001 REV. NO. : RO0 LOG SHEET NO. : L - 03 SHEET 1 / 1
JOINT INSPECTION PROTOCOL FOR COMPLETION OF STRUCTURE AND EQUIPMENT

SI. NO
1 2
ACTIVITY
OBSERVATION
3 4 5 6 7 8
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER
SIGN. &DATE
DOC. NO. : QPE-FHS-001 REV. NO. : RO0 LOG SHEET NO. : L - 04 SHEET : 1 / 3
FEEDBACK ON FIELD QUALITY PLAN
In the Field Quality Plan (FQP), for following Checks / Log sheets may be added / rewritten / deleted (cannot be carried out / not required) due to reasons as mentioned below:
Sheet No. Of FQP
Check No. / Log Sheet No.
Proposed Change / Reasons / Remarks
From PROJECT UNIT NO. RATING FRT-FQP-013-REV 00
To Head/FQA, CVL, Tiruchirappalli. DOC. NO. : QPE-FHS-001 REV. NO. : RO0 SHEET :1/1

FQP - Fuel Handling System

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ID NO.

FIELD QUALITY PLAN

FUEL HANDLING SYSTEM

SHREE MEGA POWER (2x150MW)

CETHAR VESSELS LIMITED

DOC. No: QPE-FHS-001 REV. No : R00 / Oct-2010

FIELD QUALITY PLAN

SHREE MEGA POWER

CETHAR VESSELS LIMITED

DOC. NO. : QPE-FHS-001

REV. NO. : R00 SHEET: 1 / 1

DOC. NO. : QPE-FHS-001

REV. NO. : RO0 SHEET : 1 / 1

REFERENCE OF SHEETS AMENDED

AMENDMENT NO. & DATE

DOC. NO. : QPE-FHS-001

AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECKS

REV. NO. : RO0 SHEET : 1 / 1

CHECKING / WITNESSING AUTHORITY

CVL B MAJOR SCL

CVL C MINOR SCL

QAE -QUALITY ASSURANCE ENGINEER HOS-HEAD OF SECTION

DOC. NO. : QPE-FHS-001

REV. NO. : RO0 SHEET: 01 / 09

Capacity / Type: System: Sub-system: Area:

: 2 X 150MW : BOILER : FUEL HANDLING SYSTEM : ERECTION

FIELD QUALITY PLAN

1.0 1.1 1.2

V M Dumpy level / Water level / Tape Tape M M M Tape Tape Tape

B B Drawing / erection manual -do-do-do-do-

1.3 1.4 1.5 1.6 2.0 2.1 2.2 2.3

100% 100% 100% 100%

Nil Nil Tape / Piano wire / Water level

Transport/ packing Doc. Nil Drawing

100% 100% 100%

Pre-assembly of columns before erection , wherever applicable.

MAIN SUPPLIER :CVL SIGNATURE

FIELD QUALITY PLAN

Drawing / erection manual -do-do-

V Water level / Tape Theodolite / Tape / Plumb bob

-doDrawing / erection manual -do-

MAIN SUPPLIER :CVL SIGNATURE

FIELD QUALITY PLAN

FQP No. : QPE-FHS-001 REV. No. : R00 PAGE No.: 04 / 09

REFERENCE DOCUMENT/ ACCEPTANCE STANDARD

-doDrawing Procedure for grouting Drawing / Grout manufactures Recommendation

Grouting of column bases.

Alignment of columns at every stage of erection.

Theodolite / Tape / Plumb bob

Drawing / erection manual

MAIN SUPPLIER :CVL SIGNATURE

FOR CUSTOMER USE

FIELD QUALITY PLAN

WELDING Procedure for structural welder / welding operator qualification at site

V/R Time temperatur e Recorder / Thermal Chalk

Pre heating and interpass temperature.

As per Reference Document

MAIN SUPPLIER :CVL SIGNATURE

FIELD QUALITY PLAN

100% 10% 100%

100% 100% 100% 10.00% For Customer Use

Main Supplier: CVL Signature

FIELD QUALITY PLAN