INTRODUCTION

Indian Register of Shipping (IRS) is an autonomous organization,

established in March 1975, following a decision of the Union Cabinet and Registered under section 25 of Companies Act 1956 as a Not for Profit organization. IRS was formed with active support and cooperation of the Ministry of Transport, Government of India (GOI), which it continues to enjoy. IRS has no profit motive and primarily aspires only for self support, development and growth. The company has no shareholder, hence no dividends are distributed and surplus, if any, is ploughed back into the organization for promoting its objective and activities and services to its customers, through appropriate Research and Development. IRS is widely recognized for its technical competence, vast experience in related fields and customer friendly approach. Its proven expertise developed in the Marine sector with excellent track record has enabled IRS to suitably diversify its services to the Industrial Sector and to the field of quality management system certification. Indian Register of Shipping has three divisions: 1. Marine Services 2. Indian Register of Quality System 3. IRS Industrial Services The third aspect IRS Industrial Services which is relevant here and covers the following aspects of projects: 1. Third Party Inspection & certification of Projects 2. Project monitoring, Quality Assurance & Surveillance 3. Third Party Technical Quality audits & Projects 4. Design Evaluation 5. Proactive & cost effective expediting services 6. Technical Investigation & Advisory Services Further infrastructure is backbone of countrys economic development. Owing to high cost & complexity, there is a need to monitor the quality of work on a regular basis.

Emphasizing on this, IRS Industrial services ventured into third party Inspection & certification of infrastructure projects. IRS IS provide third party inspection & technical audit services to a) b) c) d) e) f) g) Networking h) i) Water treatment Plants, Head works and connected gravity & rising ESR & connected Distribution Pipe lines mains pipe lines We have pleasure to cater to your needs from our various 16 offices spread over India and further wish to state that we have an International presence in ten top countries of the world. Bridges (Rail/ Road), Roads & Highways (Flexible / Rigid), Buildings (High rise, Township, Green Building), Irrigation Projects (Dams, Canals & Via ducts) Sport Complex, Skywalks Sewage Treatment Plants & allied Underground Drainage

FOREWORD
The first post-independence development plan for Mumbai, formulated by the Mayer-MODAK Committee dates back to 1948 which suggested Satellite Towns North of Mumbai. Ten years later, the BARVE Committee suggested the formation of a township on the mainland across the Thane Creek as a counter-magnet to draw away population from the over crowded city. Accordingly NMMC was constituted on 17th Dec, 1991; by the state government for the catering to the requirements of 29 villages in CIDCO Navi Mumbai Project and 15 villages from KALYAN. The local Self Government started functioning from 1st Jan, 1992. NMMC has an area of 344.70 sq. km. under its supervision. The population in 1991 was just 3, 97,000; which rose to 7, 50,000 in 2001 census and during the last decade it has grown substantially. Navi Mumbai is a beautiful planned city; a Counter Magnet for Mumbai. It has been developed as an Independent, Fully Self Contained Metro City, having the Worlds Large, Totally Planned, Well Balanced, and Modern City. The Well Planned Transportation Net-Work consisting of Road, Rail, and Water Way System: makes Navi Mumbai easily accessible from all parts of the Country. The proposed Domestic cum International Airport is envisaged to further enhance this accessibility The development plan for Navi Mumbai envisages planning & development of various nodes [There are 8 nodes.] or township. The entire Navi Mumbai township is expected to have about 20 nodes with a population of about 2 million. The urban development consists of a Well Planned System for Sewerage & Water Supply exist in NMMC area. Such three Sewage Treatment Plants at BELPUR CBD, SANPADA & KOPARKHAIRNE having capacities of 19, 37.5, & 87.5 MLD are already in the process of becoming functional with under-ground drainage system in tow. In order to cope up with massive tasks taken on the shoulders, it has become imperative to draw up a coherent urbanization policy to implement the projects on mission mode such as J.N.N.U.R.M. Indian Register of Shipping (IRS) was appointed as Third Party Quality Audit of Sewage Treatment Plants vide letter of acceptance No. NMMC / EE (SS/PT) / 497 /20-11 dated 23rd Nov, 2011 and subsequent W.O. No.NMMC/EE(SS/PT)/601/2011 dtd.15.12.2011. The scope of the Audit includes the Technical Audit of site records, tender documents, drawings, quality control practices, programme of works etc.

consisting in the process of implementation of quality system for execution of the Sewage Treatment Plants. Accordingly the 2nd Quality audit was conducted by us for the Integrated Development of Sewerage System in Navi Mumbai Corporation area (Underground Sewerage System) Providing of Sewer Network and Improvement in Sewerage System in Vashi and Turbhe Ward. Constructing, Erecting and Commissioning of Sewage Treatment Plant based on advance technology including operation and Maintenance for 3 years at sector-20.Sanpada during the period from 18.1.12 to 20.1.12. . The Quality Audit report is classified under following heads 1. Details of work & status of the work. 2. Structure of Audit team & dates of audit. 3. Organizational set up & experience level of a. NMMC, b. PMC and c. Contractor 4. Review of compliance of earlier audit report. 5. Methodology & Quality assurance plan. 6. Control of Data & documentation at site. 7. Plants & equipments deployed at site. 8. Workmanship. 9. Quality control of testing. 10. Contractual aspects. 11. Safety aspects. 12. Visits of senior officers & their instructions / observations. 13. Site observations of Civil, Mechanical & Electrical Engineering Works. 14. Executive Summary. The above documents were seen for the period from 1.6.2010 to 28.2.2011, as 2 nd Third Party Technical Quality Audit was limited to nine months from the date of commencement. The status & observations under each heads are given in detail item wise. Findings & suggestions/recommendations are described in Audit summary. Some photographs illustrating workmanship and quality of works are taken during site inspection carried out along with the NMMC officials; PMC and Contractors representative are enclosed, with our comments. We hope that the findings / suggestions submitted for your perusal are taken in right perspective thereby enhancing quality of the work in general.

1.0 Details of Works: Name of work Under the Integrated Development of Sewerage System in Navi Mumbai area (Underground Sewerage System for NMMC). Providing of Sewer Network and Improvement in Sewerage System in Vashi and Turbhe ward. Constructing, Erecting and commissioning of Sewerage Treatment Plant based in advance technology including operation and maintenance for 3 years at Sector 20, Sanpada. Part A Designing, Constructing, Erecting and Commissioning of Sewage treatment plant of avg. capacity 37.5 MLD based in advance technology including operation and maintenance for 3 years at Sector 20, Sanpada. Part B 1. Designing, providing and Laying of Sewer Network and Improvement in Sewerage System at Turbhe and Vashi ward. Supplying and Installation of Sewerage Pumping Machinery at Sector 9 (SPH) Sanpada, Sector 9D (SPH) Turbhe, Sector 30 (SPH), Sector 3 (SPH), Sector 12 (SPH), Sector 28 (SPH) Vashi and Turbhe ward and Designing, constructing and commissioning of sewerage pump house at Vashigaon. NMMC/TENDER/ACE/745/2009 Dtd. 18.08.2009 127.5 Crs. No 18.08.2009 Part A 16 Months (Including Monsoon) Part B 24 months (Including Monsoon) 18.08.2009 18.08.2009 Part A 31.12.2011 Part B 31.03.2012 M/s. Gharpure Engineering and construction Pvt. Ltd M/s. Tandon & Associates

Work order no Tender Cost Revised Cost if any Date of work order Time period as per tender Date of commencement as per Tender Actual date of starting of work Revised date of completion Name of the contractor Name of Project Management Consultancy

Part: A: STP: C-tech raft & wall concrete in progress Primary unit footing & plinth beam in progress Sluge sump - Raft concrete in progress Wert well plinth work in progress Blower room Staircase in progress of HT Sub station footing in progress Admin bldg. 1stslab in progress % ge of progress 76.77% Part:B: UGD Pipe laying around 30 Kms. Completed Pumping machinery 51.72% Vash gaon pump house 50.70% RMC Supplier 1) M/s. RMC India Ltd, 2) M/s. Lafarge approved by 3) Ms. Godrej 4) Ms. Ultratech 5) M/s. Venkateshwara NMMC Asphalt mix M/s. Swastik Infraprojects Ltd. supplier approved by NMMC

Actual work

Status

2.0 Structure of Audit team: M/s. Indian Register of Shipping has deployed their qualified and experienced surveyors for Audit Work as below: Sr. No. 1. 3. 4. 5. 6. 8.. Designation Team Leader Auditor Auditor Auditor Auditor Auditor Name Mr. R. C. Bhave Mr. M. D. Deshmukh Mr. G. B. Sable Mr. N. C. Shah Mr. T.K. Dutta Mr. V.P. Nipurte

3.0 Organization set up I. Organization set up of NMMC:

Sr. No. 1 2 3 4

Designation Addl. City Engineer Executive Engineer Deputy Engineer Junior Engineer

Name Mr. Surendra W. Patil Mr. Arvind Shinde Mr. Santosh s. Unawane Mr. Prashant Deshmukh Mr. Vishwe

II. Organization Set-up of PMC M/s. Tandon & Associates:

Sr .N o 1 2 3 4 5

Designation

Name

Qualification

Works experience

Project Manager Deputy Manager Sr. Engg. Sr. Engg. Sr. Engg.

Mr. Anil Kokane Mr. Yogesh Kondalkar Mr.Mahesh Banwaskar Mr. P. Rajulkar Mr. Raj Nagargoje

M. tech Civil M. tech Civil B.E. Civil B.E. Civil B.tech

10 years 5 years 4 years 4 years 3 years

Comments / observations: i. The agreement between NMMC & PMC Viz. M/s. Tondon and Asso. Is available now but after going through the contents, it is observed that details regarding man power deployment is not mentioned.

III. Organization Set-up of Contractors M/s. Gharpure Engineering and construction Pvt. Ltd: Sr No 1 2 Designation Project Manager Construction Manager Name Mr. Anil Khadke Mr. Milind Jadhav Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Pradeep Ubhe Abhay Potdar Suresh Newale Ganesh Sonawane Sachin Jadhav Tanmay Bhabal Wadgaonkar P.S. Hirve Qualification B.E. Civil Engr Works experience 30 Years 15 Years 8 15 6 7 Years Years Years year

Senior Engineer

Civil Engr.

Quality Engineer

Mech. Engr.

2 Years 1 Years 30 year 25 Year

Supervisors

Mr. Sampat Jadhav Mr. B. T. Nalwade

35 Year 25 Year

Comments / observations: The present technical staff in adequate for the execution of project.

10

4.0 REVIEW OF COMPLAINCES OF EARLIER AUDIT REPORT : Since the compliance report for 1 st periodic audit was not received the points raised in that remain non complied. The above matter is discussed with NMMC , PMC & the Contractor for early submission of compliance report. 5.0 Methodology & Quality Assurance Plan: I. It is stated by the contractor that tender conditions do not specify preparation of methodology for the work, hence methodology is not prepared. II. It is suggested that contractor shall prepare a methodology for each and every item of the BOQ to know how the items will be executed by means of methodology of the sequence etc. III. It is obligatory on the part of contractor to prepare QAP within 14 days from commencement of work and as such QAP is prepared by the contractor but not approved by PMC / NMMC. IV. It is further noticed that many points are not being complied as stated in the QAP prepared by the contractor though it is claimed that QAP is prepared for their own guidance. 7.0 Control of Data and Documentation: a) Base Documents: i) Tender copy Vol. I & II ii) Work Order copy iii) STP billing break up (Approved) iv) Correspondence file v) Daily progress reports Technical Documents: A. STP i) Concrete consumption register- Day to day concrete consumption of various grades of concrete is maintained in register. ii) Cube testing register- Cube test register is maintained at site. iii) Reinforcement steel challan file is maintained at site .

b)

iv)

R.C.C. Pipe File- R.C.C Pipe invoice along with manufacturers test record is maintained

11

v)

Batch record file Date wise concrete batch record is maintained

vi)

Mix design file RMC concrete was procured from Lafarge, Ultratech, and RMC India. Mix design from Lafarge, Ultratech, and RMC India was approved by PMC M/s. Tandon & Associate vii) Instruction book- Instruction book should be maintained at site to record suggestions of senior officers visit / their observations of ongoing works & compliances of the same.

viii) Drawing file- Various Drawing files are maintained as per various units of
sewage treatment plant. ix) Shuttering/reinforcement checked/approved etc. The general remark of inspection passed is ticked in the RFI which in fact should have been more elaborate taking into the account above aspects of importance. B . a. b. c. d. e. f. g. UGDUnder mentioned documents were found maintained at site. Approved General master plan/cross section Challans along with MTCs for pipes/materials Level register Cube test register Approval/testing of pipes record Bill record Source approval record

Remark: in addition to above some records not available during audit are as follows. i) Approved hydro test record ii) Approval for bitumen macadam 8.0 Plants and Equipments deployed at site: The site laboratory has the following equipments 1. Cube moulds (150mmx150mmx150mm)-40 nos. 2. CTM of capacity 1000KN 3. Sieves-1 set 4. Core cutter 5. Oven 6. Weighing Balance of capacity 10Kg. 7. Slump cone-3 nos.

12

Remark: Quality control lab has been established at site. All necessary equipments were available at site. Calibration of CTM is available. 8.0 WORKMANSHIP & SITE OBSERVATION 1. Visited new Sewage Pumping Station in Vashi sector-31 Wet Well completed. Screen of inlet raw- sewage is not installed, lots of lump/plastics was observed during audit. 4 pumps installed along with control panels, Flooring Balance. Compound wall around plant & infrastructure development is still balance. 2. Old Pumping Station in Sector 9A, Sanpada. New pumps, are installed along with control panel. 3. UGD Worksi. Sector 4 (sanpada ) It is observed during visit that corramandel cement was used for construction of manhole, a deviation from tender specification. Sector 5 It is observed that top levels of old manhole & new manhole were at different elevation .this may cause problem in construction of new proposed road. Sector- 9 TMT MMC reinforcement steel was used for construction of manhole,a deviation from tender spec. Sector 16 800 dia pipe laying work is in progress (water line) since this was fouling in UGD system. Cross-sectional width for laying pipe is not being maintained as per approved cross section i.e. 500 mm clearance on either side for easy maneuvering for carrying out sub base works below pipe.. Sector -29 Push through is in progress. Safety precaution shall be strictly followed as location is near petrol pump & continuous vehicle movement near the work site.

13

9.0 Quality Control & Testing A. Reinforcement records have been reviewed & following are the observation REMARK MTC / ITC AVAILABL E ITC MTC MTC MTC MTC MTC MTC MTC ITC ITC ITC ITC /MTC / OK MTC / OK/ ITC MTC / OK/ ITC MTC / OK/ ITC MTC - OK MTC / OK/ ITC MTC* MTC / OK/ ITC MTC / OK/ ITC MTC / OK/ ITC MTC / OK/ ITC MTC / OK/ ITC

SR . NO . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

DATE OF RECEIPT 6.6.10 8.6.10 8.6.10 8.6.10 1O.6.10 1O.6.10 1O.6.10 1O.6.10 23.6.10 24.6.10 30.6.10 1.7.10 1.7.10 3.7.10 3.7.10 18.7.10 18.7.10 18.7.10 18.7.10 18.7.10 28.8.10 28.8.10 29.8.10

DIA OF BAR

SUPPLYER / AGENCY / SECONDARY MANUFACTURER

QTY IN MT 20.010 22.160 9.920 11.900 9.660 9.870 20.130 19.970 2.0.040 20.020 20.060 14.800

CAST NO. / LOT NO. RT/42 B GT-62 GT-70 GT-67 RT/45 B RT/42 B RT/47 B RT/60.B GT-75 GT-75 GT-75 GT-86 GT-81 GT-81 GT-81 GT-90 GT-94 GT-89 GT-89 GT-89 RT/100 B RT/100 B RT/100 B

20 JAIN STEEL [REGENCY] 20 JAIN STEEL [GUARDIAN] 12 16 12 20 JAIN STEEL [REGENCY] 16 20 12 SUMIT STEEL[GUARDIAN] 12 20 12 20 20 20 12 16 20 10 12 8 10 SUMIT STEEL[ REGENCY] 8 SAPANA STEEL[GUARDIAN] NEETA STEEL[GUARDIAN]

7.060 20.060 20.820 15.080 1.820 8.100 15.000 10.240 10.160 10.150 20.780

14

24 25 26 27 28 29 30 31 32 33 34

13.11.10 13.11.10 13.11.10 13.11.10 13.11.10 13.11.10 16.12.10 16.12.10 16.12.10 16.12.10 16.12.10

8 12 20 25 10 16 8 12 12 16 20 JATIN STEEL {ECEIVED FROM VASHI PUMP HOUSE} [REGENCY] SHUBH M.L. SHAH & SONS [REGENCY]

15.43 14.98 20.21 4.08 8.110 11.98 2.095 7.360 6.490 7.56 0.74

RT/184 B

MTC / OK/ ITC NO MTC & ITC OK NO MTC & ITC OK NO MTC & ITC OK NO MTC & ITC OK NO MTC & ITC OK MTC OK & NO ITC MTC OK & NO ITC MTC OK & NO ITC MTC OK & NO ITC MTC OK & NO ITC

1.

For the reinforcement steel received, Physical Testing is done for 0.2 % Proof Stress Value, UTS, Elongation and Chemical Testing for Carbon, Sulphur, and Phosphorous % Content and generally found in order. The testing is done in Structwel Designers & Contractors, TCR Engineering Services, both NABL accredited Labs; but Vigilance and Quality Control Regional Lab, Turbhe, Navi Mumbai is PWDs Vigilance Regional Laboratory. Total Quantities of Reinforcement Steel received as per Challans are not matching with actual received [receipt] in the Reinforcement Test Register. On 16.12.10 the 8, 12, 16, 20, and 25 dia. steel is received from M/S JATIN STEEL, but shifted from Vashi Pump House for which no entry is made in the Steel Testing Register(STR) [Test reports to be submitted from the other site and record should be available in STR.

2.

3.

15

4.

Test results of Guardian Steel of Lot / Cast No. 75 & 86 no separate tests are conducted for 12 mm dia bar. Only one test conducted in A.R.O. V & Q Control PWD Lab at Turbhe. MTC is available for the material brought from Vashi Pump House for all the consignments of 8, 12, 16, 20, and 25 MM dia steel with individual quantities mentioned in Regency Thermax MTC dated 14 \ 12 \ 2010 vide Test Certificate No. Regency / TMX / 2586 / 2010 dated 14 \ 12 \ 2010; but independent test certificate not available. Reinforcement Test Register is maintained properly with all the requisites and individual Test Results recorded with signatures of Contractors / PMC & NMMC authorities. But it is not exhaustive considering different Cast Nos. of steel received. 20 mm dia bar steel received on 6 \ 6 \ 2010 & 8 \ 6 \ 2010 from two different Secondary Manufacturers viz. Regency Thermax & Guardian Steel vide Cast No. RT/42-B & GT-62 respectively; Quantity being 20.010 MT and 22.160 MT respectively, where as only one ITC is available and Lot wise testing is not conducted. Steel received 12 mm dia Sumit Steel [Guardian] of 40.06 MT dated 23 \ 6 \ 2010 having Cast / Lot No. GT-75 and from NEETA Steel [Guardian]; of 14.8 MT, having Cast / Lot No. GT-86 test report from V & Q Control Regional Lab Navi Mumbai shows only one specimen test for the 12bar. Where as different Cast Nos. are recorded for which separate tests should have been conducted. Further only on specimen is tested in this case, which is not as per the Codal Provision. Reinforcement steel received on 10 \ 6 \ 2010 of 12, 16, and 20 MM from Regency Steel [Supplier JAIN Steel] show different Cast No. of 20 MM bar steel however only one specimen tested in V & Q Control Lab at Turbhe for all the diameters mentioned above. Reinforcement steel received on 8 \ 6 \ 2010 of 12, 16, and 20 MM from Guardian Steel [Supplier JAIN Steel] shows Cast No. as GT-70, GT-67 & GT-62. Only one test conducted in V & Q Control Lab, vide No. 1416 as per dated 30 \ 6 \ 2010

5.

6.

7.

8.

9.

10. .

B.

Observation on Mix Design:

16

i. PMC, Tondon & associates has approved RMC plant vendor Venkateshwara . via. Letter no. T&A/NMMC/SNG/RMC/335 dated 29-6-2010. M/S Tandon Associates, PMC has approved the vendors for RMC suppliers on the basis of trial mix, physical & chemical test record of concrete ingredients . Record of physical & chemical tests of concrete ingredient from Supplier Venkateshwara is available however the tests on ingredient has been carried out after approval of mix design. ii. Mix design for M25 grade has not been produced during Audit. C. i. Concrete test Cube test record is maintained at site & It is observed that some cube tests results of M35 grade concrete carried out on 19 ,20 ,24 January 2011 are less than 35 N/mm2. Standard deviation has been computed as per Sp-23 for various concreting period & results of concrete cube tests during audit . Standard deviation computed is satisfying for good quality concrete criteria. No NDT test i.e. Rebound hammer test & ultrasonic pulse velocity test record is available at site,since the photograph shown indicated this. Independent cube tests have been carried out at structwel lab, PWD & SKG Lab. Frequency of testing has not been maintained as per 15.2.2 of IS 456 for following concreting works. Grade of concrete Sr No. M35 1 2 3 4 5 6 7 17.6.2010 28.6.2010 29.7.2010 30.6.2010 3.7.2010 7.7.2010 8.7.2010 Date of casting Particular Raft C-Tech basin Raft C-Tech basin Raft C-Tech basin Raft C-Tech basin Raft C-Tech basin Raft C-Tech basin Raft C-Tech Quantity 198 cu-m 3 no 255 cu-m 3 no 225 cu-m 3 no 210 cu-m 5 no 237 cu-m 3 no 198 cu-m 238 cu-m 3 no 4 no 4 no 17 5 no 4 no 4 no 5 no Test carried out at site 5 no Required frequency of Testing 4 no

ii.

iii.

iv.

v.

9.7.2010

basin Raft C-Tech basin

5 no 220 cu-m 4 no

D. Concrete batch record Concrete batch slips have been verified co-relating mix design during audit & found in order. E. RFI record has been maintained at site. Stage passing of various activities, noncompliances, suggestions have been recorded on RFI sheets as per standard inspection procedure . RFI are duly signed by Contractor, PMC and NMMC. F. Building construction material - Brick, sand , cement challan ,MTC , test record is maintained at site. G. Cement consumption record to ascertain the quality of various work i.e Brick work , plaster .coping ,flooring , etc. is not maintained. H. Bar bending schedule was prepared at initial level of project. FOR UGD

A. R.C.C. Pipe R.C.C. pipe has been procured from Dhere concrete product,

Siddhivinayak cement product, Mahadev precast , Vaitarna cement & pipe, Bharat spun pipe, Amey concretcek Pvt.ltd & Vendor are approved by PMC Tondon Associate. B. Third party inspection certificate including a) Inspection test plan report including i) Workmanship & finish verification ii) Dimension verification iii) Three edge load bearing test iv) Hydrostatic testing v) Permeability test vi) Straightness test As per IS 458/2003 Class NP3 RCC Pipe for each lot wise testing is available however following detail reports are not available i) Third party reviewed physical & chemical test reports of coarse & fine aggregate Cement, steel etc. ii) Calibration record of measuring instrument, test equipment. iii) MTC of cement, steel. C. No record of newly constructed Vashi pump house has been produced during audit. D. Cement , brick , sand & coarse aggregate test record has been maintained. E. Cement consumption record to ascertain the quality of various work i.e PCC ,Manhole brick work & plaster etc. is not maintained. F. No record of reinstatement of road etc. available. i.e. Job mix design for various layer, test record of various material or ingredient of WBM .,DBM, BM, AC. 18

G. As R.C.C pipe line is designed for gravity flow, the slope of R.C.C pipe line shall be desirable to control sewer gases and to maintain self cleansing velocities at all rates of flow within the design limits. It is observed that level record is maintained for excavation, PCC , Invert level , Ground level is maintained chainage wise & duly signed by PMC &NMMC. Slope for laying various diameter RCC Pipes is maintained with in the permissible limits. H. Concrete cube test record is maintained.

Contractual Aspects: I.
II. Bar chart planning is prepared by the contractor but not approved by PMC / NMMC. The time extension is approved three times. There is no variation in contract up to 28.2.2011. It is stated by the contractor that no weekly / monthly progress is being submitted. however it is stated by the contractor that PMC is submitting MPR based on the information and facts. RFI is being maintained for each and every activity duly signed by contractor, PMC and NMMC engineer. Work order book is not maintained by the contractor though obligatory to maintain as per contract conditions. PMC had some format for issuing necessary instructions to the contractor whenever solicited but there is no trace of compliances for the instructions given by PMC engineer. QAP and safety manual is not approved by PMC and NMMC. Till period of 31.05.2010. Contractor has claimed Four R.A. Bills and mobilization advance payment. No claims were made towards price escalation. 11.0 SAFETY MEASURES: I. CAR and W.C. are valid policy are in force since commencement of the work and both are valid up to 20.08.2012 and 20.08.2011 respectively. II. Contractor is having a labour Licence no DC / THA / KLA / 057 / 057/55 dated 18.12. 2009 is valid up to 31.12.2011. III. It is obligatory on the part of contractor to submit and get approval of safety manual from PMC / NMMC IV. Contractor has prepared a safety manual in general but same is not approved by PMC / NMMC. 12.0 Electrical Observations:

III.

IV. V. VI.

VII. VIII.

IX.
X.

19

Document referred:-Tender Specification & Material Inward Register. Scope of Audit is for the period 1.6.2010 to 28.02.2011. The verification of the material quality system done based on sample delivery challans as found from respective inward material register and the observations are given below: 1. Crompton Greaves supplied motors as per delivery challan 11136 dated 2.6.2010. Data sheet, QAP are not available. Also, there is no test certificate from manufacturer available. 2. Chavare Engineering supplied MCC and control panels as per delivery challan 407 to 412 dated 26.9.2010. QAP is not available. Routine test certificates from manufacturer are available. However, type test certificates from manufacturer as indicated in tender specification are not available. 3. Polycab Cables supplied wires & cables as per delivery challan 00270 dated 2.11.2010. Data sheet, QAP are not available. Also, there is no test certificate from manufacturer found. Only MTCs for component materials are available. 4. Chavare Engineering supplied Level Transmitters as per delivery challan 331 dated 16.12.2010. Data sheet are available for FMU43 & FMU90 type Level Transmitters. But for level Transmitter type FDU90 there is data sheet available. Also, QAP and test certificates from manufacturer are not available.

13.0 Mechanical works:

20

1) MS PIPES (ERW) A) Above Qty verified with challan & found in order Certificates for the same are not available to be provided 2) BLOWERS SWAM MAKE SIZE/MAKE 600MMX 6.35 THK/LANCO QTY(MTRS) 21 CHALLAN NO 048/49/50 DT 13/12/2010 18915 DT 17/12/2010 18915 DT 17/12/2010 18915 DT 17/12/2010 18915 DT 17/12/2010 18915 DT 17/12/2010 18915 DT 17/12/2010 18915 DT 17/12/2010 18916 DT 17/12/2010 18916 DT 17/12/2010 024263 DT 29/12/2010

2 B CLASS/LANCO 5.99 2 B CLASS/LANCO 5.99 3 B CLASS/LANCO 91.55 5 B CLASS/LANCO 231.88 6 B CLASS/LANCO 163.89 12 B CLASS/LANCO 144 16X6.35THK/LANCO 148 8X 5THK/LANCO 109 14X 6.35THK/LANCO 78 820O/DX 8THK/LANCO 16NOS Sr no :-48 to 53-6nos Cap :-5750nm3/hr Motor:- 225 hp 1100 rpm Sr no :- NADZC 2276 to 2281-6NOS

A) Above Qty verified with challan & found in order Certificates for the same are available but motor certificates to be provided B) Datasheet/QAP seen & found ok C) Guarantee certificate to be provided 3) VALVES KIRLOSKAR MAKE A) Qty checked as per register verifying challan & found ok B) No certificates available C) Datasheet/QAP seen & fou

21

EXECUTIVE SUMMARY 1) Organizational Setup The agreement between NMMC & PMC Viz. M/s. Tondon and Asso. Is available now but after going through the contents, it is observed that details regarding man power deployment is not mentioned. Contractor/s M/s. Gharpure Engineering Pvt. Ltd has given the list of Technical staff with qualifications & experience and generally it is in order.

ii.

iii.

2 ) REVIEW OF COMPLIANCE OF EARLIER AUDIT REPORT: i. Since the compliance report for 1 st periodic quality audit was not received the points raised in that remain non complied. The above matter is discussed with NMMC ,PMC , & Contractor for early submission of compliance report. 3) i. 4) ii. Methodology and Quality Assurance Plan: Certain important documentation is needed and the site staff is given suggestions in this regard. Control of Data & Documentation at site: Certain important documentation is needed and the site staff is given suggestions in this regard.

5) Plants & Equipments: i. 6) i. Quality control lab has been established at site. All necessary equipments were available at site. Quality Control & Testing: Third party inspection certificate including inspection test plan report along with Workmanship & finish verification Dimension verification ,Three edge load bearing test , Hydrostatic testing Permeability test, Straightness test as per IS 458/2003 Class NP3 for each lot wise testing is available however following detail reports are not available a. Third party reviewed physical & chemical test reports of coarse & fine aggregate Cement, steel etc. b. Calibration record of measuring instrument, test equipment. c. MTC of cement, steel No record of newly constructed Vashi pump house has been produced during audit.

ii.

22

iii. iv. v.

No record of reinstatement of road etc. available. i.e. Job mix design for various layer, test record of various material or ingredient of WBM .,DBM, BM, AC. No NDT test i.e. Rebound hammer test & ultrasonic pulse velocity test record is available at site Cement consumption record to ascertain the quality of various work i.e Brick work , plaster .coping ,flooring , etc. is not maintained

7) Contractual Aspects: i. ii. iii. iv. v. Bar chart planning is prepared by the contractor but not approved by PMC / NMMC. There is no variation in contract up to 28.2.2011. It is stated by the contractor that no weekly / monthly progress is being submitted. however it is stated by the contractor that PMC is submitting MPR based on the information and facts. PMC had some format for issuing necessary instructions to the contractor whenever solicited but there is no trace of compliances for the instructions given by PMC engineer. QAP and safety manual is not approved by PMC and NMMC. Till period of 31.05.2010. Contractor has claimed Four R.A. Bills and mobilization advance payment.

vi.

8) Safety Aspects: I. CAR and W.C. are valid policy are in force since commencement of the work and both are valid up to 20.08.2012 and 20.08.2011 respectively. II. Contractor is having a labour Licence no DC / THA / KLA / 057 / 057/55 dated 18.12. 2009 is valid up to 31.12.2011. III. It is obligatory on the part of contractor to submit and get approval of safety manual from PMC / NMMC IV. Contractor has prepared a safety manual in general but same is not approved by PMC / NMMC. 9) Electrical observationsFollowing compliance as per Tender requirements to be fulfilled by the Contractor: i. ii. iii. iv. Compliance not received against observation made during first audit dated 15.12.2011. This is to be fulfilled. In most cases there is no QAP available. This is to be arranged for all the materials delivered. Test certificate for motors from manufacturer to be made available. Type test certificate for MCC panel to be arranged.

23

v. vi.

Test certificate of cable to be produced. Test certificates of Level transmitters to be arranged.

10) Mechanical Observationi. It is observed that the delivery pipe connected to Blower passing through the Blower room wall (housing 6nos Blower) give vibration to the wall & some cracks are observed on the wall. These vibration can be contained by providing rubber/wrapping to the outer surface of pipe for the wall portion & further a saddle support from the ground outside the wall before bend portion to be provided which can also minimize vibration on the wall ii. Sludge pump discharge is seen to be by passed & discharged into open nallah instead of going to sludge sump which is to be avoided.

SUGGESTIONS

24

TO IMPROVE LONGEVITY AND SAFETY OF STPs IN GENERAL Suggestions to improve Longevity and Safety of STPs in general: I.] It is observed in all STP s that the main walkways passing through C Tech Basins are provided Antiskid Ceramic Tiles along with Poly Carbonate Circular Roof and this is alright considering main area of operation as well as for Visiting Personals. However, the other walkways are left bare without tiling and the concrete finish is also rough. These walkways are on top of C Tech Basins wall portion projecting on either side. The rough finish on top of walk way will soak rainwater during rainy season. Further transverse cracks are observed in this slab which when saturated by rainwater can endanger reinforcement of slab as well as walls of C Tech Basins. This problem cannot be solved by just sealing the cracks even with epoxy. Therefore, it is suggested to cover this entire portion with Chequered tiles or any other suitable material. II.] The above walkways have SS railing on both sides with two horizontal runners, however the bottom [above the walkway slab] portion is left open without any arrester in the form toe flat, so that no accident can occur slipping through this large gap. Regular maintenance gangs will walk on this plant walkways and hence this precaution is necessary from safety point of view, for the workers. III.] Decanter Actuator Arm niche is open now and is susceptible for mishap. It is therefore suggested to have a raised platform so that any person will not hamper Arm Movement along with smooth ride. [Arm Movement will not be hampered along with smooth ride by any person.]

25