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ID NO.

FIELD QUALITY PLAN


FOR

PRESSURE PARTS
(ERECTION)

FOR

SHREE MEGA POWER (2x150MW)

CETHAR VESSELS LIMITED


TIRUCHIRAPPALLI
FIELD QUALITY ASSURANCE DEPARTMENT

DOC. No: QPE-PP-002 REV. No : R02 / MARCH 2010


FRT-FQP-001-REV 00

FIELD QUALITY PLAN


FOR

PRESSURE PARTS
(ERECTION)

FOR

SHREE MEGA POWER


PREPARED BY (P.Gnanagiri, Sr.Engineer / FQA) REVIEWED BY (G. Umakanthan, VP / PP&NPP) APPROVED BY (V Kandhsamy, Chief / FQA) DOCUMENT No. QPE-PP-002 R02 / March 2010 CONTROLLED / INFORMATION COPY ID No. NO. OF PAGES: 41 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-PP-002

CONTENTS

REV. NO. : R02 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-12 FEEDBACK ON FIELD QUALITY PLAN

1 1 14 1 20 1

FRT-FQP-003-REV 00

DOC. NO. : QPE-PP-002

STATUS OF AMENDMENTS

REV. NO. : R02 SHEET : 1 / 1

SL. NO.

REFERENCE OF SHEETS AMENDED

AMENDMENT NO. & DATE

REMARKS

NIL

FRT-FQP-004-REV 00

DOC. NO. : QPE-PP-002

AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECKS

REV. NO. : R02 SHEET : 1 / 1

CLASSIFICATION OF CHECKS

CHECKING / WITNESSING AUTHORITY


CVL QAE

ACCEPTING AUTHORITY
HEAD/FQA

CRITICAL SCL FQE (QC ENGR.) ERECTION ERECTION (QC ENGR.) ERECTION ERECTION HEAD/QA

CVL B MAJOR SCL

QAE-INCHARGE

FQE

CVL C MINOR SCL

QAE

FQE

LEGNDS:

QAE -QUALITY ASSURANCE ENGINEER FQE -FIELD QUALITY ENGINEER QC ENGR.-QUALITY CONTROL ENGINEER

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

DOC. NO. : QPE-PP-002

STATEMENT OF CHECKS

REV. NO. : R02 SHEET: 01 /14

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

: 2 X 150MW : BOILER : PRESSURE PARTS : 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. In case of variation in parameters indicated in the characteristics column, the values mentioned in the drawings shall prevail.

4. The above sub-system covers Drum,Headers,Down comer pipes,Riser pipes/ Super heater connecting links,Panels,Cyclone inlet duct,Cyclone,Cyclone outlet chamber,Vortex finder,Circular to rectangular transition / Loop seal / Downchute panel,Buck stays and furnace guides,Coils and tubes,Primary super heater coil,Secondary and final super heater coil,Re heater , Economiser,,welding,Hardness survey,General and Hydraulic test.

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

FQP No. : QPE-PP-002 REV. No. : R02 PAGE No.: 02 / 14


CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW PACKAGE: EPC CONTRACT No.: EBJ 072 & 073
QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS/ITEM

INSTRUMENT

1.0 1.1

DRUM Check the inspecting authority's stamp on drum and certificate. Readiness of structure for boiler drum erection.

V/R

Drawing/IBR certificate. Drawing / structures log sheet Drawing -do-do-do-do-do-

100%

1.2

V/R

100%

1.3 1.4 1.5 1.6 1.7 1.8

Ground inspection of drum,its orientation. Ensure clearance between drum and structural members during hoisting. Drum suspension 'U' rod dimensions and freeness of nuts. Drum suspension supports alignment. Alignment of drum. Minimum projection of threads above the nuts in the drum suspension rods.

V V M M M M Tape Water level/Tape -doTape

B B B B A A

100% 100% 100% 100% 100% 100%


FOR CUSTOMER USE

L-01 L-02 L-02

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. :R02 PAGE No.: 03 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FORMAT FREQUENCY OF OF CHECK RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

1.9 1.10 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Verify verticality of column after drum erection.

M V

Theodolite/ Total station

A B

Drawing/ structure log sheet Drawing

100% 100%

Assembly of drum internals. HEADERS: Check inspecting authority's stamp on headers and certificate. Identification of the headers. Cleanliness of headers. Bow in headers (Tolerance:1mm/M,Max.5mm for membrane panel headers and max.5mm for other headers. Header scarffing line(Tolerance:1mm max. ) Completion of supports. Alignment of headers and elevation,horizontality and distance from reference axes.

V/R

A
C

Drg./IBR certificate.
Shipping list/Drg.

100% 100% 100%

V
V M Water level/Tape
-do-

B B
B

Drawing -do-do-do-

100%
100%

M
V M

B -doA

100% 100% L-03

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 QC ENGR.(ERECTION)OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 04 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FORMAT FREQUENCY OF OF CHECK RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

3.0 3.1 3.2 3.3 3.4 3.5 3.6 4.0 4.1 4.2 4.3 4.4

DOWN COMER PIPES(DC pipes): Identification of DC pipes. Cleanliness of the pipes. Orientation of DC pipes. Alignment of DC pipes(Tolerance: Verticality of DC pipes:1 mm/M,5 mm max.) Alignment of supports. Completion of seismic guides. RISER PIPES/SH CONNECTING LINKS: Identification of the pipes. Cleanliness of the pipes(Sponge test with compressed air). Alignment of pipes. Completion of supports.

M V V V

Tape

B C

Drawing Drawing/Shipping list

100% 100% 100%

B
B Tape/plumb bob B B B

Drawing.
-do-

100% 100% 100% 100%

M
V

-do-do-

V
V M V

C
B

Drawing/shipping list Drawing -do-do-

100%
100% 100% 100%

B B

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 05 /14 CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT CLASS

5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6.0 6.1 6.2

PANELS(COMBUSTOR / STEAM COOLED WALL PANEL): Identification of panels. Width,diagonals&location of opening of the panels. (Tolerance:panel width:2 mm. Diagonal difference 5 mm max Cleanliness of the panels(sponge test with compressed air). Completion of supports. Completion of panel to panel joints. Verticality of panels. Alignment of Combustor / steam cooled wall panels. CYCLONE INLET DUCT : Elevation and Orientation of the inlet duct. Cyclone inlet duct distance w.r.t. Boiler axis.

V M V V V M M Plumb bob/ Tape/piano wire Tape/scale Water level/Tape Tape Tape

C B B B B B A

Shipping list/Drg. Drawing

100% 100% 100%

-do-do-do-do-

100% 100% 100% 100% L-04 L-05

M M

A B

-do-do-

100% 100%
FOR CUSTOMER USE

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 06 /14 CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT CLASS

6.3 7.0 7.1 7.2 7.3 7.4

Ensure the completion of all the supports. CYCLONE: Elevation and orientation of the cyclone top header. Elevation and orientation of the cyclone bottom header. Cyclone distance W.r.t. Boiler axis. Ensure: a)Before assembling the water cooled cyclone panel piece-I to IV,vortex finder should be placed at inside of the water cooled cyclone. b)After erection the water cooled cyclone,vortex finder should be temporary positioned at neck portion of the water cooled cyclone in such a way and support brackets at quartrant points,guide pipes should be located as per drawing and aligned to match with the support opening given in the vortex finder by means of support rods. After alignment,support brackets and guide pipes should be full welded with water cooled cyclone.

M V

Tape Water level/Tape Water level/Tape Tape

A B

Drawing/Erection Drawing

100%

M M M

A B B

-do-do-do-

100% 100% 100%

-do-

100%

-do-

100%

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 07 /14 CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT CLASS

c)After welding the vortex finder supports ,vortex finder should be replaced from its position and it should be placed at inside of the cyclone for neck portion refractory working. d)After completion of refractory work at neck portion,vortex finder should be placed at its original location and it supported with the help of support rods. The support rod should be welded with rear end of the guide pipe . e)Erection completion of all the supports at different elevation. f)Completion of welding. 8.0 8.1 8.2 8.3 CYCLONE OUTLET CHAMBER: Cleanliness of the panels(Air test). Elevation and orientation of the outlet chamber. Cyclone outlet chamber distance w.r.t. Boiler axis.

M V

Tape

A B

Drawing/Erection Drawing

100% 100%

-do-

100%

V V

B B
B

-do-do-

100% 100% 100%

V
M M Water level/Tape Water level/Tape

B A

Drawing -do-

100% 100%
FOR CUSTOMER USE

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 REV. No. : R02 PACKAGE: EPC PAGE No.: 08 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

8.4 9.0 9.1 9.2 9.3

Ensure the completion of all the supports. VORTEX FINDER: Elevation and orientation of the vortex finder. Centerline of vortex finder w.r.t. Boiler Axis. Ensure the vortex finder is in level. CIRCULAR TO RECTANGULAR TRANSITION / LOOP SEAL / DOWNCHUTE PANEL: Cleanliness of the panels(sponge test with compressed air). Elevation and orientation of the panel. BUCKSTAYS AND FURNACE GUIDES: Identification of the components. Completion of the buck stay channel,stirrup angle with beams.

V Water level/Tape Tape Spirit level

Drawing

100%

M M M

B A B

-do-do-do-

100% 100% 100%

10.0 10.1 10.2


11.0 11.1 11.2

V M
Water level/Tape

B B

100% -do100%

V
V

C B

Drawing/shipping list Drawing

100% 100%
FOR CUSTOMER USE

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 09 / 14 CONTRACT No.: EBJ 072 & 073
CLASS QUANTUM/ FORMAT REFERENCE DOCUMENT/ FREQUENCY OF ACCEPTANCE STANDARD OF CHECK RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

11.3 11.4 11.5 11.6 12.0 12.1 12.2 12.3

Completion of attachment welds such as scalloped plates and lugs. Alignment of buck stay beams. Completion of corner joints. Completion of furnace guides. COILS AND TUBES: Identification of the coils. Cleanliness of the coils(sponge test with compressed air). Alignment of coils w.r.t. inlet and outlet headers. Pitch of economiser hanger tubes above R.H-II and distance between economiser hanger tubes and back pass front/rear wall.

V M V V
Tape

B B B

Drawing -do-do-

100% 100% 100%

-do-

100%

V V M Tape/water level Tape

C B B

Drg./Shipping list

100% 100%

Drawing

100%

12.4

-do-

100%

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST. REVIEWED BY

FOR CUSTOMER USE

APPROVED BY

APPROVAL SEAL

FRT-FQP-007-REV 00

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER FQP No. : QPE-PP-002 REV. No. : R02 SUB SYSTEM: PRESSURE PARTS PAGE No.: 10 / 14
TYPE OF CHECK INSTRUMENT CLASS

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW PACKAGE: EPC CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FORMAT FREQUENCY OF OF CHECK RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

13.0 13.1 13.2 13.3 13.4 13.5

PSH(PRIMARY SUPER HEATER COIL): Identification of PSH coils. Clearance between end coil assembly and back pass sidewalls. Individual pitches between coils. Clearance between coil ends and back pass front/rear wall. Pitch of economiser hanger tubes above PSH and distance between economiser hanger tubes and back pass front/rear wall. SECONDARY/FINAL SUPER HEATER: Identification of super heater assembly. Clearance between end coil assembly and combustor side walls. Individual pitches between coils. Location of the assembly w.r.t. furnace axis.
V M M M Tape Tape Tape C A B B

V M M M M Tape Tape Tape Tape

C B B A B

Drg./shipping list Drawing -do-do-do-

100% 100% 100% 100% 100% L-06 L-06 L-06 L-06

14.0 14.1 14.2 14.3 14.4

Drawing/Shipping list Drawing -do-do-

100% 100% 100% 100% L-07 L-07

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 11 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

15.0 15.1
15.2 15.3

REHEATER: Identification of Reheater coils. Clearance between coil ends and back pass front/rear wall. Individual pitches between coils. ECONOMISER: Identification of economiser coils. Clearance between end coil assembly and Steam cooled wall panels. Individual pitches between coils. Clearance between coil ends and back pass front/rear walls. WELDING: Qualification of welders. Fitup of pressure parts.

C Tape Tape A B

Drawing/shipping list Drawing -doDrawing/Shipping list Drawing -do-do-

100% 100% 100% L-08 L-08

M M V
M M M

16.0 16.1
16.2 16.3 16.4 17.0 17.1 17.2

C
Tape Tape Tape A

100%
100% 100% 100%

L-09 L-09 L-09

B A

V/R V/M

A A

IBR welder's certificate/WPS/PQR.


CVL/PR/029(Latest)

100% 100%
FOR CUSTOMER USE

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 12 / 14 CONTRACT No.: EBJ 072 & 073
CLASS QUANTUM/ REFERENCE DOCUMENT/ FREQUENCY ACCEPTANCE STANDARD OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

17.3 17.4

Adoption of correct procedure,method and approved consumables. Completion of pre-heating,welding and post heating of weld joints.

V V

A A

List of approved welding consumables.

100% 100%

Drg./ QAC/F/020 (Latest) Drg./CVL/PR/029 (latest)/CVL/PR/006 (Latest)/CVL/PR/014 (Latest)/CVL/PR/095 (Latest)/CVL/PR/009 (Latest) Drawing/QAC/F/020 (Latest) / CVL/PR/002A (Latest)

17.5

NDE of welds(Type and quantum).

As per Drg.

17.6

Post weld heat treatment of (PWHT)of welds.

Time-Temp. Recorder.

-do-

17.6

HARDNESS SURVEY : a) P91 welds. b)All other alloy steel welds in header and links. Identification of weld joints and maintenance of records indicating number of weld joint,heat treatment carried out,NDE results,acceptance and rejection/repair details.

M M V/R

Hardness tester -do-

A A A Drg./QAC/F/020 (Latest)

100% 3% 100% Log book

17.7

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 13 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

18.0 18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 18.9

GENERAL: Verticality and loading of suspensions. Cold compression of all springs and locking of the spring assembly. Completion of pressure parts attachment welds.
Closing of voids and cut-outs made during erection.

V V V V V V V V

Drawing -do-do-do-do-do-do-doDrawing / IBR certitificate

100% 100% 100% 100% 100% 100% 100% 100%

B B
B B B B B

Locking of supports for hydraulic test. Servicing of valves. Completion of drain/vent valves. Ensure welding of metal temperature pads on superheater and re heater coils. Ensure ground survey by IBR for all pressure parts components.

100%

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO

FIELD QUALITY PLAN


SYSTEM: BOILER SUB SYSTEM: PRESSURE PARTS
TYPE OF CHECK

CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 14 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)

CHARACTERISTICS

INSTRUMENT

19.0 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8

HYDRAULIC TEST: Welding of insulation hooks/studs and attachments to pressure parts completion before hydraulic test. Seal welding of all site RT plugs. Ensure that the studs /nuts of blind flange are tensioned to the required torque.
Readiness of total system for hydraulic test.

V
V LPI kit Hydraulic stud tensioner

B
B

-doDrawing / LPI procedure Drawing Drawing/Procedure for Hydraulic test -do-

100%
100%

B
B

100%

V Pressure gauge

100%

L-10

Completion of air test of the system. Max.test pressure:2 kg/cm(g). Rectification of leak welds and details. Clearance of milestone activity. Completion of hydraulic test.

V/M V/R V V/M

A A A

100% 100% 100% 100%

L-11 L-11

Pressure gauge

L-12

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 QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(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

DOC. NO. : QPE-PP-002

DOCUMENTS REFERRED IN QUALITY PLAN


SL. NO 1 2 3 4 5 6 7 8 9
10

REV. NO.: R02 SHEET :1/1

Reference Document
Erection Manual-Pressure parts. Procedure for Liquid Penetrent Examination Procedure for Radiographic Examination Procedure for Magnetic Particles Examination. Procedure for Post Weld Heat treatment Procedure for Visual Inspection. Procedure for Ultrasonic Examination. Heat Treatment Parameters List of Approved Welding Consumables

Document / Procedure No
SMP/Erec/002(Latest). CVL/PR/006 (Latest)

Issuing Authority
CONS. QA&C

CVL/PR/095(Latest)

QA&C

CVL/PR/014 (Latest)

QA&C

CVL/PR/002A (Latest)

QA&C

CVL/PR/029 (Latest) CVL/PR/009(Latest) QAC/F/020 (Latest) CVL/AWCL/001(Latest)

QA&C QA&C QA&C QA&C CONS.

Procedure for Hydraulic test

SMP/Hydro test / 003(Latest)

Legend: QA&C Quality Assurance & control

FQA Field Quality Assurance CONS.-Construction.

NOTE:CVL will submit Hydraulic test procedure before hydraulic test for customer approval.

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 00 SYSTEM SUB - SYSTEM AREA DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 00 SHEET : 1/1

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

'U' ROD MEASUREMENT


ARM TO ARM DISTANCE

LA

CL OF DRUM

R
LEGEND: LA-Arm Length R-Radius of curvature As measured Left(C1) Axis 1 Axis-2 Right (C2) Axis 1 Axis-2 20 mm 20 mm Tolerance

SL.NO

Description

As per Drg.

01 02

Arm length Arm to arm Distance (At two location)

01.Twist between limbs (Actual)............. mm 02.Freeness of nut : OK / NOT OK

(Tolerance :10 mm Max.)

NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER

SIGN. &DATE

DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 01 SHEET : 1 / 1

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

DRUM SUSPENSION ARRANGEMENT -ALLIGNMENT


CL OF FURNACE

I A G

II B J

D1

D2
DRUM AXIS
BOILER AXIS

H C

I D

IV

III

REFERENCE DRG.NO................................................. 1.Disposition of Drum axis from centre line of furnace (Tolerance:1 mm/ M;Max.5 mm) 2.Elevation of drum suspension support beam(EL)

As per Drg._________ mm Actual:A_______mm;B_________ mm

LHS As per drg. Actual 3.spacing of washer plate with respect to longitudinal axis of boiler & drum axis. (Tolerance :1 mm /M ; Max. 3 mm)

RHS

Tolerance 5 mm

C As per Drg Actual

4. Diagonal difference between washer plate locations. (Tolerance : Max. 5 mm) 5.Orientation of rocker plate: Actual :
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER

D1=_____ mm D2=_____ mm

D1~D2=________ mm As per Drg.___________ from drum axis. I______ II______ III______ IV________
SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 02 SHEET : 1 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

DRUM ALIGNMENT
CL OF FURNACE

``

I
BOILER AXIS

II
DRUM AXIS

EL B

EL ` `

LHS

IV

III

RHS

Reference Drawing No: 1.Elevation of Drum As per Drg: (Tolerance -Elevation:5 mm ;Cumulative of I&II,III&IV not to exceed 8 mm) Actual :ELI = ELII = ELIII = ELIV =

2.Spacing of Drum Axis with reference to centre to centre line of furnace. As per Drg.________ mm (Transverse axis-Tolerance:1mm/M; Max.5 mm) Actual:A=_________ mm B=_________ mm 3.Axial disposition of drum centre with respect to longitudinal axis of boiler. Actual__________ mm (Tolerance: 5 mm) Towards LHS/RHS 4.Verticality of drum suspension rod(U-Rod) (Tolerance:10 mm) 5.Contact of 'U' rod with drum: All dimensions are in mm.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 02 SHEET : 2 /2

LHS=_________ mm RHS=_________ mm LHS-OK / NOT OK , RHS-OK / NOT OK

LOCATION OF HEADERS-HEADERS PARALLEL TO DRUM AXIS


INSTRUMENT REGN NO. DATE OF INSPECTION DRAWING / DOCUMENT NO.

EL 1

EL 2 Tolerances: Elevation: 3 mm Spacing : 3 mm

All dimensions are in mm.


Sl.no Header Distance from drum axis to details header axis Actual As per Drg Left Right As per Drg Left Right Shift from boiler axis to header centre Actual-Tolerance As per Drg EL-1 Left EL-2 EL-3 Elevation Actual Right EL-4

NAME PROJECT UNIT NO. RATING FRT-FQP-012-REV 00 INSPECTED BY CLEARED BY CUSTOMER

SIGNATURE&DATE

DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 03 SHEET : 1 / 2

LOCATION OF HEADERS-HEADERS PERPENDICULAR TO DRUM AXIS


INSTRUMENT REGN NO. DATE OF INSPECTION DRAWING / DOCUMENT NO.

EL 1

EL 2 Tolerances: Elevation: 3 mm Spacing : 3 mm

All dimensions are in mm.


Sl.no Header Distance from drum axis to details header axis Actual As per Drg Left Right As per Drg Left Right Shift from boiler axis to header centre Actual-Tolerance As per Drg EL-1 Left EL-2 EL-3 Elevation Actual Right EL-4

NAME PROJECT UNIT NO. RATING FRT-FQP-012-REV 00 INSPECTED BY CLEARED BY CUSTOMER

SIGNATURE&DATE

DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 03 SHEET : 2 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

VERTICALITY OF COMBUSTOR WALL / STEAM COOLED WALL PANELS


LEFT

1
FURNACE AXIS

LEFT

FURNACE

FRONT

FRONT

BACK

REAR

REAR

PASS

BOILER AXIS

RIGHT

RIGHT

Elevation at

Front wall L M R

Right side wall F M RR L

Rear wall M R F

Left side wall M RR

LEGEND : L-Left ; M-Middle ; R-Right ; RR-Rear ; F-Front


Tolerance:10 mm Max. (Top to bottom of panel for its total length) All dimensions are in mm.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 04 SHEET : 1 / 1

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

COMBUSTOR ALIGNMENT E
LEFT

A D1
FRONT

C D2
REAR

G
Elevation Combustor Top (Near roof) As per Drg. Actual A B

RIGHT

H
D E F G H D1 D2

Combustor As per Drg. middle(Elevati Actual on:18 m) As per Drg. Combustor Bottom Actual

Tolerance:Furnace width & depth : +10mm or-15mm; Furnace diagonal difference : 20 mm max.

All dimensions are in mm.


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 05 SHEET : 1 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

FURNACE ALIGNMENT -BACK PASS E


LEFT SIDE

F D2

FRONT

D1

FURNACE AXIS

C
REAR

BOILER AXIS

RIGHT SIDE

Elevation Back pass top (Near roof) As per Drg. Actual As per Drg. Actual Above Economiser As per Drg. Actual As per Drg. Actual

D1

D2

Above RH-II

Below Economiser

Tolerance:Back pass width & depth : +10 mm or -15 mm; Back pass diagonal difference : 20 mm max.
All dimensions are in mm.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 05 SHEET : 2 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

PRIMARY SUPER HEATER-COIL CLEARANCE


Tolerance:10 mm COIL Coil end pitch between centre line of back pass side wall and end coil assembly As per drawing Actuals FRONT REAR P. S.H LEFT RIGHT

PITCH OF COILS
As per drawing:_________ mm Tolerance:10 mm

Coil to coil Number

Measured values Front Rear

Coil to coil Number

Measured values Front Rear

Coil to coil number

Measured values Front Rear

All dimension are in mm


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 06 SHEET : 1 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

SPACING BETWEEN ECONOMISER HANGER TUBES&BACK PASS WALLS


As per drawing : Y1 =_______ mm A =_______ mm B =_______ mm Tolerance: Y1 = 3 mm A & B = 20m Measured values. A Y1 B

ECONOMISER HANGER TUBE NO.

Measured values. A Y1 B

ECONOMISER HANGER TUBE NO.

LEGEND: Y1 Spacing between Economiser hanger tubes. A-spacing between back pass front wall and economiser hanger tubes. B-spacing between back pass rear wall and economiser hanger tubes. All dimension are in mm
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 06 SHEET : 2 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

SECONDARY / FINAL SUPER HEATER -COIL CLEARANCE


Tolerance:25 mm COIL Coil end pitch between centre line of side wall and end coil assembly As per drawing Actuals FRONT REAR FINAL SH LEFT RIGHT

SECONDARY / FINAL SUPER HEATER -PITCH OF COILS


As per drawing:_________ mm Tolerance:25 mm

Coil to Coil to Measured coil coil values Number Number

Measured values

Coil to coil number

Measured values

Coil to coil number

Measured values

All dimension are in mm


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 07 SHEET : 1 / 1

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

REHEATER-COIL CLEARANCE FOR COIL ASSEMBLY :UPPER / LOWER


Tolerance:10 mm COIL Coil end pitch between centre line of side wall and end coil assembly As per drawing Actuals FRONT REAR REHEATER.SUPPORT LEFT RIGHT

REHEATER -PITCH OF COILS


As per drawing:_________ mm Measured values Coil to coil number REHEATER FRONT REAR Coil to coil number Tolerance:10 mm Measured values REHEATER FRONT REAR

All dimension are in mm


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 08 SHEET : 1 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

REHEATER- COIL CLEARANCE FOR COIL ASSEMBLY :UPPER / LOWER Tolerance:20 mm


Clearance between centre line of Back pass Front / Rear wall and coil ends. Coil number Measured values FRONT REAR As per Drawing Coil number REHEATER FRONT REAR

Measured values FRONT REAR

All dimension are in mm


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 08 SHEET : 2 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

ECONOMISER -COIL CLEARANCE FOR COIL ASSEMBLY :UPPER / LOWER


Tolerance:10 mm COIL Coil end pitch between centre line of side wall and end coil assembly As per drawing Actuals FRONT REAR ECONOMISER LEFT RIGHT

ECONOMISER -PITCH OF COILS


As per drawing:_________ mm Measured values Coil to coil number ECONOMISER FRONT REAR Coil to coil number Tolerance:10 mm Measured values ECONOMISER FRONT REAR

All dimension are in mm


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 09 SHEET : 1 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

ECONOMISER- COIL CLEARANCE FOR COIL ASSEMBLY :UPPER / LOWER Tolerance:20 mm


Clearance between centre line of Back pass Front / Rear wall and coil ends. Coil number Measured values FRONT REAR As per Drawing Coil number ECONOMISER FRONT REAR

Measured values FRONT REAR

All dimension are in mm


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 09 SHEET : 2 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

JOINT INSPECTION PROTOCOL PRIOR TO HYDRAULIC TEST


SL.NO 1 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. ACTIVITY Completion as per log sheets and records. Completion of all supports. Cold compression of spring supports. Locking of supports. Welding completion of all joints as per EWS. NDE completion as per EWS. PWHT completion of applicable joints as per EWS. Void closing and furnace sealing. Completion of pressure parts attachment welding. Buck stay beam completion with corner connection and guides. Completion of trim piping. Removal of all temporary supports and freeness of furness. Completion of metal temperature pads on SH/RH coils. OBSERVATION

REMARKS:

Boiler pressure parts are cleared for Hydraulic test.


NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP -002 REV. NO. : R02 LOG SHEET NO. : L - 10 SHEET : 1 / 1

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

AIR TEST OF BOILER REQUIREMENTS: Design pressure Working pressure Test pressure Reference document Circuits included in the test : : : : : kg/cm (g) kg/cm (g) kg/cm (g)

OBSERVATIONS: Date of test Test pressure Test witnessed by Details of failure noticed Details of rectification REMARKS: : : : : : kg/cm (g)

Air test of boiler at the test pressure of ...........kg/cm (g) carried out on ................and found satisfactory. The boiler is cleared for Hydraulic test.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 11 SHEET : 1 / 2

INSTRUMENT REGN NO. DATE OF INSPECTION DRAWING / DOCUMENT NO.

DETAILS OF FAILURE AND RECTIFICATION DURING AIRTEST / HYDRAULIC TEST

SL. NO

LOCATION

TEST NATURE OF PRESSURE FAILURE kg/cm(g)

FAILURE AT

WELD AT DETAILS OF NDE RESULTS SHOP/ SITE REPAIR

REMARKS

NOTE :Failure at :1.Butt weld 2.Seal weld 3.Attachment weld 4.Hand hole plate weld 5.Thermowell weld 6.Cuts & gouges
NAME PROJECT UNIT NO. RATING FRT-FQP-012-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGNATURE&DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 11 SHEET : 2 / 2

INSTRUMENT REGN.NO DATE OF INSPECTION DRAWING/DOCUMENT REF.

HYDRAULIC TEST OF BOILER


REQUIREMENTS: Design pressure Working pressure Hydraulic test pressure Statutory code requirement Reference document Circuits included in the test Temperature of the water in the system OBSERVATIONS: Date of filling Date of hydraulic test Temperature of the water in the system Hydraulic test pressure Holding time Test witnessed by REMARKS: Hydraulic test of boiler at the test pressure of ...........kg/cm (g) carried out on ................and found satisfactory. The boiler is cleared for further operation. : : : : : : ........C kg/cm (g) Minutes : : : : : : : kg/cm (g) kg/cm (g) kg/cm (g) IBR

NAME PROJECT UNIT NO. RATING FRT-FQP-012-REV 00 INSPECTED BY CLEARED BY CUSTOMER

SIGN. &DATE

DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 12 SHEET :1 / 1

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-PP-002 REV. NO. : R02 SHEET :1/1