1

Construction of DLF Mall of India

On-Site Training Report

And

Summer Internship Project

On

“Safety and Quality Management System”

Submitted by

Bhoomika Mansharamani (1009740028)

Galgotias College of Engineering and Technology

Greater Noida

2

CERTIFICATE

This is to certify that this project report entitled “IN PLANT TRAINING REPORT WITH SAFETY

AND QUALITY MANAGEMENT SYSTEM” by BHOOMIKA MANSHARAMANI, submitted in

partial fulfillment of the requirements for the degree of Bachelor of Technology in Mechanical

Engineering from GALGOTIAS COLLEGE OF ENGINEERING AND TECHNOLOGY, during the

academic year 2013-14, is a bonafide record of work carried out under my guidance and supervision

during 19th June 2013-19th July 2013.

Tarun Chandra

Quality Manager, MEP Department,

L & T Constructions

3

Acknowledgement

One cannot achieve worthwhile in the field of technical education until or unless theoretical education

acquired in the classroom is effectively wedded to its practical approach.

I take this opportunity to express my profound gratitude and deep regards to my project guide and mentor

Mr. Tarun Chandra (Quality Manager, QA/QC department, Mall of India) for his exemplary

guidance, monitoring and constant encouragement throughout the course of this project. The blessing,

help and guidance given by him from time to time shall carry me a long way in the journey of life on

which I am about to embark.

I also take this opportunity to express a deep sense of gratitude to Mr. Vikas Saini (MEP head), Mr.

Manoranjan Raheja (MEP Coordinator), Mr. Deepak Mittal (Assistant Manager MEP), Mr.

VarinderPal Singh (Assistant Manager, FF), Sudhir Kumar (Assistant Manager, FF), Mustafa

Raza (Assistant Manager, HVAC) & Mr. Bhoopendra Rathore (Senior Engineer), for their cordial

support, valuable information provided by them in their respective fields and guidance, without which I

couldn’t have achieved knowledge about HVAC, Quality Management and would not have got any lead

to approach the methodology to be followed. I am grateful for their cooperation during the period of my

internship.

Last but not the least, I thank almighty, my parents, and friends for their constant encouragement without

which this internship would not be possible.

Bhoomika Mansharamani

4

Index S.NO Topic Page No

2 Abstract………………………………………………………………………………... 5

3 History of Larsen and Toubro…………………………………………………………. 6

4 Project Brief…………………………………………………………………………… 7

5 Basic Layout of the Mall of India Project……………………………………………... 8

6 Major Quantities of Work……………………………………………………………… 9

7 Major item of project value……………………………………………………………. 10

8 Scope of MEP………………………………………………………………………….. 11

9 MEP Department………………………………………………………………………. 12

10 HVAC…………………………………………………………………………………. 13

11 Diesel Generator………………………………………………………………………. 18

12 Quality Management System………………………………………………………….. 19

13 Test And Commissioning At Mall Of India…………………………………………… 25

5

2. Abstract

Quality Management is the act of overseeing all activities and tasks needed to maintain a desired level of

excellence. This includes creating and implementing quality planning and assurance, as well as quality

control and quality improvement. For this, a full fledge system is installed which defines several

guidelines for the industries to ensure full satisfaction of the customer and how we can enhance it.

Material Inspection and Work Inspection Report are prepared before installing any system or device at

the construction site. On spot training of the workers and periodic safety checks are done at the site.

At L&T, Environment, Health & Safety (EHS) is given the highest priority. The EHS policy enunciated

by the Corporate Management lays emphasis on Environment, Health and Safety through a structured

approach and well defined practices. Systems and procedures have been established for implementing the

requisites at all stages of construction and they are accredited to the International standards of ISO

9001:2008, ISO 14001:2004 and OHSAS 18001:2007. L&T continues to maintain the trail blazing

tradition of meeting the stringent quality standards and adherence to time schedules in all the projects.

In this project, several processes used by L&T constructions at Mall Of India site, to ensure and control

quality of the product as well as safety of the manpower are outlined.

6

3. History of Larsen & Toubro Larsen & Toubro (L&T) is India’s largest technology, engineering,

manufacturing and construction organization with a record of over 70 years. L&T

is also adjudged India’s best managed and most respected company on various

attributes of customer delight and shareholder value. L&T Construction’s cutting

edge capabilities cover every discipline of construction – civil, mechanical, and

electrical and instrumentation engineering and services extend to large industrial

and infrastructure projects from concept to commissioning.

L&T Construction has played a prominent role in India’s industrial and infrastructure development by

executing several projects across length and breadth of the country and abroad. For ease of operations and

better project management, in-depth technology and business development as well as to focus attention

on domestic and international project execution, entire operations of L&T Construction is structured into

four Independent Companies.

ECC – The Engineering Construction and Contracts Division of L&T is India’s largest construction

organization with over 60 years of experience and expertise in the field. ECC figures among the World’s

Top Contractors and ranks 29th among top global contractors and 77th among international contractors

as per the survey conducted by Engineering News Record magazine, USA (August 2011).

Larsen & Toubro Limited is the biggest legacy of two Danish Engineers, who built a world-class

organization that is professionally managed and a leader in India's engineering and construction industry.

It was the business of cement that brought the young Mr. Henning Holck-Larsen and Mr. S.K. Toubro

into India. They arrived on Indian shores as representatives of the Danish engineering firm F L Smidth &

Co in connection with the merger of cement companies that later grouped into the Associated Cement

Companies.

Together, Mr. Holck-Larsen and Mr. Toubro founded the partnership firm of L&T in 1938, which was

converted into a limited company on February 7, 1946. Today, this has metamorphosed into one of India's

biggest success stories. The company has grown from humble origins to a large conglomerate spanning

engineering and construction.

7

4. Project Brief

• CLIENT DLF LIMITED

• NAME CONSTRUCTION OF MALL OF INDIA AT NOIDA.

• LOCATION SECTOR - 18, NOIDA

• TOTAL AREA OF LAND 13.42 ACRE (APPROX.)

• BUILT-UP AREA 27,49,180 SQFT

• NO. OF FLOORS 3 BASEMENTS + GR. FLOOR LEVEL + FIVE FLOORS

• MAIN CONTRACTOR LARSEN & TOUBRO LIMITED

• ARCHITECTURE DESIGN PLUS

• PROJECT VALUE Rs. 447 CRORE (EXCLUDING SERVICE TAX)

8

5. Basic Layout of the Mall of India Project

Fig 5.1 Layout

9

6. Major Quantities of Work

S. No. ITEM DESCRIPTION UOM QTY

1 Excavation & Backfilling Cum 76133

2 PCC Cum 14475

3 RCC Cum 72300

4 Formwork Sqm 281860

5 Reinforcement MT 11960

6 Reinforcement Coupler Nos 134383

7 Str. Steel MT 850

8 VDF Flooring Sqm 94283

9 Block Masonry – 100mm Sqm 13635

10 Block Masonry – 200mm Cum 14262

11 Internal Plastering Sqm 173025

12 External Plastering Sqm 19780

10

7. Major Item of Project Value

Fig 7.1

0%1% 8%4%

12%

2%3%1%

7%

33%

24%

3% 2%Excavation/ Backfilling

PCC

RCC

Formwork

Reinforcement

Str. Steel

Block Masonry

Plastering & VDF

Mis Works

MEP Works

Finishing Works

Waterproofing

External Development

11

8. Scope of MEP

Service Subcontractor Cost Main items of Work

HVAC Blue Star 41.08 Cr. Chiller- 5 x1000 TR & 2 x350 TR AHU’s & FCU’s- 512 Nos. FAN – (Cent-190 Nos., Axial- 181 Nos.) Jet Fan- 327 Nos. Ducting – 35000 Sqm Piping – 35 KM

Electrical Trimoorti 24 Cr. DG Sets- 11 Nos. (2000KVA- 9 Nos. 1010 KVA- 2 Nos.) Transformer- 8 Nos. HT Panel- 1 Set LT Panels- 85 Nos. Conduit- 249 KM Cable Tray – 13 KM Wire- 256 KM

PHE & FPS

Scenario 18.91 Cr. Piping- 123 KM Fire Pump- 6 Nos. PHE pumps- 7 Nos. Toilet – 32 Nos.

Lift & Escalator

Thyssen Krupp 26.5 Cr. Lift – 22 Nos. Escalator- 80 Nos.

12

9. MEP Department

MEP Activities

HVAC

FIRE FIGHTING(FPS)

PLUMBING

ELECTRICAL WORKS/LIFT & ESCALATORS/BMS

PANELS & TRANSFORMERS

PLANNING AND DOCUMENTATION

QUALITY

Packages Sub-Contractors

HVAC Blue Star Ltd.

Fire Fighting and Plumbing Scenario India

BGMS Bose

BMS Johnson Control (I) Ltd.

Electricals Trimoorti

STP(Sewage Treatment Plant) Watcon Water

Lift and Escalator Thyssenkrupp

FTTH Radius Infratel

Gen Set Sudhir D.G.

13

10. HVAC HVAC (heating, ventilation, and air conditioning) is the technology of indoor and vehicular environmental

comfort. HVAC system design is a sub discipline of mechanical engineering, based on the principles

of thermodynamics, fluid mechanics, and heat transfer. Refrigeration is sometimes added to the field's

abbreviation as HVAC&R or HVACR, or ventilating is dropped as in HACR (such as the designation of

HACR-rated circuit breakers).

HVAC is important in the design of medium to large industrial and office buildings such

as skyscrapers and in marine environments such as aquariums, where safe and healthy building conditions

are regulated with respect to temperature and humidity, using fresh air from outdoors.

10.1 DETAILS OF HVAC AT DLF MALL OF INDIA

Main Contractor Larsen & Toubro

Sub-Contractor Blue Star LTD

HVAC Consultant Dew Point Consultants Pvt Ltd

Architect Design Plus

Amount Of Work Rs. 41,08,00,000

Date of LOI issued 8th February 2012

10.2 Introduction

All air conditioning systems require a means for generating the cooling effect that offsets building heat

gain due to external loads (sun, wind, outdoor temperature) and internal loads (heat and moisture from

people, lights, and equipment). In smaller buildings and residential applications, this is usually

accomplished with an air-based system that ducts cold air from the point of generation (usually on the

roof) to each space in the building that requires cooling.

Larger buildings and multiple building campuses usually use a chiller plant to provide cooling. In such

systems, chilled water is centrally generated and then piped throughout the building to air handling units

serving individual tenant spaces, single floors, or several floors. Ductwork then runs from each air handler

to the zones that are served.

Heat transfer loops in refrigeration system

14

10.2.1 Types of Air Conditioning System

Depending upon the type of fluid used either for heating or cooling, air-conditioning methods can be

classified as:

a) Direct Expansion system (also referred as unitary system)

In this system, a self-contained air conditioned unit is located in or next to the space to be air

conditioned. It consists of minimum essential components producing cooling effect generally using

direct expansion system. Heating is also included with the unit itself. In this system if heater is added,

or it is adopted to heat pump arrangement by transfer valve, it can be used as year-round air

conditioning system

Advantages:

1) Individual room control is inexpensive and simple

2) Installation is simple and takes less time

3) Initial cost is normally low compared to central system.

Disadvantages:

1) As the components are selected and matched by the manufacturer, the system is less flexible in terms

of airflow rate, condenser and evaporator sizes.

2) Power consumption per TR can be higher compared to central systems.

3) Close control of space humidity is generally difficult.

These systems are used for air conditioning of individual rooms of large office buildings, classrooms,

hotels, shopping centers etc.

b) All Air System

In this system, air conditioned plant is remotely located in the central pace and the conditioned air is

sent through the ducts and distributed into the air conditioned spaces through inlets.

15

Advantages:

1) It is possible to provide good room air distribution and ventilation under all conditions of load.

2) Since the air-conditioning plant is located at remote place, low noise level is achieved in the room.

3) Building pressurization can be achieved easily.

Disadvantages:

1) Occupy more space.

2) Balancing of airflow quantity is time consuming and sometimes could be difficult to achieve.

3) Installation of these systems is time consuming.

They are especially suited to buildings that require individual control of multiple zones, such as office

buildings, classrooms, laboratories, hospitals, hotels, ships etc.

They are also extensively used in applications that require very close control of the conditions in

conditioned spaces such as cleanrooms, operation theatres, research facilities etc.

c) All water system

In this system, water is used to pick up/give the heat in the conditioned space (or room).

Advantages

1) Since specific heat of water is more than air, all water systems require less space compared to all

air systems.

16

2) Individual room control is possible and at the same time the system offers all benefits of a large

central system.

Disadvantages

1) Requires higher maintenance compared to all air system.

2) Draining of condensate can be messy and may also create health problems.

3) Noise level in the room is more compared to all air system.

All water systems using Fan Coil Unit (FCU) are most suitable in buildings requiring individual room

control such as hotels, apartment buildings, and office buildings.

Larger buildings and multiple building campuses usually use a chiller plant to provide cooling. In such

systems, chilled water is centrally generated and then piped throughout the building to air handling units

serving individual tenant spaces, single floors, or several floors. Ductwork then runs from each air handler

to the zones that are served. Chilled water-based systems result in far less ductwork than all-air systems

because chilled water piping is used to convey thermal energy from the point of generation to each point

of use.

Though more costly to install and more complicated to operate, a chiller plant offers a number of benefits

over simple packaged cooling units, including greater energy efficiency, better controllability, and longer

life. Additionally, a chiller-based system can be much more efficient in terms of space utilization within

the building because components need not be located within the same space. One reason that less space

is needed is that the size of pipes that convey chilled water throughout the building is much smaller than

the size of air ducts that would deliver cold air to provide the same cooling effect. One pound of water

can store about four times as much thermal energy as the same mass of air, and—because water is much

denser than air—a pound of water has a much smaller volume than the pound of air. The combination of

increased thermal capacity and higher density makes water an ideal medium for space-efficient heat

transfer.

17

10.3 DUCTS

Ducts are used in heating, ventilation, and air conditioning (HVAC) to deliver and remove air. These

needed airflows include, for example, supply air, return air, and exhaust air. Ducts also deliver, most

commonly as part of the supply air, ventilation air. As such, air ducts are one method of ensuring

acceptable indoor air quality as well as thermal comfort.

A duct system is often called ductwork. Planning ('laying out'), sizing, optimizing, detailing, and finding

the pressure losses through a duct system is called duct design.

Ducts can be made out of the following materials:

Galvanized mild steel is the standard and most common material used in fabricating ductwork.

10.3.1 Duct System Components

Besides the ducts themselves, complete ducting systems contain many other components.

(a) Vibration isolators: A duct system often begins at an air handler. The blowers in the air handlers

can create substantial vibration and the large area of the duct system would transmit this noise and

vibration to the inhabitants of the building. To avoid this, vibration isolators (flexible sections)

are normally inserted into the duct immediately before and after the air handler. The rubberized

canvas-like material of these sections allow the air handler to vibrate without transmitting much

vibration to the attached ducts. The same flexible section can reduce the "bang" that can occur

when the blower engages and positive air pressure is introduced to the ductwork.

(b) Take-off: Downstream of the air handler, the supply air trunk duct will commonly fork, providing

air to many individual air outlets such as diffusers, grilles, and registers. When the system is

designed with a main duct branching into many subsidiary branch ducts, fittings called take-

offs allow a small portion of the flow in the main duct to be diverted into each branch duct. Take-

offs may be fitted into round or rectangular openings cut into the wall of the main duct. The take-

off commonly has many small metal tabs that are then bent to retain the take-off on the main duct;

round versions are called spin-in fittings. Other take-off designs use a snap-in attachment method,

sometimes coupled with an adhesive foam gasket to provide improved sealing. The outlet of the

take-off then connects to the rectangular, oval, or round branch duct.

(c) Stacks, boots, and heads: Ducts, especially in homes, must often allow air to travel vertically

within relatively thin walls. These vertical ducts are called stacks and are formed with either very

wide and relatively thin rectangular sections or oval sections. At the bottom of the stack, a stack

boot provides a transition from an ordinary large round or rectangular duct to the thin wall-

mounted duct. At the top, astack head can provide a transition back to ordinary ducting while

a register head allows the transition to a wall-mounted air register.

(d) Volume Control Damper: Ducting systems must often provide a method of adjusting the volume

of air flow to various parts of the system. VCDs (Volume Control Dampers - Not to Be confused

with Smoke/Fire Dampers) provide this function. Besides the regulation provided at the registers

or diffusers that spread air into individual rooms, dampers can be fitted within the ducts

themselves. These dampers may be manual or automatic. Zone dampers provide automatic control

in simple systems while VAVs allow control in sophisticated systems.

(e) Smoke/Fire Dampers: Smoke dampers are automated with the use of a mechanical motor often

referred to as an Actuator. A probe connected to the motor is installed in the run of duct, and

detects smoke within the duct system which has been extracted from a room, or which is being

supplied from the AHU (Air Handling Unit) or elsewhere within the run. Once smoke is detected

within the duct, the Actuator triggers the motor release and Smoke and Fire dampers are found in

ductwork, where the duct passes through a firewall or fire curtain. The smoke damper will

18

automatically close until manually re-opened. You will also find Fire dampers in the same places

as smoke dampers, depending on the application of the area after the firewall. Unlike smoke

dampers, they are not triggered by any electrical system, which is perfect in the event of an

electrical failure where the Smoke dampers would fail to close. Fire dampers may be mounted in

either horizontal or vertical configurations. Vertically mounted fire dampers are gravity operated

while horizontal fire dampers are spring powered. In either case, a fire damper's most important

feature is known as a fusible link. A fusible link is a piece of metal that will fail at a specified

temperature allowing the damper to open under gravity or spring power, effectively sealing the

duct, containing the fire, and denying it the necessary air to burn.

(f) Plenums: Plenums are the central distribution and collection units for an HVAC system. The return

plenum carries the air from several large return grills (vents) or bell mouths to a central air handler.

The supply plenum directs air from the central unit to the rooms which the system is designed to

heat or cool.

(g) Terminal units: While single-zone constant air volume systems typically don't have them, other

types of air distribution systems often have terminal units in the branch ducts. Usually there is one

terminal unit per thermal zone. Some types of terminal units are VAV 'boxes' of either single or

dual duct, fan-powered mixing boxes of either parallel or series arrangement, and induction

terminal units. Terminal units may also include either, or both, a heating or cooling coil.

(h) Air terminals: Common, but grille ‘Air terminals' are the supply air outlets and 'return' or 'exhaust

air inlets'. For supply, diffusers are most s, and for very small HVAC systems such as in residences,

'registers' are also used widely. Return or 'exhaust grilles' are used primarily for appearance

reasons, but some also incorporate an air filter and are known as 'filter returns'.

11. Diesel Generators A diesel generator is the combination of a diesel engine with an electric generator (often an alternator)

to generate electrical energy. Diesel generating sets are used in places without connection to the power

grid, as emergency power-supply if the grid fails, as well as for more complex applications such as peak-

lopping, grid support and export to the power grid. Sizing of diesel generators is critical to avoid low-load

or a shortage of power and is complicated by modern electronics, specifically non-linear loads.

Generating sets are selected based on the Electrical load they are intended to supply, the electrical loads

total characteristics (kwe, kVA, and Harmonic Content including starting currents (normally from motors)

and non-linear loads. The expected duty, for example, emergency, prime or continuous power as well as

environmental conditions such as altitude, temperature and emissions regulations must be taken into

account as well.

Most of the larger generator set manufacturers offer software that will perform the complicated sizing

calculations by simply inputting site conditions and connected electrical load characteristics

Only Diesel generator required the less time to operate so most commonly for power back up diesel

generators are preferred though it generates electricity at high cost. Total 11 DG’s are installed in this site

on B03 floor. Among them nine are of capacity 2000KVA i.e. approximately 1600KW at 415 volts. The

alternator used in DG is Stamford brushless AC alternator. It is separately excited and self-regulated. It

has class H insulation, salient pole revolving field, single/double bearing, and automatic voltage regulator.

The DG has a silencer suitably optimized to reduce noise also have a 990 liters free standing fuel tank.

The special features of Cummins engines like STC(step timings controls) injectors, low temperature after-

cooler, square combustion chamber, optimized turbo charging and precision heavy duty cam-shaft make

these engines the ultimate in exceptional fuel efficiency all across the operating ranges.

19

12. Quality Management System

Quality management system is a comprehensive and fundamental rule/belief, for leading and operating

an organization, aimed at continually improving performance over the long term by focusing on customers

while addressing the needs of all other stake holders. QMS is becoming increasingly important to the

leadership and management of all organizations.

There are eight basic principles of Quality Management System-

Principle 1:

Customer-Focused Organization: "Organizations depend on their customers and therefore should

understand current and future customer needs, meet customer requirements and strive to exceed customer

expectations".

Principle 2:

Leadership: "Leaders establish unity of purpose and direction of the organization. They should create and

maintain the internal environment in which people can become fully involved in achieving the

organization's objectives."

Principle 3:

Involvement of People: "People at all levels are the essence of an organization and their full involvement

enables their abilities to be used for the organization's benefit".

Principle 4:

Process Approach: "A desired result is achieved more efficiently when related resources and activities

are managed as a process."

Principle 5:

System Approach to Management: "Identifying, understanding and managing a system of interrelated

processes for a given objective improves the organization's effectiveness and efficiency."

Principle 6:

Continual Improvement: "Continual improvement should be a permanent objective of the organization."

Principle 7:

Factual Approach to Decision Making: "Effective decisions are based on the analysis of data and

information."

Principle 8:

Mutually Beneficial Supplier Relationships: "An organization and its suppliers are interdependent, and a

mutually beneficial relationship enhances the ability of both to create value.

12.1 Elements of Quality Management System (a) Quality Assurance: Quality Assurance is a set of activities intended to establish confidence that

quality requirement will be met. Two principles included in QA are:

Fit for purpose: The product should be suitable for the intended purpose.

Right first time: Mistakes should be eliminated.

QA includes management of the quality of raw materials, assemblies, products and components, services

related to production, and management, production and inspection processes.

20

(b) Quality Control: Quality Control is a process by which entities review the quality of all factors

involved in production. This approach places an emphasis on three aspects:

Elements such as controls, job management, defined and well managed processes, performance

and integrity criteria, and identification of records

Competence, such as knowledge, skills, experience, and qualifications

Soft elements, such as personnel, integrity, confidence, organizational culture, motivation, team

spirit, and quality relationships.

The quality of the outputs is at risk if any of these three aspects is deficient in any way. Quality control

emphasizes testing of products to uncover defects and reporting to management who make the decision

to allow or deny product release.

12.2 Ways of Ensuring Quality at Mall Of India Project (a) Method Statement:

• The document used in a tender process which sets out questions for the suppliers to answer

which help us understand how you intend to provide the goods or services.

• Method statement is issued by the sub-contractor and is finally approved by the consultant of the

Client. And after the approval the method statement is ready to be implemented.

(b) Technical Submittal:

Submittals are required to verify that the correct products and quantities will be installed on the

project. This is of 2 types:

• Product data submittal: The product data submittal usually consists of the manufacturer’s

product information. The general information included in the product data submittal are

a) Manufacturer, trade name, model or type number and quantities

b) Size and physical characteristics

c) Description of use and performance characteristics

• Shop drawing: A shop drawing is a drawing or set of drawings produced by

the contractor, supplier, manufacturer, subcontractor, or fabricator. Information included in shop

drawing:

a) Notes of changes or alterations from the construction documents.

b) Information needed to fabricate the product.

c) Installation information

21

(c) Drawing approvals:

It’s a multistage process.

Stage 1: Client prepare a GFC (Good for Construction) Drawing

(Sends it to)

Contractor

Stage 2: Contractor prepares a SHOP DRAWING based on GFC.

(Sends it to)

Client (for approval)

Stage 3: If satisfied, client approves the drawing and the structure is ready for construction as per the

drawing.

If not, he sends it back to the contractor for revision.

Stage 4: The contractor, in last, prepares an “As Build Drawing” which includes the final drawing and

any changes made in the shop drawing during construction due to site condition.

(d) Checklist: It is a list proposed by the contractor to check the implemented work on the

construction site and is approved by the client.

12.3 Ways of controlling quality at Mall of India Project

a) Material Inspection Request (MIR):

The material inspection request is used by a consultant that is inspecting a piece of a material to issue

comments and record the findings of the inspection in a standard report.As soon as the materials

delivered to site, it is inspected for

Physical damages

Manufacturer Test report

Invoice/ Chalan

Compiling with approved technical specification

After the quality check of the material, there are three levels of assessment:

a. Level A: Approved

The material is OK and ready to use.

b. Level B: Approved as Noted

Material is approved with comments. Those comments are to be rectified by the sub-contractor.

c. Level C: Rejected

The material is not fulfilling the requirement of the approved technical data of the material to

be used and is rejected.

After internal inspection, Clients/Consultants are called for final inspection & the same shall be

recorded in the inspection report.

22

If there is any dilemma with the material’s test certificate issued by the manufacturer, a THIRD

PARTY TEST comes in action. Following are the steps of a third party test.

To Ensure the Manufacturer test certificate’s genuineness, Piece of the material is sent to

authorize third party laboratory for testing (National accreditation board for testing and

calibration Lab - NABL).

Test report from laboratory is compared with manufacturer’s test report.

In case of major deviation, the material shall be rejected.

23

Sample of MIR to be used at mall of India project

24

(b) Work Inspection Report:

The work inspection request is used by a consultant that is inspecting work done by the sub-contractor

to issue comments and record the findings of the inspection in a standard report.

Work done at any particular location of the project is inspected and tested by the sub-contractor,

contractor and PMC. If approved by all 3 of them, the work done is O.K. and is as per the requirement

of the client.There are three levels of assessment:

1. Level A: Approved

The work done is perfectly O.K. and need no changes.

2. Level B: Approved as Noted

The work done is approved with comments and need some changes. Those comments are to

be rectified by the sub-contractor.

3. Level C: Rejected

The work is inappropriate as per the requirement and is rejected.

Sample of WIR to be used at Mall of India

25

(c) Non-conformance report:

A report issued when a product, process or procedure does not comply with the set standards for a

particular belonging to the product, process or procedure under inspection.

There are two types of NCR:

1. Internal NCR: It’s a NCR issued by a department within an organization for same or

another department within the same organization.

2. External NCR: It’s a NCR issued by an organization for another organization that are in

any kind of contract.

• NCR issued by the PMC to the contractor.

• NCR issued by the contractor to the sub-contractor.

12.4 Non Conformance Report Closure

To close the issued NCR, there is a definite procedure. It includes of following 4 steps.

a) Root Cause: First of all, the root cause of the NCR is to be determined. The reason because of

which the NCR was issued.

b) Corrective action proposed: After determining the root cause, a corrective action is to be

proposed to close the NCR.

c) Corrective action taken: If the corrective action proposed is acceptable by the issuing

organization, the proposed corrective action is implemented.

d) Preventive action: NCR receiving organization should propose some preventive measures for non-

occurrence of same NCRs in future.

26

13. Test and Commissioning At Mall Of

India

These are done to check the material as soon as it reaches the site.

Some of the examples are:

(a) MS/GI Pipe- Site Test

Following parameters are to be checked-

Diameter of the pipe.

Thickness of the pipe –Screw gauge / venire caliper is used to find the thickness.

Length of the pipe.

Check ovality of pipes.

Apart from site test, the sample is sent to THIRD PARTY laboratory for testing:

Mechanical Test Standard Chemical Test Standard %

(max)

Yield Stress 235N/mm2 Carbon (C) 0.02

Tensile Stress 320 N/mm2 Manganese (Mg) 0.04

% of Elongation 5.65 Phosphorus (P) 0.005

Bend Test Should pass Sulphur 0.005

1. ‘V’ Groove check

Template made at site is used to check the ‘V’ groove between the two pipe ends.

2. Die-Penetrate Test (DP Test)

DP test conducted for 25% of welded joints.

Penetrant is applied on cleaned welded joint

Developer is applied after 5 min. red color spot indicates the pin hole.

27

3. Pressure Test

Pressure test is done to ensure the entire welding quality.

Water is pumped till it reaches double the working pressure & maintained for 24hrs.

If any leak, the same shall be rectified and redo the test.

It is less expensive.

4. Holiday Test

It is for underground pipes, where pipes are wrapped with antirust protection to avoid cathodic

reaction.

Test is conducted to identify air holes in wrapping, which if left buried may lead to rusting of pipe.

Operate on the principle - High Voltage Units with necessary safety arrangements.

5. Radiography Test

As per TAC 10% of total weld has to be radio graphically tested.

Defective welds are rectified & tested again.

Expensive & Time consuming.

(b) FIRE FIGHTING PUMPS

1. Head in meters

Head is derived from Discharges pressure measured from pressure gauge.

28

2. Fire Pump Testing

This test is done to ensure that the pump will operate without any mechanical difficulty and

protect the facility if a fire should occur.

Test Procedure

Start the pump with a drop in system pressure. Record the starting pressure.

Check the pump packing glands to verify that a slight discharge of water is visible.

Check for excessive vibrations, unusual noise, or other sign of malfunction. Make corrections as

needed.

Record the systems suction and discharge pressure.

Periodically verify that the pump and driver are not over heating during the test.

Shut down the pump manually.

3. Current Consumption

Starting & running current is measured with the help of tong tester. Horse Power (HP) is

derived from running current of motor.

(c) HVAC (Heating, Ventilation and Air Conditioning)

1. G.I. Duct test - Light Test and pressure test

It is to ensure no hole in duct & duct joints for air leakage

High intensity halogen lamp is lighted from one side of the duct and other side closed with

dummy.

This test is done only during evening time.

Holes in the duct identified by leakage of light and redo the test after closing the hole with

sealant.

2. AHU– Commissioning Test

2.1 Rotation of Motor

Direction of the motor rotation is very important and Proper output shall not be obtained unless

otherwise the motor rotates in right direction.

29

2.2 Noise test and performance test

Noise test is very important, as these equipment are installed very near to working environment

Human feels uncomfortable when the noise level increases beyond 70dba

With the help of sound level meter, noise of AHU is measured 2mtrs from the AHU

The unit shall be replaced incases the noise level found more than the specified value.

Discharge ( CFM ) has to be verified with anemometer

3. Pump–Commissioning Test

3.1 Flow rate in lpm

Pitot tube is used to find out velocity of water from pump.

Area of the pipe is measured.

3.2 Discharge pressure

Discharge pressure is calculated with the help of pressure gauge fixed in discharge side.

3.3 Efficiency

Eff-1 pumps used for HVAC chiller water pumping as the operation of these pumps are

continuous. Pump efficiency is calculated by finding ratio of output to input power.

4. Chiller – Commissioning Test

4.1 Performance Test

Chiller Capacity (TR) = 500 x Qw x (T2-T1)

12000

Where,

TR = Capacity in TR (Tons of Refrigerant)

Qw = Water Flow rate through chiller (usgpm)

T1 = Water temperature at chiller outlet (Deg F)

T2 = Water temperature at chiller inlet (Deg F)

Qw to be obtained from the collar characteristic curves based on the pressure difference.

4.2 Refrigerant gas Pressure Test (R134)

4.3 Suction & Discharge pressure Test

4.4 Temperature Test For Evaporator & Condenser

4.5 Flow Rate Test For Evaporator & Condenser

4.6 Noise Level Distance @ 1 mtr & 2 mtr

4.7 Vibration Test