copy of fqp -fuel handling system

7/30/2019 Copy of FQP -Fuel Handling System

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ID NO.:

FIELD QUALITY PLAN

FOR

FUEL HANDLING SYSTEM

FOR

SHREE MEGA POWER(2x150MW)

CETHAR VESSELS LIMITEDTIRUCHIRAPPALLI

FIELD QUALITY ASSURANCE DEPARTMENT

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

FRT-FQP-001-REV 00


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FIELD QUALITY PLAN

FOR

BOILER STRUCTURES

FOR

SHREE MEGA POWER

PREPARED BY(P.Vijayaragavan, Engineer / QA)

REVIEWED BY(N.Narayanasamy,VP /UB& UPP )

APPROVED BY(V. Kandhsamy, Chief / FQA)

DOCUMENT No. QPE-FHS-002

R00 / OCT-2010

ID No. DATE OF ISSUE

COPY No:CONTROLLED /INFORMATION

COPY

NO. OFPAGES:

30

ISSUED BY

ISSUED TO:

CETHAR VESSELS LIMITEDTIRUCHIRAPPALLI

FIELD QUALITY ASSURANCE DEPARTMENT

FRT-FQA-002-REV 00


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CONTENTS

DOC. NO. : QPE-FHS-001

REV. NO. : R00

SHEET: 1 / 1

Sl. No DESCRIPTION NO. OF SHEETS

1 STATUS OF AMENDMENTS 1

2.AUTHORISATION FOR DIFFERENT CATEGORIES OFCHECKS

1

3. STATEMENT OF CHECKS 9

4. DOCUMENTS REFERRED IN QUALITY PLAN 1

5. LOGSHEETS : L-00 TO L-04 5

6 FEEDBACK ON FIELD QUALITY PLAN 1

FRT-FQP-003-REV 00


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STATUS OF AMENDMENTS


REV. NO. : RO0

SHEET : 1 / 1

SL.NO.

REFERENCEOF SHEETSAMENDED

AMENDMENT NO.& DATE

REMARKS

NIL

FRT-FQP-004-REV 00


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AUTHORISATION FOR DIFFERENTCATEGORIES OF CHECKS


REV. NO. : RO0

SHEET : 1 / 1

CLASSIFICATION OFCHECKS

CHECKING / WITNESSING AUTHORITYACCEPTINGAUTHORITY

A CRITICAL

CVL QAE HEAD/FQA

SCL CONSTRUCTION SCL

B MAJOR

CVL ERECTION QAE

SCL CONSTRUCTION SCL

C MINOR

CVL ERECTION HOS

SCL --- SCL

LEGNDS: QAE -QUALITY ASSURANCE ENGINEER

HOS-HEAD OF SECTION

NOTE

1.QAE shall witness 'A' category checks. He is also authorised to carry outsurveillance in any of B and C category of checks at his discretion.

2. In case of non-conformity, accepting authority shall ensure disposition beforeaccepting 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


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STATEMENT OF CHECKS


REV. NO. : RO0

SHEET: 01 / 09

Capacity / Type: : 2 X 150MW

System: : BOILER

Sub-system: : FUEL HANDLING SYSTEM

Area: : ERECTION

NOTES:

1. For checks where log sheets are not called for, suitable records should be maintained in theform of log book / protocols.

2. As an evidence of having carried out the work satisfactorily, a general purpose log sheet,L-00 shall be maintained for all the checks.

3. The above sub-system covers Foundation and erection of structures, truck tippler,gantry,lconveyors, transfer tower,vibrating feeder,vibrating screen & Crushers with house,metaldetectors, magnetic separators and belt weigher

FRT-FQP-006-REV 00


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SUPPLIERS NAME& ADDRESS

Cethar Vessels Limited4,Dindigul Road,

Tiruchirappalli-620 001

FIELD QUALITY PLAN CUSTOMER: M/S.SHREE CEMENT LTD.PROJECT: SHREE MEGA POWER

2X150MW

PACKAGE: EPC

CONTRACT No.: EBJ 072 & 087

SYSTEM: BOILER

Sub system: Fuel handling system

FQP No. : QPE-FHS-001REV. No. : R00PAGE No.: 02 / 09

SL.NO

CHARACTERISTICS/ITEMTYPE

OFCHECK

INSTRUMENT CLASS

REFERENCEDOCUMENT/

ACCEPTANCESTANDARD

QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD

REMARKS/HOLD POINTS (H)

1.0 FOUNDATION

1.1 Availability of identified & protected permanent benchmark V B 100%

1.2 Elevation of top of foundation pedestals with referenceto permanent bench mark

MDumpy level /Water level /

TapeB

Drawing /erectionmanual

100% L - 01

1.3 Disposition of foundation pedestals with reference tolongitudinal axis of boiler and reference axis M

Tape A -do- 100% L - 01

1.4 Spacing between the foundation pedestals M Tape B -do- 100% L - 01

1.5 Diagonals of the main column foundation pedestals M Tape B -do- 100% L - 011.6 Pitch distance of foundation pedestal bolts on both the

axes and its diagonalsM Tape C -do- 100% L - 01

2.0 STRUCTURES

2.1 Material Receipt Verification &Identification CheckV Nil B

Transport/packing Doc.

100%

2.2 Check for cleanliness of structures before erection.V Nil B Nil 100%

2.3Pre-assembly of columns before erection , whereverapplicable. V/M

Tape /Piano wire /Water level

B

Drawing 100%

LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR;A SHALL BE WITNESSED BY QA E OF CVL & CUSTOMER,B SHALL BE WITNESSED BY ERECTION OF CVL & CUSTOMER ANDC SHALL BE WITNESSED BY ERECTION OF CVL.TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.

FOR CUSTOMER USE

MAIN SUPPLIER :CVL

SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL

FRT-FQP-007-REV 00


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2X150MW

PACKAGE: EPC


SYSTEM: BOILER



SL.NO

CHARACTERISTICSTYPE

OFCHECK

INSTRUMENT CLASS

REFERENCEDOCUMENT/

ACCEPTANCESTANDARD

QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD


2.4 Individual column piece camber and sweep(Tolerance :1mm/M : 10 mm max.).

M-do- B


100%

2.5 Camber and sweep for assembled columns(Tolerance :1mm/M ; 18 mm max.).

M -do- B -do- 100%

2.6 Total length of column before erection(Tolerance : 15 mm max.).

M Tape B -do- 100%

2.7 Orientation of columns. Check for match mark,elevationmark, Column No.,splice size etc.

V B -do- 100%

2.8 Ensure matching of center line of base plate with pedestalaxes.

V B -do- 100%

2.9 Elevation of column at 1 meter level with reference tobenchmark (Tolerance : 5 mm).

MWater level /

TapeB


100%

2.10 Alignment of first piece of column with horizontal beamsand vertical bracings (Tolerance :Position w.r.t. referenceaxis : 5mm; elevation: 5 mm).

MTheodolite /

Tape /Plumb bob

B -do- 100%

LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR;A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER,B SHALL BE WITNESSED BY ERECTION OF CVL & CUSTOMER ANDC SHALL BE WITNESSED BY ERECTION OF CVL.TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.

FOR CUSTOMER USE

MAIN SUPPLIER :CVL

SIGNATUREREVIEWED BY APPROVED BY APPROVAL SEAL

FRT-FQP-007-REV 00


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2X150MW

PACKAGE: EPC


SYSTEM: BOILER



SL.NO

CHARACTERISTICSTYPE

OFCHECK

INSTRUMENT CLASS

REFERENCEDOCUMENT/

ACCEPTANCESTANDARD

QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD


2.11 Completion of boxes with main brace level members ( MBL). V B -do- 100%

2.12 Grouting gap below the column base(Min. 20mm ; max. 70 mm). M Tape B Drawing 100%

2.13 Verification of test certificates and batch certificates of groutmaterial.

V AProcedure for

grouting100%

2.14 Grouting of column bases. V/R ADrawing / Groutmanufactures

Recommendation100% L - 04

2.16 Alignment of columns at every stage of erection. MTheodolite /

Tape /Plumb bob

ADrawing / erection

manual100% L - 05

LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR;A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER,B SHALL BE WITNESSED BY ERECTIONOF CVL & CUSTOMER ANDC SHALL BE WITNESSED BY ERECTION OF CVL.TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.

FOR CUSTOMER USE

MAIN SUPPLIER :CVL


FRT-FQP-007-REV 00


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2X150MW

PACKAGE: EPC


SYSTEM: BOILER


FQP No. : QPE-FHS-001REV. No. : R00PAGE No.: 05/ 09

SL.NO

CHARACTERISTICSTYPE

OFCHECK

INSTRUMENT CLASSREFERENCE DOCUMENT/ACCEPTANCE STANDARD

QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD


4 WELDING

4.1 Qualification of welders V / R AProcedure for structural

welder / welding operatorqualification at site

100%

4.2Availability of approved WPS , Heat TreatmentSchedule,Erection Manual, Calibration testcertificates of instruments used.

R A 100%

4.3 Adoption of correct procedure , approvedelectrodes and methods.

V/R A

Drawings / Procedure forreceipt inspection and

control of weldingconsumable at site / Heat

Treatment Parameters

100%

4.4 Pre heating and interpass temperature. V/R

Timetemperatur

eRecorder /ThermalChalk

A

Drawing / Guidelines for

Erection / Heat TreatmentParameters

As per

ReferenceDocument

LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR;A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER,B SHALL BE WITNESSED BY ERECTIONOF CVL & CUSTOMER ANDC SHALL BE WITNESSED BY ERECTION OF CVL.TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.

FOR CUSTOMER USE

MAIN SUPPLIER :CVL


FRT-FQP-007-REV 00


11/21





2X150MW

PACKAGE: EPC


SYSTEM: BOILER



SL.NO

CHARACTERISTICSTYPE

OFCHECK

INSTRUMENT CLASS

REFERENCEDOCUMENT/

ACCEPTANCESTANDARD

QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD

REMARKS/HOLD POINTS

(H)

5.0 NDE

a) Edge preparationi .MPI for new edges prepared at site after flame cutting /trimming of respective member where t 38mm.

V ACVL/PR/014 Rev.04CVL/PR/006 Rev.03

100%

ii . MPI/LPI for all gas cut edges for t 20mm and below38mm.

-do- 10%

iii . MPI/LPI for all bevel edges for t 20mm prior towelding

-do- 100%

b) Butt weldsi. MPI/ LPI on all back gouged / ground grooves

prior to welding from second side.V B

CVL/PR/014 Rev.04CVL/PR/006 Rev.03

100%

ii. RT for t 32mm. V A CVL/PR/095 Rev.00 100%

Iii. MPI/LPI on finished welds for t > 25mm to t < 32 mm. V BCVL/PR/014 Rev.04CVL/PR/006 Rev.03

100%

Iv. MPI/LPI on finished welds up to 25 mm thick. V B -do- 10.00%LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR;A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER,

B SHALL BE WITNESSED BY ERECTION OF CVL & CUSTOMER ANDC SHALL BE WITNESSED BY ERECTION OF CVL.

TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P-PHYSICAL & T- TEST.

For Customer UseMain Supplier: CVL

Signature Reviewed By Approved By Approval Seal


12/21





2X150MW

PACKAGE: EPC


SYSTEM: BOILER



SL.NO

CHARACTERISTICSTYPE

OFCHECK


QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD


d) Fillet welds

I.)LPI/MPI For welds between flange and web andbearing stiffeners.

V BCVL/PR/006 Rev.03CVL/PR/014 Rev.04

100%

ii.) LPI/MPI For other welds joining plate members inwhich both plate members are over 25 mm thick.

V B -do- 100%

iii.) LPI for All other welds V B CVL/PR/006 Rev.0310% of

weld length

6.0 Gantry construction

i) Provision of Stool Support V

ii) Provision of Deck sheet at fuel point Viii) Idlers location & alignment M Tape A Drawing 100%iv) Provision of mounting bracketv) Provision of floor grills

V B Do--

vi) Individual piece Dimension, holes location, bend &twist

Vii) Gantry assembly dimension, holes location , bend &Twist .

M Tape A Do--

7 Head End & Tail End with pulleys Stringer arrangement M Do--

i) Alignment

ii) Centre to Centre Distance8 Drive Arrangement

i) Alignment ( Axial & radial) MDialMicrometer

A Drawing 100.00%


FOR CUSTOMER USE

MAIN SUPPLIER :CVL


FRT-FQP-007-REV 00


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2X150MW

PACKAGE: EPC


SYSTEM: BOILER



SL.NO

CHARACTERISTICSTYPE

OFCHECK


QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD


9 Skirt Board arragement at Fuel feeding point V B Drawing 100.00%

10 Grizzly hopper with Vibrating feederI) Hopper orientation , dimensions & Alignment M Tape A Drawing 100.00%ii) Vibratory feeder location & Alignment M -Do- A Drawing 100.00%

11 Crusher , Screen & Vibrating feeder

I) Orientation

ii) Location M Tape A Drawing 100%

iii)Alignment

12 Inter connecting Chute

I) Dimension , M Tape A Drawing 100%

ii) Welding Soundness Visual B

iii) location M Tape A

Drawing 100.00%

13 Laying of Belt V

I) Splicing V B Drawing 100%

14 ii) Hardness at the joint M Hardnesstester

A 70 5 DegShore A

100%

15 Provision of Scrapper V A Drawing 100.00%


FOR CUSTOMER USE

MAIN SUPPLIER :CVL REVIEWED BY APPROVED BY APPROVAL SEAL


14/21





2X150MW

PACKAGE: EPC


SYSTEM: BOILER


FQP No. : QPE-FHS-001REV. No. : R00PAGE No.: 09/ 09

SL.NO

CHARACTERISTICSTYPE

OFCHECK


QUANTUM/FREQUENCY

OF CHECK

FORMATOF

RECORD


16 Trial run with all Safety accessories

i) Provision of pull chord Switches V ADrawing /Equipment

manual100%

ii) Smooth operation

iii) Vibration & Noise level of Drives

17 Provision of Guard

18 Provision of Fire fighting system V A Drawing 100%

19 Assembly of Conveyor hood V A Drawing 100%

20Erection of Dust extraction system , Dust suppressionsystem & Ducting

V A Drawing 100%

21 Cladding V B Drawing 100%


FOR CUSTOMER USE

REVIEWED BY APPROVED BYAPPROVAL

SEALMAIN SUPPLIER :CVL


15/21

DOCUMENTS REFERRED INQUALITY PLAN

DOC. NO. : QPE--002

REV. NO.: RO0

SHEET : 1 / 1

SL.NO Reference Document

Document /Procedure No Issuing Authority

1Erection Manual-Boiler supportingstructures

SMP/Erec/002 Construction

2 Quality Plan - Structural BI079/012 Q A & C

3 Procedure for Liquid PenetrentExamination

CVL/PR/006 Q A & C

4 Procedure for Radiographic Examination CVL/PR/095 Q A & C

5Procedure for Magnetic ParticlesExamination

CVL/PR/014 Q A & C

6 Procedure for Post Weld Heat treatment CVL/PR/002A Q A & C

7 Procedure for grouting CVL/FQA/PR/003 FQA

8 Procedure for visual inspection CVL/PR/029 Q A & C

9Procedure for Structural welder / weldingoperator qualification at site

CVL/FQA/PR/002 FQA

10 Welding Consumable Selection Chart BGS-2-24 to BSG-2-027 Engineering

11 List of Approved Welding Consumables CVL/AWCL/001 Q A & C

Notes:

QA&C Quality Assurance & control

FQA Field Quality Assurance

FRT-FQP-009-REV 00


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RECORD OF QUALITY CHECKS

SHEETNO. OF. FQP

CHECKNO.

RESULTSACHIEVED OK /

NOT OK

DRAWING /DOCUMENTREFERENCE

FORMAT OFRECORD

INSPECTED BYSIGN. & DATE

CLEAREDBY SIGN.& DATE

REMARKS

Note: Any protocol made is to be numbered & mentioned in Format of Record column.

PROJECT SYSTEM SUB - SYSTEM AREA DOC. NO. : QPE-FHS-001

UNIT NO. REV. NO. : RO0

RATINGLOG SHEET NO. : L - 00

SHEET : 1/1

FRT-FQP-010-REV 0


17/21

INSTRUMENT REGN.NO

DATE OF INSPECTION

DRAWING/DOCUMENT REF.

PITCH AND DIAGONAL DISTANCE OF FOUNDATION BOLTS

AS PER DRAWING

PEDESTAL DESIGNATION A B a1 a2 a3 a4 b1 b2 b3 b4 D1 D2

L

R

L

R

L

R

L

R

L

R

Tolerances: 1. Pitch Distances : 3mm 2. Diagonal Difference : 5mm max All dimension are in mm

NAMESIGN.&DATE


PROJECT INSPECTED BY REV. NO. : RO0

UNIT NO. CLEARED BY LOG SHEET NO. : L - 01

RATING CUSTOMER SHEET : 1 / 1

FRT-FQP-011-REV 00


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INSTRUMENT REGN.NO

DATE OF INSPECTION


GROUTING OF COLUMN BASES

1. Column number ( identification) :

2. Grout material Specification :

3. Ratio of proportion of grout mix :

4. Whether any additives added : Yes / No

If yes ,details :

5. Date of grouting :

6. Whether test cubes have been taken : Yes / No

If yes ,details :

7. Remarks :

The following column bases _____________________________ are cleared for further erectionafter _______days of curing.

NAMESIGN.&DATE




RATING CUSTOMER SHEET: 1 / 1

FRT-FQP-011-REV 00


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INSTRUMENT REGN.NO

DATE OF INSPECTION


VERTICALITY OF COLUMNS

ColumnNumber

Elevation inmetres

Inclined towards (mm)

East West North South

Tolerance : 1mm / M, 25 mm Max.

NAMESIGN.&DATE




RATING CUSTOMER SHEET 1 / 1

FRT-FQP-011-REV 00


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INSTRUMENT REGN.NO

DATE OF INSPECTION


JOINT INSPECTION PROTOCOL FOR COMPLETION OFSTRUCTURE AND EQUIPMENT

SI. NO ACTIVITY OBSERVATION

1

2

3

4

5

6

7

8

NAMESIGN.

&DATE




RATING CUSTOMER SHEET : 1 / 3

FRT-FQP-011-REV 00


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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 To

Head/FQA,CVL,Tiruchirappalli.

PROJECT DOC. NO. : QPE-FHS-001

UNIT NO. REV. NO. : RO0

RATING SHEET : 1 / 1

FRT-FQP-013-REV 00

copy of fqp -fuel handling system

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