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WITH REFERENCE TO THE NIT, PUBLISHED IN THE WEB SITES FOR PROVIDING
FIELD QUALITY ASSURANCE SERVICES FOR CIVIL, STRUCTURAL, TG, BOILER &
PIPING, ELECTRICAL AND C&I WORKS AND SAFETY SERVICES FOR 1X250 MW UNIT
# 3 AT BUDGE-BUDGE PROJECT, CESC, WEST BENGAL., FOLLOWING CHANGES
MAY PLEASE BE NOTED AND COMPLIED WHILE SUBMITTING THE OFFER FOR THE
SUBJECT JOB.
BIDDERS TO NOTE THAT TCN-01 WILL FORM PART OF TERMS & CONDITION OF
TENDER DOCUMENT.
ALL OTHER TERMS & CONDITIONS OF THE TENDER REMAIN UNCHANGED.
BIDDERS ARE REQUESTED TO SUBMIT OFFER BY DUE DATE.
SR MANAGER (SCT)
CLARIFICATIONS OF PRE-BID DISCUSSION ON 26/04/2007 AT PSER ,HQ, KOLKATA FOR PROVIDING FIELD QUALITY ASSURANCE SERVICES FOR CIVIL,
STRUCTURAL, TG, BOILER & PIPING, ELECTRICAL AND C&I WORKS AND SAFETY SERVICES FOR CESC BUDGE BUDGE PROJECT (1x 250 MW)
EXTENSION UNIT 3.
(TENDER NO - PSER:SCT:BDG-Q742:07)
Page 1 of 1
Sl
no
Description/
tender clause no
Tender clause
Bidders querries
Clarifications by BHEL
NIT, Annexure II
Sl. No. 8.0 & 9.3
B3
B4
CLAUSE 7.0
Gr.-a,b,c,d,e
Clause
No.
5.9,
5.9(a), 5.9(b), 13.4
For witnessing of testing outside Visit to Kolkata needs Provision for making additional payment
towards witnessing the testing in Kolkata
the project site, in Kolkata or else review.
is not applicable for this contract and is
where..
___
C. VOL-III
C1
VOL-III,
Rate
Schedule, GROUP f:
(SAFETY)
QTY
Column
26
APPROVED BY
HEAD / QLY, PSER
SR MANAGER/QLY, PSER
DOCUMENT NO.
QPE - CL 04-52
20.08.2004
R00 / 20.08.2004
COPY NO.
ISSUED TO
DATE OF ISSUE
CONTROLLED / INFORMATION COPY
ISSUED BY
(SIGNATURE & DESIGNATION)
CONTENTS
PSER
S.NO.
DESCRIPTION
1 /
1 SHEETS
NO. OF SHEETS
1.
STATUS OF AMENDMENTS
2.
3.
14
i)
Raw Materials
ii)
iii)
Forming
iv)
Fit up
v)
Pre-heating
vi)
Welding
Foundation Checks
x)
xi)
4.
5.
Table A1 to A6
6.
WPS
7.
8.
16
FMT-QP-003 REV.00
STATUS OF AMENDMENTS
PSER
SL.
NO.
REFERENCE
OF SHEETS
AMENDED
AMENDMENT NO.
& DATE
-NIL -
FMT-QP-016 REV.00
REMARKS
SHEETS
Classification of checks
Inspection agency
Clearing agency
Critical
Major
Minor
Symbol
Description
Legend :
Customer
QAE
DVC
Quality Assurance Engineer
Note :
1. Quantum of check shall be 100% for all characteristics unless
otherwise mentioned in reference documents.
2. QAE is also authorised to carry out surveillance in any of the B and
C category of checks at his discretion.
3. In case of non-conformity, before accepting , BHEL shall ensure
dispositioning and the same shall be reflected in Logsheets/protocols.
FMT-QP-004 REV
Classification of checks
Inspection agency
Symbol
Clearing agency
Description
Task performer
&
surveillance by QAE
(if available)
Critical
Major
Task performer
HOS
Minor
Task performer
Task performer
Legend :
HOS
HOS
Head of Section
QAE
Note :
4. Quantum of check shall be 100% for all characteristics unless
otherwise mentioned in reference documents.
5. QAE is also authorised to carry out surveillance in any of the B and
C category of checks at his discretion.
6. In case of non-conformity, before accepting , clearing agency shall
ensure dispositioning and the same shall be reflected in
Logsheets/protocols.
FMT-QP-004 REV.01
STATEMENT OF CHECKS
PSER
Capacity / Type :
2 x 250 MW
System :
Sub-system :
------------------------
Area :
Erection
1 /
14
SHEETS
NOTES :
1. For checks where logsheets are not called for, suitable records should be maintained in the form
of logsheets / protocols.
2. As an evidence of having carried out the work satisfactorily, a general purpose logsheet,
L-00 shall be maintained for all the checks.
3. Drawing / Contract requirements shall apply over and above the checks given.
4. Abbreviations used in the column Type of check are:
R : Record verification
M: Measurement
V : Visual
P : Physical
T : Test
FMT-QP-005 REV.00
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
1.0
1.1
RAW MATERIALS
Ensure that the raw materials (including Stainless steel) is as
per the specification
1.2
Ensure that the raw material is free from defects like cracks,
seams, laps, lamination and pitting
NOTE:
1. UT on all plates >25mm thickness
In the absence of correlation with TCs test shall be carried
out on the materials as per specification.
2.0
2.1
2.2
2.3
2.4
TYPE
OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
SHEET
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
Test / Test
certificates,
Drawing, IS2062,
8500, 808, 3502
100%
T/R
R/T
ASTM-A435
100%
100%
V/M
Steel Tape
Drawing &
Annexure-II
100%
Steel Tape
Annexure-II
100%
Ensure that the raw materials are cut by using suitable method
Annexure-II
100%
Drawing
100%
R00
2
14
SHEETS
FORMAT OF
RECORD
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
S.NO.
TYPE
OF
CHECK
2.5
Check that the raw materials after cutting are identified with
part number.
3.0
3.1
4.0
FIT UP:
4.1
4.2
Check that the gap is minimum for all fillet welds ( max. gap
2 mm )
4.3
4.4
INSTRUMENT
AREA : ERECTION
CLASS
SHEET
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
R00
3
14
FORMAT OF
RECORD
Drawing
100%
Drawing
100%
Measuring Tape
Drawing
100%
Protocol
Measuring Tape
Drawing
100%
Protocol
Ensure that the butt weld joints are properly aligned and the
offset is not to exceed 10% of the thickness of the thinner
part of the joint. Maximum permitted value is 3.2 mm.
Measuring Tape
Drawing
100%
Protocol
Measuring Tape
Drawing
100%
Protocol
FMT-QP-015 REV. 01
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
S.NO.
AREA : ERECTION
TYPE
OF
CHECK
INSTRUMENT
CLASS
SHEET
R00
4
14
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
5.0
PREHEATING:
5.1
Thermal chalk
Annexure-II
100%
Protocol
5.2
Thermal chalk
Annexure-II
100%
Site Log
6.0
WELDING:
6.1
T/R
Welding
Manual, WPS,
IS817 & ASME
SEC. IX
100%
Site Log
6.2
Welding
Manual, WPS,
IS817 & ASME
SEC. IX
100%
Site Log
6.3
Drawing
100%
Site Log
6.4
WPS
100%
6.5
Bevel protractor
100%
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
S.NO.
TYPE
OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
14
FORMAT OF
RECORD
6.6
6.7
Measuring Tape
Drawing
100%
Protocol
7.0
7.1
Testing
equipment
Drawing ,
Annexure-I &
NDE Manual
As per
Annexure-I
protocol
8.0
8.1
Specification
100%
8.2
Drawing
100%
b)Part Number
Drawing
100%
V
M
C
B
Drawing
Specification
100%
100%
SHEET
R00
100%
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
S.NO.
TYPE
OF
CHECK
9.0
FOUNDATION CHECKS:
9.1
9.2
9.3
9.4
9.5
9.6
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
100%
L-01
Drawing
100%
Drawing
100%
Dumpy Level
Drawing &
Annexure-I
100%
L-02
Measuring Tape/
Theodolite
Drawing &
Annexure-I
100%
L-03
Measuring Tape
Drawing &
Annexure-I
100%
L-04
9.7
Measuring Tape
Drawing &
Annexure-I
100%
L-05
10.0
10.1
FMT-QP-015 REV. 01
100%
14
FORMAT OF
RECORD
Measuring Tape
SHEET
R00
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
AREA : ERECTION
TYPE
OF
CHECK
INSTRUMENT
CLASS
Measuring Tape
10.2
10.3
SHEET
R00
7
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
Drawing &
Annexure-I
100%
L-06
Drawing &
Annexure-I
100%
L-06
Drawing &
Annexure-I
100%
L-07
Note:
10.4
1.
2.
3.
Check camber, sweep, match mark and total length after trial
assembly of columns.
Note: thickness of packer plates shall be decided based on
total length of columns and the top level of corresponding
foundation.
FMT-QP-015 REV. 01
Measuring Tape
14
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
S.NO.
TYPE
OF
CHECK
INSTRUMENT
AREA : ERECTION
SHEET
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
Drawing &
Annexure-I
100%
CLASS
R00
8
FORMAT OF
RECORD
11.0
11.1
11.2
Measuring Tape
Drawing &
Annexure-I
100%
L-08
b) Sweep
Measuring Tape
Drawing &
Annexure-I
100%
L-08
c)
Measuring Tape
Drawing &
Annexure-I
100%
Measuring Tape
Drawing &
Annexure-I
100%
e)
Measuring Tape
Drawing &
Annexure-I
100%
f)
End plates are aligned and in one plane on both the ends.
Measuring Tape
Drawing &
Annexure-I
100%
FMT-QP-015 REV. 01
14
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
11.3
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
AREA : ERECTION
TYPE
OF
CHECK
INSTRUMENT
CLASS
M/V
Measuring Tape
SHEET
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
Drawing
100%
R00
9
14
FORMAT OF
RECORD
SHEETS
REMARKS
Proper fit up
T/R
Drawing,
Welding Manual
& Annexure-I
100%
c)
T/R
Drawing &
Annexure-I
100%
T/R
Drawing &
Annexure-I
100%
d) LPI on finished welds 100% for butt welds and 10% for
fillet welds.
Butt Welds :
1. Radiography : Spot radiography shall be carried out on 100 % joints in Tension zone and 10% joints in Compression zone. Minimum 300 mm length shall be
spot radiographed. When radiography is not possible, Ultrasonic test shall be carried out after grinding the surface
2. Ultrasonic Test : 10 % of all other Butt welds shall be subject to spot radiography test and the entire balance butt weld for Ultrasonic test
FMT-QP-015 REV. 01
Class of
check `A'
Acceptance
standard as
per NDE
Manual.
STATEMENT OF CHECKS
REV. NO.
PSER
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
TYPE
OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
SHEET
QUANTUM /
FREQUENCY
OF CHECK
12.1
100%
12.2
Ensure cleaning of packer plates and that they are free from
undulations and burrs.
100%
12.3
12.4
12.5
Drawing &
Annexure-I
100%
Drawing
100%
Drawing
100%
12.6
100%
12.7
Measuring Tape
& Plumb bob
100%
Measuring Tape
12.8
Measuring Tape
Drawing
100%
R00
10 /
14
FORMAT OF
RECORD
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
12.9
SUB-SYSTEM : STRUCTURE
CHARACTERISTICS
TYPE
OF
CHECK
INSTRUMENT
AREA : ERECTION
SHEET
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
Drawing &
Annexure-I
100%
Drawing &
Annexure-I
100%
Drawing
100%
CLASS
R00
11 /
FORMAT OF
RECORD
12.11
12.12
100%
12.13
100%
12.14
Drawing &
Annexure-I
100%
12.15
Drawing
100%
Annexure-I
100%
12.16 Ensure tightness of bolts (HSFG/HT bolts as the case may be)
FMT-QP-015 REV. 01
M/V
Plump bob /
Theodolite
Compressive
Testing m/c
Torque Wrench
14
L-09
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
AREA : ERECTION
TYPE
OF
CHECK
INSTRUMENT
CLASS
Plump bob
SHEET
12 /
14
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
Drawing &
Annexure-I
100%
L-09
Plump bob/
Theodolite
Drawing &
Annexure-I
100%
L-10
Water Level
Drawing &
Annexure-I
100%
Water Level
Drawing &
Annexure-I
100%
c)
Water Level
Drawing
100%
Measuring Tape
Drawing
100%
S.NO.
12.17
SUB-SYSTEM : STRUCTURE
R00
CHARACTERISTICS
12.18
12.19
L-11
L-12
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
S.NO.
12.20
TYPE
OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
SHEET
QUANTUM /
FREQUENCY
OF CHECK
12.21
SUB-SYSTEM : STRUCTURE
Drawing
100%
c)
Spirit Level /
Water Level
Drawing
100%
d) tightness of bolts.
Torque Wrench
Annexure-I
100%
e)
Drawing
100%
100%
FMT-QP-015 REV. 01
Torque Wrench
100%
Drawing
100%
13
R00
/
14
FORMAT OF
RECORD
SHEETS
REMARKS
STATEMENT OF CHECKS
REV. NO.
PSER
S.NO.
13.0
SUB-SYSTEM : STRUCTURE
TYPE
OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
SHEET
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY
OF CHECK
c)
FMT-QP-015 REV. 01
T/R
Welding Manual /
NDE Manual /
WPS
100%
T/R
Welding Manual /
NDE Manual /
WPS
100%
Welding Manual /
NDE Manual /
WPS
100%
NDE Test
Equipment
14
R02
/
FORMAT
OF
RECORD
14
SHEETS
REMARKS
DOCUMENTS REFERRED IN
QUALITY PLAN
PSER
Sl. No.
Reference Document
1 SHEETS
Issuing Authority
Drawings
WPS
Trichy
Welding Manual
PS-NR
NDE Manual
PS-NR
6.
ASME : Sec IX
7.
ASTM A 435
8.
FMT-QP-017 REV.00
Annexure - I
Doc. No. QPE-CL-04-52
Rev. No. R00
Sheet No. 1 of 3
POWER HOUSE STRUCTURE - ERECTION TOLERANCES
FOUNDATION
TOLERANCES
1.
- 25 mm
+ 15 mm
2.
1 mm per meter
max. + 5 mm
3.
1 mm per meter
max. + 10 mm
4.
+ 3 mm
5.
+ / - 5 mm
6.
+ 15 mm min.
7.
Grouting gap
70 mm (Max.)
Note: Tolerance on thickness of grouting should not be allowed on negative side. The minimum thickness of grouting shall be
thickness of grouting shown in the drawing.
II
COLUMNS
TOLERANCES
1.
1 mm per meter
Max. 10 mm
2.
1 mm per meter
Max. 10 mm
3.
15 mm
4.
1 mm per meter
Max. 15 mm
5.
1 mm per meter
Max. 15 mm
6.
1 mm per meter
max. 25 mm
7.
5 mm Max.
Annexure - I
Doc. No. QPE-CL-04-52
Rev. No. R00
Sheet No. 2 of 3
III
TOLERANCES
+ 5 mm
Deviation of upper chord (in the middle of span) from vertical plane 1/250
running through center of support.
height
of structure
IV
+ 5 mm
+ 5 mm
+ 5 mm
GENERAL
TOLERANCES
+ 5mm
As per Drawing
Normal tightening
calibrated
wrench
torque
Annexure - I
Doc. No. QPE-CL-04-52
Rev. No. R00
Sheet No. 3 of 3
V
1.0
2.0
BUTT WELDS
2.1
2.2
100% Radiographic testing (RT) on tension zone welds and 10% RT on compression zone
welds of crane & bunker girder shall be carried out. Where RT is not possible. Ultrasonic
test shall be carried out after grinding the surface.
10% Radiographic Test (Minimum) & Ultrasonic test for the entire balance butt weld shall
be carried out for all structures except structures covered under Sl. No. 2.2
2.3
3.0
FILLET WELDS
3.1
3.2
3.3
Where the thickness of both the members is greater than 25 mm, LPI shall be done on entire
weld length.
3.4
On all other fillet welds, LPI shall be done on minimum 5% of total weld length at random
with minimum 300 mm at a particular location.
4.0
COLUMNS:BASE/TOP
5.0
100 % LPI
COAL BUNKERS
100 % NDT of all butt welds and all critical fillet welds are to be
done.
Apart from manufacturers TC of structural materials, site may
organise sample test of steel material at established laboratory during
various stages of project activities as per decision of BHEL engineers.
Adequate number of safe platforms and easy approach both from
bunker floor as well as from feeder floor are to be provided for
inspection of fit-up and welding of joints.
Annexure - II
Doc. No. QPE-CL-04-52
Rev. No. R00
Sheet No. 1 of 1
Upto 20 mm (including)
None
None
Over 20 mm to 40 mm (including)
65 C
20 C
Over 40 mm to 63 mm (including)
110 C
66 C
Over 63 mm
150 C
110 C
AS PER TABLE A1
AS PER TABLE A2
4.0 DEVIATIONS
4.1 ACCEPTABLE DEVIATIONS IN AS FARICATED STEEL
AS PER TABLE A3
STRUCTURES
AS PER TABLE A4
BOLT HOLES.
AS PER TABLE A5
STRUCTURAL STEEL.
AS PER TABLE A6
TABLE - A1
Tolerable Deviation from designed linear dimensions in mm in the part & processed for fabrication.
Deviation/Tolerances in mm
Sl.
1.5 m 1.5 m
2.5 m
4.5 m
9.0 m
No.
Characteristic
to
&.
to
to
to
below 2.5 m
4.5 m
9.0 m
15 m
1.
15 m
&
above
2.5
3.0
3.5
4.0
4.5
5.0
1.5
2.0
2.5
3.0
3.5
4.0
1.5
2.0
2.5
3.0
3.5
4.0
0.5
1.0
1.5
2.0
2.5
3.0
4.0
4.0
4.0
5.0
6.0
6.0
ii)
5.0
5.0
5.0
8.0
10.0
10.0
2.
3.
i)
2.0
2.0
2.5
3.0
3.5
4.0
ii)
1.5
1.5
1.5
1.5
1.5
1.5
3.0
4.0
5.0
7.0
10.0
15.0
2.0
2.0
3.0
5.0
7.0
10.0
0.5
1.0
1.5
2.0
2.5
3.0
3.0
4.0
5.0
7.0
10.0
15.0
2.0
2.0
3.0
5.0
7.0
10.0
0.5
1.0
1.5
2,0
2.5
4.0
TABLE A.2
Tolerable deviations of fabricated member from designed geometrical shape
Deviation
S. No.
Characteristic
1. Curvature of assembly Parts
a) Gap between a sheet and a steel rule face over 1 m length
b) Gap between a taut string and vertex face of an angle
flange or web of channel and joist.
2.
3.
1.5 mm
0.001 L, but not
greater than 10 mm
L - length of member
2 mm
5 mm
2 mm
3 mm
-do-
0.005D
D-diameter of
circumference
0.003D
-do-
i) at Junction point
0.005b
b-width of flange
O.Olb
b-width of flange
0.005b
b- width of flange
O.Olb
b-width of flange
0.003h
Remarks
Other Deviations:
a) Shifting of axes or riveting / bolting lines for lattice
structures from theoretical eccentricity.
3.0 mm
1/1500
TABLE-A.3
Acceptance Deviations in as fabricates steel structures.
Sl.
Characteristic
No.
1.
Deviation / Tolerance
COLUMNS
a)
b)
Deviation in length 'L' measured distance from bottom surface of the column footings, to the group of
holes for trusses, fasteners, collar beams, purlins and other elements to be connected to column.
When L is under 10 m
10 mm
When L is over 10 m
l5 mm
Deviation in distance 'L' from bottom surface of the column footing to the top of crane brackets.
When L is under 10 m
5 mm
when L is over 10 m
10 mm
c)
Deviation in distance from bearing surface of the bracket to the first fastener of 1 mm
the element to the connected to column.
d)
e)
f)
g)
1/1000 of length
element but not more
i) At splice joint
2 mm
10 mm
3 mm
element of column to the clear or heating plate or column to the cleat or seating
plate for fastening of collar beams, purlins, girders. etc. (Fish plates, brackets)
2.
TRUSSES
a) Deviation in span 'L' of the truss between end erection holes in gussets of supporting units or between
external planes of supporting gussets or angles when trusses are resting on brackets or supports:
When L is under 25 m
7 mm
When L is over 25 m
3 mm
1 mm
3 mm
supports.
e) Sag of separate elements between node points.
1/1500 of length of
element but not more
than 10 mm.
TABLE A.3
S.
No
3. BEAMS
a)
4.
Characteristic
Deviation/ Tolerance
Deviation in span L of beams between bend erection holes, outer Surfaces of end plates:
When L is under 25 m
10 mm
When T is over 25 m
b)
Deviation in the height of beam as measured from the bearing surface to the top
of upper flange.
3 mm
c)
3 mm
d)
5.
3 mm
12 mm
Number of erection
bolts shall be at least
30% of the total No. of
holes.
TABLE-A.4
S.No,
1,
Tolerance No. of
deviation in each group
+ 1 mm
Over 16 mm
+ 1.5 mm
No limit
2.
No limit
+ 1 mm
+ 1.5 mm
3.
4.
No limit
Not permitted
i) Upto 1 mm
Upto 50%
Upto 10%
NOTE : Burrs in holes shall be removed, the depth and width of countersunk hole shall not deviate from the
standard by more than 1.5 mm.
Table A 5
Permissible Fabrication Deviation of Structural Steel
S No.
1.
Name of Deviations
Column
Value of Deviation
(Tolerance)
a)
Assembly Fits
Base plate and column
0.1 mm
b)
Frame Joints
2.0 mm
c)
1.5 mm
d)
1.5 mm
e)
1.5 mm
f)
0.1 mm
g)
0 .1 mm
h)
Beam brackets
2 .0 mm
2.
Beams
1.5 mm
3.
Crane Girders
0.1 mm
4.
1.5 mm
b)
1.5 mm
c)
1.5 mm
d)
5.
Purlin
TABLE -A6
Maximum Permissible & Tolerances in Erected Steel Structures
Description
Sl. No.
1
Tolerance
5 mm
b) in lateral direction
5 mm
5 mm
iii) Out of plumbness (verticality) of column axis from true vertical axis, as
measured at column top:
a) For columns without any special requirements:
1) upto and including 30 m height
H/1000 or 25 mm
whichever is less
2) over 30 m height
H/1200 or 35 mm
whichever is less
H/1000 or 20 mm
whichever is less
2) Over 30 m height
H/1500 or 25 mm
whichever is less
H/1500 or 10 mm
whichever is less
5 mm
vi) Deviation in any bearing or seating level with respect to true level.
5 ram
5 mm
NOTE
1. Tolerance specified under iii (a) and iii (b) should be read in conjunction with iv and v.
2. 'H' is the column height in mm.
TABLE- 6 (Contd.)
Description
S. No.
2.0
Tolerance
Shift, at the centre of span of top chord member with respect to the vertical
plane passing through the centre of bottom chord.
1/250 of height of
truss in mm at centre
of span or 15 mm
Whichever is less
ii) Lateral shift of top chord of truss at the centre of span from the vertical plane 1/1500 of span of
passing through the centre of supports of the truss
truss in mm or 10 mm
whichever is less
iii)
Lateral shift in location of truss from its true axis in plan
10 mm
iv)
v)
3.
5 mm
1/1200 of span of
truss in mm or 20
mm whichever is less
Shift in the centre line of crane rail with respect to centre line of web
crane girder.
ii) Shift in plan of alignment of crane rail with respect to true axis of
crane rail at any point,
iii)
+ 5 mm
(5 + 0.25(S-15)) mm
subject to a maximum of
10 mm, where S in meters
is true track gauge.
iv)
Deviation in the crane rail level at any point from true level
10 mm
v)
vi)
15 mm
20 mm
2 mm subject to grinding of
surfaces
for
smooth
transition
SHEET
NO. OF QPI
CHECK
NO.
RESULTS
ACHIEVED
OK / NOT OK
DRAWING /
DOCUMENT
REFERENCE
FORMAT OF
RECORD
CHECKED BY
SIGN. & DATE
REMARKS
ACCEPTED BY
SIGN. & DATE
Note : Any protocol made is to be numbered & mentioned in Format of Record column.
SYSTEM
SUB-SYSTEM
AREA
PROJECT
UNIT NO.
RATING
SHEET
FMT-QP-007 REV. 00
SHEETS
DATE OF INSPECTION
PSER
Foundation for :
Unit No.
BHEL input
Customer
Date Reference :
Sub-contractor :
Main Construction
Drawing No. :
on (Date)
Certified that the above foundation has been constructed as IS 456. It is declared fit for erection work
of based on the following details :
1. Foundation cast -- As per IS
2. Shuttering and re-enforcement
As per IS 456
Results
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
Top Elevation
measurement
Deviation from
drawing value
Column No.
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
Column No.
From
To
Spacing
Drawing
Actual
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
Column No.
From
Diagonal
D1
To
Column No.
From
NAME
To
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
TYPE -II
TYPE - I
Column No.
a1
a2
1'
2'
3'
4'
D1
D2
a1
a2
1'
2'
3'
4'
D1
D2
As per drawing
TYPE - II
Column No.
As per drawing
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 4 SHEETS
DATE OF INSPECTION
PSER
Column No.
a1
a2
1'
2'
3'
4'
D1
D2
As per drawing
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 2 / 4 SHEETS
DATE OF INSPECTION
PSER
Type - IV
Column No.
a1
a2
a3
a4
1'
2'
3'
4'
D1
D2
As per drawing
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 3 / 4 SHEETS
DATE OF INSPECTION
PSER
Type-V
Column No.
a1
a2
a3
NAME
a4
b1
b2
SIG. / DATE
b3
b4
d1
d2
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 4 / 4 SHEETS
Column No.
Piece No.
Camber
M
Sweep
M
NAME
Length
B
SIG./DATE
PROJECT
CHECKED BY
REV. NO.
UNIT NO.
ACCEPTED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.00
R 00
1 SHEETS
DATE OF INSPECTION
PSER
Assembled Piece
Tolerance 1 mm / M Max.
15 mm
Elevation Level
From Bottom
Elevation Level
From Bottom
Note : Measure at every 5 Meter level. (Fix Piano wire to full length of column) Measure the reading and only deviation in "+" or "_" Values
J1
J2
J3
J4
J5
J6
Match mark
TOTAL LENGTH : As Per Drg.
MEASURED :
DIFFERENCE :
NAME
SIGNATURE / DATE
TOLERANCE : 15 mm
DOC. NO. QPE-CL-04-52
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-009 REV. 00
CUSTOMER
SHEET
SHEETS
SLOPE at D
Slope actual
As Per Drawing
CAMBER AND SWEEP
LOCATION
CHAMBER
SWEEP
Match Mark : Indicate OK if it is correct and if any deviation inform through SAR.
Location
Match Mark
TOTAL LENGTH
As Per Drawing
Measured
Difference
Tolerance
5 mm
NAME
SIG./DATE
PROJECT
CHECKED BY
REV. NO. R 00
UNIT NO.
ACCEPTED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.00
1 SHEETS
GROUTING GAP
(All Measurements in mm)
Column No.
Column No.
NAME
Column No.
SIG./DATE
PROJECT
CHECKED BY
REV. NO.
UNIT NO.
ACCEPTED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.00
R 00
1 SHEETS
Column
No.
Inclined to wards
Left
Right
Front
Rear
Location
Inclined towards
Left
Right
Front
Rear
SIG./DATE
PROJECT
CHECKED BY
REV. NO.
UNIT NO.
ACCEPTED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.00
R 00
1 SHEETS
CRANE GIRDER
Level
Column
No.
Level
Column
No.
Level
Column
No.
Level
Tolerance Max. 5 mm
All Dimension in mm.
NAME
SIG./DATE
PROJECT
CHECKED BY
REV. NO.
UNIT NO.
ACCEPTED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.00
R 00
1 SHEETS
Location
NAME
Measured
Length
SIG./DATE
Deviation
PROJECT
CHECKED BY
REV. NO.
UNIT NO.
ACCEPTED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.00
R 00
1 SHEETS
STRUCTURES
(Erection)
MEJIA TPS EXTN. ( UNITS 5 & 6 )
2 x 250 MW
(M/s. Damodar Valley Corporation)
PREPARED BY
SR MANAGER/QLY,PSER
DOCUMENT NO.
ORIGINAL DATE OF ISSUE
REVISION NO. & DATE
APPROVED BY
HEAD/QLY, PSER
QPE-BR-04-55
20.08.2004
R00Dt. 20.08.2004
COPY NO.
ISSUED TO
DATE OF ISSUE
CONTROLLED / INFORMATION COPY
ISSUED BY
(SIGNATURE &
DESIGNATION)
CONTENTS
PSER
Description
No. of Sheets
Status of amendments
01
01
Statement of checks
06
01
13
01
*****
FMT-QP-003 Rev.00
STATUS OF AMENDMENTS
SHEET 1 / 1 SHEET
PSER
Sl.No.
Reference of Sheet(s)
Amended
- NIL -
FMT-QP-016 Rev. 00
Remarks
Classification of checks
Inspection agency
Clearing agency
Symbol
Description
Critical
Major
Task performer
HOS
Minor
Task performer
Task performer
Legend :
Task performer
&
surveillance by QAE
(if available)
HOS
HOS
QAE
Note :
FMT-QP-004 REV.01
Classification of checks
Checking Authority
Accepting Authority
Customer
&
BHEL
Customer
&
BHEL
Symbol
Description
Critical
Major
Customer
&
BHEL
Customer
&
BHEL
Minor
BHEL
BHEL
Legend
Customer :
M/S DVC
Note :
DVC shall witness "A" category checks. He is also authorised to carry out
surveillance in any of the "B" and "C" category of checks at his discretion.
FMT-QP-004 REV.00
STATEMENT OF CHECKS
SHEET 1 / 6 SHEETS
PSER
Capacity / Type
2 x 250 MW
System
BOILER
Sub-System
STRUCTURES
Area
ERECTION
For checks where log sheets are not called for, suitable records shall be
maintained in the form of log book / protocols.
: Measurement
Visual
Test
FMT-QP-005 Rev. 00
Record Verification
DOC.NO.: QPE-BR-04-55
REV.NO.: R00
STATEMENT OF CHECKS
PSER
SYSTEM : BOILER
SL NO.
SHEET
SUB-SYSTEM : STRUCTURES
CHARACTERISTICS / ITEM
6 SHEETS
AREA : ERECTION
TYPE
OF
CHECK
INSTRUMENT
QUANTUM/
CLASS FREQUENCY
OF CHECK
REFERENCE DOCUMENT/
ACCEPTANCE STANDARD
FORMAT
OF
RECORD
FOUNDATION :
1.
100%
Relevant Drawing
2.
Dumpy level /
Water level /
Tape
100%
- do -
L - 01
3.
Tape
100%
- do -
L - 02
4.
Tape
100%
- do -
L - 02
5.
Tape
100%
- do -
L - 03
6.
Tape
100%
- do -
L - 04
Tape /
Piano wire /
Water level
100%
- do -
- do -
100%
- do -
STRUCTURES :
1.
2.
FMT-QP-006 REV.01
REMARKS
DOC.NO.: QPE-BR-04-55
REV.NO.: R00
STATEMENT OF CHECKS
PSER
SYSTEM : BOILER
SL NO.
SHEET
SUB-SYSTEM : STRUCTURES
CHARACTERISTICS / ITEM
6 SHEETS
AREA : ERECTION
TYPE
OF
CHECK
INSTRUMENT
QUANTUM/
CLASS FREQUENCY
OF CHECK
REFERENCE DOCUMENT/
ACCEPTANCE STANDARD
3.
Tape /
Piano wire /
Water level
100%
Relevant Drawing
4.
Tape
100%
- do -
5.
100%
- do -
6.
100%
- do -
7.
Water level /
Tape
100%
- do -
8.
Theodolite /
Tape /
Plumb bob
100%
- do -
9.
10.
11.
FMT-QP-006 REV.01
- do Tape
100%
- do -
100%
Work Instruction
for Grouting
FORMAT
OF
RECORD
L-06
REMARKS
DOC.NO.: QPE-BR-04-55
REV.NO.: R00
STATEMENT OF CHECKS
PSER
SYSTEM : BOILER
SL NO.
SHEET
SUB-SYSTEM : STRUCTURES
CHARACTERISTICS / ITEM
6 SHEETS
AREA : ERECTION
TYPE
OF
CHECK
12.
13.
14.
15.
INSTRUMENT
REFERENCE DOCUMENT/
ACCEPTANCE STANDARD
FORMAT
OF
RECORD
100%
Drawing / Grout
Manufacturers
Recommendation
L - 05
Theodolite /
Tape /
Plumb bob
100%
Drawing
L - 06
Bolt Tension
Calibrator /
Torque wrench
100%
- do -
Piano wire /
Tape /
Water level
100%
- do -
16.
- do -
100%
- do -
17
100%
-do-
18.
Tape /
Plumb bob /
Water level
100%
- do -
19.
Bolt Tension
Calibrator /
Torque wrench
100%
- do -
FMT-QP-006 REV.01
V/R/
T
QUANTUM/
CLASS FREQUENCY
OF CHECK
L - 07
REMARKS
DOC.NO.: QPE-BR-04-55
REV.NO.: R00
STATEMENT OF CHECKS
PSER
SYSTEM : BOILER
SL NO.
SHEET
SUB-SYSTEM : STRUCTURES
CHARACTERISTICS / ITEM
6 SHEETS
AREA : ERECTION
TYPE
OF
CHECK
INSTRUMENT
QUANTUM/
CLASS FREQUENCY
OF CHECK
REFERENCE DOCUMENT/
ACCEPTANCE STANDARD
20.
Theodolite /
Plumb bob /
Tape
100%
21.
Theodolite /
Tape
100%
- do -
22.
100%
-do-
23.
100%
- do -
24.
100%
-do-
25.
100%
26.
100%
27.
100%
FMT-QP-006 REV.01
Theodolite /
Plumb bob /
Tape
Relevant Drawing
- do -
FORMAT
OF
RECORD
L - 06
L - 07
L - 08
L - 06
REMARKS
DOC.NO.: QPE-BR-04-55
REV.NO.: R00
STATEMENT OF CHECKS
PSER
SYSTEM : BOILER
SL NO.
1.
SHEET
SUB-SYSTEM : STRUCTURES
CHARACTERISTICS / ITEM
CLASS
QUANTUM/
FREQUENCY
OF CHECK
REFERENCE DOCUMENT/
ACCEPTANCE STANDARD
V/R
100%
Welding Manual
100%
As per
Reference
Document
Drawing / Heat
Treatment Manual
Drawing /
Welding Manual /
Heat Treatment
Manual
NDE Manual
Heat Treatment
Manual
INSTRUMENT
3.
V/M
4.
V/R
100%
5.
7.
V/T
R
B
B
100%
100%
8
8.1
100%
Drawing
8.2
100%
Drawing
100%
Specification
Time
Temperature
Recorder /
Thermal Chalk
a)Assemblies designation
b)Part Number
c)Any other important identifications
Ensure Dry Film Thickness of paint is as per specification
FMT-QP-006 REV.01
6 SHEETS
AREA : COMMISSIONING
TYPE
OF
CHECK
2.
8.3
FORMAT
OF
RECORD
REMARKS
DOCUMENTS REFERRED IN
QUALITY PLAN
PSER
Reference Document
Sl. No.
Issuing Authority
1.
Welding Manual
2.
NDE Manual
3.
4.
FMT-QP-017 REV.00
SHEET
NO. OF QPI
CHECK
NO.
RESULTS
ACHIEVED
OK / NOT OK
DRAWING /
DOCUMENT
REFERENCE
FORMAT OF
RECORD
INSPECTED BY
SIGN. & DATE
CLEARED BY
SIGN. & DATE
REMARKS
Note : Any protocol made is to be numbered & mentioned in Format of Record column.
PROJECT
SYSTEM
SUB-SYSTEM
AREA
UNIT NO.
RATING
SHEET 1
FMT-QP-007 REV. 01
SHEET
INSTRUMENT REGN.NO.
DATE OF INSPECTION
PSER
DRAWING / DOCUMENT
REF.
- 20 mm
Sl,
No.
Pedestal
Designation
Sl.
No.
Pedestal
Designation
S1L
16
S6R
S2L
17
S7R
S3L
18
S8R
S4L
19
S9R
S5L
20
S10R
S6L
21
S11
S7L
22
S12
S8L
23
S13
S9L
24
S14
10
S10L
25
S15
11
S1R
26
S16
12
S2R
27
S17L
13
S3R
28
S18L
14
S4R
29
S17R
15
S5R
30
S18R
Top
Elevation
DOC. NO.:QPE-BR-04-55
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
PROJECT
FMT-QP-008 REV.01
SHEET
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT NO.
PSER
S2L
S6L
S3L
S7L
S4L
S8L
S5L
S9L
S10L
FRONT
S17L
S18L
S11
S6R
S1R
S12
S7R
S2R
S8R
S3R
NAME
S13
S9R
S14
S17R
S15
S16
S18R
S10R
S4R
SIGNATURE / DATE
S5R
DOC. NO.:QPE-BR-04-55
R00
PROJECT
INSPECTED BY
REV. NO.:
UNIT NO.
CLEARED BY
RATING
FMT-QP-009 REV.01
CUSTOMER
SHEET
L-02
SHEETS
REAR
S1L
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT
REF.
PSER
Sl.No.
Spacing
Between
As per
drawing
Sl.No.
Spacing
Between
29
30
S6L & BA
31
S7L & BA
32
S8L & BA
33
S9L & BA
34
S17L & BA
35
S18L & BA
36
S1OL & BA
37
BA & S6R
10
38
BA & S7R
11
39
BA & S8R
12
40
BA & S9R
13
41
BA & S17R
14
42
BA &S18R
15
43
BA &S10R
16
44
17
45
18
46
19
47
20
48
21
49
22
50
23
51
24
52
25
26
27
28
Actual
As per
drawing
Actual
Tolerances:
1. Between adjacent foundation pedestals centres:
2. Spacing between first and last row of foundation:
All dimensions are in mm.
NAME
1 mm / M, 5 mm max.
1 mm / M, 15 mm max.
SIGNATURE & DATE
DOC. NO.:QPE-BR-04-55
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
PROJECT
FMT-QP-008 REV.01
SHEETS
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT NO.
PSER
S2L
S6L
S3L
S7L
S4L
S8L
S5L
S9L
S10L
FRONT
S17L
S18L
S11
S6R
S1R
S12
S7R
S2R
S8R
S3R
NAME
S13
S9R
S14
S17R
S15
S16
S18R
S10R
S4R
SIGNATURE / DATE
S5R
DOC. NO.:QPE-BR-04-55
R00
PROJECT
INSPECTED BY
REV. NO.:
UNIT NO.
CLEARED BY
RATING
FMT-QP-009 REV.01
CUSTOMER
SHEET
L-03
SHEETS
REAR
S1L
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT
REF.
PSER
Sl.No.
Diagonal
between
Measurement
Sl.No.
Diagonal
between
11
12
13
14
10
Difference
Measurement
Difference
Tolerances :
1. Adjacent columns pedestal diagonal difference : 1 mm / M, 10 mm (max.)
2. Cumulative difference
: 1 mm / M, 25 mm (max.)
All dimensions are in mm.
NAME
DOC. NO.:QPE-BR-04-55
PROJECT
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.01
SHEETS
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT
REF.
PSER
a2
b4
D2
a4
A
a1
D1
a3
b1
b2
B
AS PER DRAWING
PEDESTAL DESIGNATION
a1
a2
a3
a4
b1
b2
b3
b4
D1
D2
L
R
L
R
L
R
L
R
L
R
: 3 mm
All dimensions are in mm
2. Diagonal Difference
5 mm max.
NAME
DOC. NO.:QPE-BR-04-55
PROJECT
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.01
SHEET
INSTRUMENT REGN.NO.
DATE OF INSPECTION
PSER
DRAWING / DOCUMENT
REF.
Column Numbers
2.
3.
4.
If yes, details
5.
Date of grouting
6.
Remarks
7.
Yes / No
Yes / No
NAME
DOC. NO.:QPE-BR-04-55
PROJECT
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.01
SHEET
INSTRUMENT REGN.NO.
DATE OF INSPECTION
PSER
DRAWING / DOCUMENT
REF.
VERTICALITY OF COLUMNS
Tolerance: 1mm / M, 25 mm Max.
Column
Number
Elevation
NAME
West
North
South
DOC. NO.:QPE-BR-04-55
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
PROJECT
FMT-QP-008 REV.01
SHEET
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT
REF.
PSER
S6R
S8L
S8R
Q1
Location
As per
drawing
S9R
R1
S10R
S1
Tolerance :
Actual
S10L
GIRDER D
S7R
P1
S
S9L
GIRDER C
GIRDER B
S7L
GIRDER A
S6L
GIRDER E
Location
P1
Q1
R1
S1
5 mm Max.
As per
drawing
Actual
NAME
DOC. NO.:QPE-BR-04-55
PROJECT
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.01
SHEETS
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT
REF.
PSER
D1
D2
D1~D2
A&B
B&C
C&D
D&E
Girder
Designation
Towards Right
Girder A
Girder B
Girder C
Girder D
Girder E
NAME
DOC. NO.:QPE-BR-04-55
PROJECT
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.01
SHEETS
INSTRUMENT REGN.NO.
DATE OF INSPECTION
PSER
DRAWING / DOCUMENT
REF.
Activity
Observation
Erection completion of :
a) All columns
b) Horizontal beams between columns
c) Vertical bracings and tie members
d) Horizontal bracing on all main brace levels (MBLs)
e) Ceiling girders, welded beams (WBs), rolled beams (RBs)
required for drum lifting & ceiling bracings.
3.
Welding completion
4.
NDE completion
5.
6.
7.
Remarks :
NAME
DOC. NO.:QPE-BR-04-55
PROJECT
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.01
SHEET
INSTRUMENT REGN.NO.
DATE OF INSPECTION
DRAWING / DOCUMENT
REF.
PSER
DOC.NO.:QPE-BR-04-55
PROJECT
INSPECTED BY
REV.NO.: R00
UNIT NO.
CLEARED BY
RATING
CUSTOMER
SHEET
FMT-QP-008 REV.01
2 / 2 SHEETS
FEEDBACK ON
QUALITY PLAN FOR INSTALLATION
PSER
In the Quality Plan for Installation (QPI), following Checks / Log sheets may be added /
rewritten / deleted (cannot be carried out / not required) due to reasons as mentioned below :
Sheet No.
Of QPI
PROJECT
UNIT NO.
RATING
Check No. /
Log Sheet No.
From :
To
Head (Quality) , BHEL , PSER
DJ 9/1, Sector II,
Salt Lake,
Kolkata 700 091
DOC.NO. QPE-BR-04-55
REV. NO. R00
SHEET 1 / 1 SHEET
FMT-QP-001 REV.01
PREPARED BY
APPROVED BY
SR MANAGER/QLY, PSER
DOCUMENT NO.
QPE - CL -04-51
20.08..2004
R00 / 20.08.2004
COPY NO.
ISSUED TO
DATE OF ISSUE
CONTROLLED / INFORMATION COPY
ISSUED BY
(SIGNATURE & DESIGNATION)
CONTENTS
PSER
S.NO.
DESCRIPTION
SHEETS
NO. OF SHEETS
1.
STATUS OF AMENDMENTS
2.
3.
Bricks
iii)
Earth Work
iv)
Cement
v)
vi)
Course Aggregate
vii)
Reinforcing Steel
viii)
Water
ix)
x)
xi)
Embedded Parts
xii)
Concreting
xiii)
Testing
xiv)
xv)
Water Supply
xvi)
xvii)
24
Bitumen Top
xx)
Plastering
xxi)
Suspended Ceiling
xxii)
4.
ANNEXURES (I TO VI )
12
5.
6.
FMT-QP-003 REV.00
STATUS OF AMENDMENTS
PSER
SL.
NO.
REFERENCE
OF SHEETS
AMENDED
AMENDMENT NO.
& DATE
- NIL -
FMT-QP-016 REV.00
REMARKS
SHEETS
Classification of checks
Inspection agency
Clearing agency
Symbol
Description
Critical
Major
Task performer
HOS
Minor
Task performer
Task performer
Legend :
Task performer
&
surveillance by QAE
(if available)
HOS
HOS
QAE
Note :
FMT-QP-004 REV.01
Classification of checks
Symbol
Checking Authority
Accepting Authority
Customer
&
BHEL
Customer
&
BHEL
Description
Critical
Major
Customer
&
BHEL
Customer
&
BHEL
Minor
BHEL
BHEL
Legend
Customer :
M/S DVC
Note :
FMT-QP-004 REV.00
DVC shall witness "A" category checks. He is also authorised to carry out
surveillance in any of the "B" and "C" category of checks at his discretion.
STATEMENT OF CHECKS
PSER
Capacity / Type :
2 X 250 MW
System :
Civil
Sub-system :
------------------------
Area :
Erection
/ 24
SHEETS
NOTES :
1. For checks where logsheets are not called for, suitable records should be maintained
in the form of logsheets / protocols.
2. As an evidence of having carried out the work satisfactorily, a general purpose
logsheet, L-00 shall be maintained for all the checks.
3. Drawing / Contract requirements shall apply over and above the checks given.
4. Abbreviations used in the column Type of check are:
R : Record verification
M: Measurement
V : Visual
P : Physical
T : Test
FMT-QP-005 REV.00
STATEMENT OF CHECKS
PSER
1.0
CHARACTERSTICS
FMT-QP-006 REV.00
TYPE OF
CHECK
INSTRUMENT
REFERENCE
DOCUMENT
Annexure-I
QPX - CL 04-51
REV.NO.
R 00
SHEET
AREA : ERECTION
CLASS
DOC. NO.
QUANTUM /
FREQUENCY
OF CHECK
100%
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
AREA : ERECTION
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET 3
CLASS
REFERENCE
DOCUMENT/
ACCEPTANCE
STANDARD
QUANTUM /
FREQUENCY OF
CHECK
IS1077
IS1077
2.3
Steel Tape
2.4
Compressive
Strength
Testing
machine
2.5
Weigh
balance, Oven
2.6
S.NO
.
CHARACTERSTICS
TYPE OF
CHECK
2.0
BRICKS :
2.1
Ensure that the bricks are free from cracks, warpage and
of uniform colour.
2.2
FMT-QP-006REV. 01
INSTRUMENT
IS1077
24 SHEETS
FORMAT OF
RECORD
REMARKS
STATEMENT OF CHECKS
PSER
3.0
CHARACTERSTICS
TYPE OF
CHECK
INSTRUMENT
R 00
Annexure-II
As per
Annexure-II
IS 2720
IRC-37
IS 2720
IRC-37
As per
Annexure-II
As per
Annexure-II
Protocol
As per
Annexure-II
As per
Annexure-II
As per
Annexure-II
Protocol
Oven, Weigh
balance
Oven, Weigh
balance
IS 2720
IS 2720
IS 2720
FORMAT OF
RECORD
24 SHEETS
QUANTUM /
FREQUENCY
OF CHECK
REV.NO.
REFERENCE
DOCUMENT
QPX - CL 04-51
SHEET 4 /
AREA : ERECTION
CLASS
DOC. NO.
REMARKS
Protocol
As per IS 2720
b)
As per IS 2720
As per IS 2720
c)
FMT-QP-006REV. 01
Protocol
Protocol
STATEMENT OF CHECKS
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
PSER
CHARACTERSTICS
TYPE OF
CHECK
INSTRUMENT
CLASS
REFERENCE
DOCUMENT
4.0
CEMENT :
Annexure-III
4.1
Test
Certificate
IS269, IS455,
IS4031,
IS1489-1
24 SHEETS
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
REMARKS
One sample
from each
lot received
from store
Consistency of cement
Vicat Needle
L-01
Vicat Needle
L-02
c)
Compressive
Testing Machine,
Cube
Mould,
Vibrator, Curing
chambers,
Standard Sand
Protocol
a)
4.2
AREA : ERECTION
100%
V/P
100%
c)
V/P
100%
V/P
100%
a)
FMT-QP-006REV. 01
STATEMENT OF CHECKS
PSER
CHARACTERSTICS
5.0
5.1
TYPE OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
DOC. NO.
QPX-CL- 04-51
REV.NO.
R 00
SHEET
QUANTUM /
FREQUENCY OF
CHECK
FORMAT OF
RECORD
Annexure-III
M
Measuring jar
Weigh balance
Sieve set, oven
Test
certificate
IS383, IS515,
IS2386
As per
Annexure- III
Protocol
Test
certificate
IS383, IS515,
IS2386
As per
Annexure-III
Protocol
Bulking of sand
Moisture content
f)
Dleterious materials
g) Petrographic examination
h) Soundness
i)
5.2
L-03
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
CHARACTERSTICS
TYPE OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
DOC. NO.
QPX-CL-04-51
REV.NO.
R 00
SHEET
7 /
QUANTUM /
FREQUENCY OF
CHECK
FORMAT OF
RECORD
As per
Annexure-III
Protocol
Annexure-III
6.0
6.1
a)
b) Moisture content
c)
Specofoc gravity
d) Crushing Strength
e)
Bulk density
f)
g) Voids
M/V
h) Soundness
Lab Test
i)
Lab Test
j)
Petrographic examination
V/P
k) Deleterious materials
Lab Test
l)
Lab Test
m) Flakiness
FMT-QP-006REV. 01
Lab Test
Test certificate,
IS383, IS515,
IS2386
L-04
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
CHARACTERSTICS
7.0
REINFORCING STEEL
7.1
7.2
a)
b)
c)
Bend Test
AREA : ERECTION
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
TYPE OF
CHECK
INSTRUMENT
CLASS
REFERENCE
DOCUMENT
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
Verification of
Test
Certificate
IS1786,
IS432 IS1566
& Drawing
Each Lot /
Batch
Test Certificate
Random
Random
Random
Protocol
b) Dimension
c)
7.3
7.4
Ensure that the joints and crossing bars are tied properly
with right gauge wire.
7.5
Screw Gauge
Protocol
Measuring
Tape
Annexure-III
Drawing &
IS2502
100%
Drawing
100 %
Drawing &
IS456
100%
24 SHEETS
REMARKS
FMT-QP-006REV. 01
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : STEEL
S.NO
.
CHARACTERSTICS
TYPE OF
CHECK
7.6
FMT-QP-006REV. 01
Measurement
Tape
CLASS
REFERENCE
DOCUMENT
Drawing
QPX - CL 04-51
REV.NO.
R 00
SHEET
AREA : ERECTION
INSTRUMENT
DOC. NO.
QUANTUM /
FREQUENCY
OF CHECK
100%
9 /
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : WATER
CHARACTERSTICS
TYPE OF
CHECK
8.0
8.1
8.2
8.3
AREA : ERECTION
INSTRUMENT
Testing
Indicator
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
10 /
CLASS
REFERENCE
DOCUMENT
QUANTUM /
FREQUENCY
OF CHECK
Annexure-III,
Test
certificate
Once a
month per
source
Annexure-III,
IS 3025 &
IS456
Once a
month per
source
Annexure-III,
IS 3025 &
IS456
Once a
month per
source
Annexure-III,
IS456
Once a
month per
source
FORMAT OF
RECORD
Site logbook
Site logbook
8.4
FMT-QP-006REV. 01
Lab Test
PH Meter
Site logbook
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : BRICKS
CHARACTERSTICS
9.0
9.1
9.2
TYPE OF
CHECK
AREA : ERECTION
INSTRUMENT
SHEET
11 /
P/V
Annexure-III
100%
100%
Drawing
100%
c)
Spirit Level,
plumb bob
Drawing
100%
Drawing/
Design
100%
Drawing
100%
Drawing
100%
Drawing
100%
Drawing
100%
R /V /P
(i)
Soundness of material
M/ V
(ii)
(iii)
Proper support
(iv)
FMT-QP-006REV. 01
R 00
QUANTUM /
FREQUENCY
OF CHECK
Measuring
Tape
e)
REV.NO.
REFERENCE
DOCUMENT
d) Staging
QPX - CL 04-51
CLASS
DOC. NO.
Hammer
Plumb bob
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
S.NO
.
CHARACTERSTICS
TYPE OF
CHECK
9.3
P/V
9.4
P/V
FMT-QP-006REV. 01
INSTRUMENT
AREA : ERECTION
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
12 /
CLASS
REFERENCE
DOCUMENT
QUANTUM /
FREQUENCY
OF CHECK
Drawing
100%
100 %
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
CHARACTERSTICS
10.0
10.1
Concrete Mixer
d) Lighting
e)
Air compressor
f)
Pumps
Generator
j)
Winches
k) Cranes
l)
FMT-QP-006REV. 01
TYPE OF
CHECK
V/P
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
13 /
QUANTUM /
FREQUENCY
OF CHECK
100%
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : BRICKS
CHARACTERSTICS
AREA : ERECTION
TYPE OF
CHECK
INSTRUMENT
REV.NO.
R 00
SHEET
14 /
REFERENCE
DOCUMENT
QUANTUM /
FREQUENCY
OF CHECK
100%
EMBEDDED PARTS :
11.1
Dumpy level,
Measuring
Tape
Drawings
b)
Drawings
c)
Measuring
Tape
Measuring
Tape
Drawings
d)
Drawings
11.2
Drawings
11.3
Drawings
11.4
Drawings
FMT-QP-006REV. 01
QPX - CL 04-51
CLASS
11.0
Plumb
bob,
Measuring
Tape
Measuring
Tape
DOC. NO.
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : CONCRETING
CHARACTERSTICS
12.0
CONCRETING :
12.1
TYPE OF
CHECK
INSTRUMENT
REFERENCE
DOCUMENT
Test certificate
IS456, IS1199
As per
Annexure-III
L-05
Test certificate
IS456, IS1199
As per
Annexure-III
Protocol
b)
12.2
IS456
12.3
V/R
Test certificate
12.4
12.5
FMT-QP-006REV. 01
15 /
Annexure-III
Test
R 00
FORMAT OF
RECORD
REV.NO.
QUANTUM /
FREQUENCY
OF CHECK
a)
a)
QPX - CL 04-51
SHEET
AREA : ERECTION
CLASS
DOC. NO.
P/M
A
Volume/weigh
batching
Slump Cone
IS456, IS2386
Part III IS1199
Annexure-IV
100%
100%
As per
Annexure-III
100%
Drawings
100%
L-05
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
12.6
SUB-SYSTEM : CONCRETING
CHARACTERSTICS
TYPE OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
c)
Thermometer
IS456
100%
M/P
Thermometer
IS456
100%
e)
: 24 to 48 hours
Slab (props left under)
: 3 days
Beams soffits (props left under)
: 7 days
Removal of props to slabs span less than 4.5m : 7 days
Removal of props to slabs spanning over 4.5m : 14 days
Removal of props to beams and arches
: 14 days
Spanning upto 6 m
FMT-QP-006REV. 01
100%
Drawing
100%
100%
QPX - CL 04-51
REV.NO.
R 00
SHEET
16 /
QUANTUM /
FREQUENCY
OF CHECK
DOC. NO.
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : CONCRETING
CHARACTERSTICS
TYPE OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
QUANTUM /
FREQUENCY
OF CHECK
12.8
between
Drawing
100%
100%
100%
100%
100%
FMT-QP-006REV. 01
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
17 /
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : TESTING
CHARACTERSTICS
TYPE OF
CHECK
13.0
TESTING :
13.1
Lab Test
13.2
Lab Test
13.3
13.4
13.5
FMT-QP-006REV. 01
AREA : ERECTION
INSTRUMENT
CLASS
REFERENCE
DOCUMENT
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
18 /
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
L-05
IS456, IS2911
Annexure-V
IS516, IS2911
Annexure-III
Test results
IS516, IS2911
100%
Load Test
IS456
Protocol
IS13311-II
Protocol
Compressive
Test Machine
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : MISCELLANEOUS
CHARACTERSTICS
TYPE OF
CHECK
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
DOC. NO.
QPX - CL 04-51
REV.NO.
R 00
SHEET
19 /
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
Protocol
14.0
14.1
Drawing
100%
14.2
Drawing
100%
15.0
WATER SUPPLY :
15.1
Drawing
100%
15.2
Drawing
100%
15.3
Pressure Gauge
Drawing
100%
Protocol
16.0
16.1
Levelling
instrument
Drawing
100%
Protocol
16.2
Drawing
100%
16.3
Drawing
100%
16.4
Ensure that all pipe i.e. fittings and fixtures are as per
relevant code and as per drawing.
Drawing
100%
FMT-QP-006REV. 01
Measuring Tape,
Levelling
instrument
Protocol
Protocol
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : MISCELLANEOUS
CHARACTERSTICS
TYPE OF
CHECK
17.0
17.1
17.2
to
17.3
17.4
18.0
WEATHERING COURSE :
18.1
18.2
19.0
BITUMEN TOP :
19.1
20.0
PLASTERING :
20.1
FMT-QP-006REV. 01
M
prior
INSTRUMENT
Dumpy Level
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
Drawing
100%
100%
V/M
Steel Tape
REV.NO.
R 00
SHEET
20 /
FORMAT OF
RECORD
100%
100%
QPX - CL 04-51
QUANTUM /
FREQUENCY
OF CHECK
Dumpy Level
DOC. NO.
Drawing
100%
Drawing
100%
Drawing
100%
Drawing
Random
Test
Protocol
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : MISCELLANEOUS
S.NO
.
CHARACTERSTICS
TYPE OF
CHECK
20.2
20.3
21.0
SUSPENDED CEILING :
21.1
M/V
21.2
21.3
22.0
22.1
23.0
Roof Decking :
a)
-
FMT-QP-006REV. 01
INSTRUMENT
Steel Tape
CLASS
REFERENCE
DOCUMENT
Drawing
Steel Tape
REV.NO.
R 00
SHEET
21 /
QUANTUM /
FREQUENCY
OF CHECK
FORMAT OF
RECORD
100%
Protocol
Drawing,
IS8183
100%
Drawing,
IS8183
100%
Sample Test
Measuring
Tape
QPX - CL 04-51
100%
Verification
AREA : ERECTION
DOC. NO.
Annexure-VI
Drawing
100%
Sample Test
Protocol
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : MISCELLANEOUS
INSTRUMENT
AREA : ERECTION
CLASS
REFERENCE
DOCUMENT
QPX - CL 04-51
REV.NO.
R 00
SHEET
22 /
CHARACTERSTICS
TYPE OF
CHECK
Sample Test
100%
IS 3618
QUANTUM /
FREQUENCY
OF CHECK
Sample Test
24.0
DOC. NO.
RECORDS :
Prepare logsheets / Protocols as per drawing and record
the following :
a)
b) Elevation / levels
c)
Slope
d) Pitch / Diagonals
e)
Spacing / Diagonals
FMT-QP-006REV. 01
V/M
Steel
Tape,
Dumpy Level,
Theodolite
Drawing
100%
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
25.0
SUB-SYSTEM : RECORDS
CHARACTERSTICS
TYPE OF
CHECK
AREA : ERECTION
INSTRUMENT
INNER SHEETS
i)
ii)
iii)
Dimensional
conformities
including
thickness, Rib depth, cover width.
Measuring
Tape
iv)
Weighing
machine
v)
ii)
iii)
Measuring
Tape
iv)
Magnetic
Gauge
FMT-QP-006REV. 01
QPX - CL 04-51
REV.NO.
R 00
SHEET
23 /
CLASS
REFERENCE
DOCUMENT
QUANTUM /
FREQUENCY
OF CHECK
Drawing /
Specification
100%
Drawing /
Specification
100%
DOC. NO.
FORMAT OF
RECORD
24 SHEETS
REMARKS
STATEMENT OF CHECKS
PSER
SUB-SYSTEM : RECORDS
CHARACTERSTICS
c)
TYPE OF
CHECK
AREA : ERECTION
INSTRUMENT
CLASS
REFERENCE
DOCUMENT
M/V
i)
ii)
iii)
iv)
FMT-QP-006REV. 01
V/ M
Measuring
Tape
Water level /
Plumb
Measuring
Tape
QPX - CL 04-51
REV.NO.
R 00
SHEET
24 /
QUANTUM /
FREQUENCY
OF CHECK
Thermal Insulation
DOC. NO.
100%
100%
FORMAT OF
RECORD
24 SHEETS
REMARKS
Annexure - I
DOC. NO. QPE-CL-04-51
REV.NO. R00
SHEET No. 1 of 2
RECOMMENDED LABORATORY EQUIPMENTS / MEASURING DEVICES / INSTRUMENTS FOR CIVIL WORKS
Sl. No.
1.
Broad Class
Routine Test Lab.
Equipments
Nomenclature Description
Utility
Test Procedure
Code Ref.
IS 5513
Cement shrinkage
Cement Cubes
IS 10086
Cube Compaction
IS 10078
Concrete Cubes
Concrete Cube Test
IS 2505
Workability check
IS 7320
Sieve analysis
Sieving
IS 383
Sieve analysis
Sieving
IS 383
Mechanical shieving
IS 5514
IS 10086
IS 9377
Annexure - I
DOC. NO. QPE-CL-04-51
REV.NO. R00
SHEET No. 2 of 2
RECOMMENDED LABORATORY EQUIPMENTS / MEASURING DEVICES / INSTRUMENTS FOR CIVIL WORKS
Sl. No.
2.
3.
Broad Class
Dimensional & Allied
Measuring Equipment
Process Control
accessories
Nomenclature Description
Utility
Dimension
3.1 Oven
Weighing
Measuring PH value
Test Procedure
Code Ref.
IS 456, IS
2720
PSER
DOCUMENTS REFERRED IN
QUALITY PLAN
Sl. No.
Reference Document
SHEETS
Issuing Authority
Drawings
PEM
2.
IS 269, 370, 383, 432, 455, 456, 515, 516, 1077, 1199, 1489-1,
1566, 1786, 2386 part 1 to 7, 2502, 2720, 2911, 3025, 3616,
4031, 4351, 5513, 5514, 7320, 8183, 9377, 10078, 10086,
13311 - II
FMT-QP-017 REV.00
Annexure - II
DOC. NO. QPE-CL- 04-51
REV NO. R00
SHEET NO. 1 of 2
FREQUENCY OF SAMPLING AND TESTING
SL No.
Method of Test
Remarks
EARTH WORK
Suitability of Fill Materials
(a)
Grain size Analysis
(b)
IS:2720 (Part V)
(c)
Shrinkage Limit
IS:2720(Part VI)
(d)
(e)
Chemical Analysis
IS:2720 (Part 5)
(i)
Organic matter
Part XXII
(ii)
Calcium Carbonate
Part XXIII
(iii)
PH
Part XXVI
(iv)
Part XXVII
II.
III
Annexure - II
DOC. NO. QPE-CL04-51
REV NO. R00
SHEET NO. 2 of 2
FREQUENCY OF SAMPLING AND TESTING
SL No.
Nature of Test /
Characteristics
IV
Method of Test
i.
ii.
Remarks
Standard Practice
d) Permeability Test .
Standard Practice
Random checks
Annexure - III
DOC. NO. QPE-CL-04-51
REV NO. R00
SHEET NO. 1 of 5
FREQUENCY OF SAMPLING AND TESTING
Nature of Test /
Characteristics
SL No.
I
Method of Test
Remarks
Coarse Aggregates
e) Particle size and shape
1S:2386 (Part I)
f)
IS:2386 (Part 3)
Moisture content
Once in 12 weeks or
change of source,
whichever is earlier.
h) Mechanical properties,
IS:2386 (Part 4)
crushing value, abrasion
value and impact value.
i)
Soundness
IS:2386 (Part 5)
j)
IS:2386(Part 7)
k) Flakiness and
petrographic
examinations
IS:2386
h) Deleterious materials
IS:2386(Part 2)
Annexure - III
DOC. NO. QPE-CL04-51
REV NO. R00
SHEET NO. 2 of 5
SL No. Nature of Test /
Characteristics
II
Method of Test
Remarks
IS:2386 (Part l)
b) Specific gravity
density voids,
absorption and
bulking.
IS:2386 (Part 3)
Once in 12 weeks or
change of source
whichever is earlier.
c) Bulkage, moisture
IS:2386 (Part 3)
content (Routine test)
To be done everyday
before start of work.
IS:2386 (Part 2)
e) Soundness and
Petrographic
examination.
IS:2386(Part 5&8)
f)
IS:2386 (Part 6)
IS:2386(Part 7)
Mortar making
properties.
Annexure - I
DOC. NO. QPE - CL 04-51
REV. NO. R00
SHEET NO. 3 OF 5
SL No. Nature of Test /
Characteristics
III
IV.
Method of Test
a. Setting time
IS:4031
b. Compressive
Strength
c. Fineness
IS:4031
CEMENT
WATER
Harmful substances,
IS-3025, IS:4031 &
pH value, initial setting IS:516
time, compressive
strength.
V.
Remarks
CONCRETE
a)
b)
Workability
(Slump and
compaction factor).
IS: 1199
ii)
As per Cl.
14.2.2 of IS:4561978 for initial
period.
c) Water cement
ratio.
IS:1199
d) Cement Content
IS:1199
e) Water-tightness
test (for water
retaining
Structures).
IS:370
Each tank or
reservoir.
f)
Physical
measurement
All structures
Finished:dimensions
Annexure - III
DOC. NO. QPX CL- 04-51
REV. NO. R00
SHEET NO. 4 OF 5
SL
No.
Nature of Test /
Characteristics
Method of Test
Remarks
Each member
b) Shuttering
i)
Materials
Visual
Random
ii)
Joints
Visual
Random
iii)
Dimensions
and plumb
Tolerances as per
Specifications.
Annexure - III
DOC. NO. QPE - CL 04-51
REV. NO. R00
SHEET No. 5 of 5
SL.
No.
VII.
VIII
Nature of Test /
Characteristics
Method of Test
Remarks
REINFORCEMENT
a) Placement
Visual/
Measurement
each
b) Cutting tolerance
Physical
measurement
Random
Visual
Random
d) Tensile strength
Lab test
EMBEDDED PARTS
a) Type of embedment
Visual/
Measurement
Each part
b) Location
Physical/
Measurement
-do-
Annexure - IV
DOC. NO. QPE - CL 04-51
REV. NO. R00
SHEETNO. 1 of 1
METHOD FOR DETERMINATION OF SLUMP OF CONCRETE
Slump test
As per IS 1199
Objective : To determine the consistency of fresh concrete and to check the uniformity
of concrete from batch to batch.
Test Procedure
1. Internal surface and mould should be cleaned thoroughly to make it free from
moisture and any set concrete.
2. Place the mould on levelled metal plate.
3. The internal surface of the mould (cone) shall be thoroughly cleaned and free from
superfluous moisture and any set concrete.
4. The mould shall be placed on a smooth, horizontal rigid and non-absorbent surface
(such as carefully levelled metal plate)
5. Cone shall be filled in four layers, each approximately one Quarter of the height of the
mould.
6. Each layer shall be tamped with 25 strokes of the rounded end of the tapping rod in
such a manner that the strokes are uniformly distributed over the cross section of the
mould and for the second and subsequent layers the rod to be penetrated into the
underlying layers.
7. After the top layer has been rodded the concrete shall be struck off level with a trowel
or tapping rod.
8. Leaked out mortar between the mould and the base plate is cleaned away.
9. The mould should be removed from the concrete immediately by raising it slowly and
carefully in a vertical direction.
10. The slump shall be measured immediately. (The slump can be measured by keeping
the tamping rod on the inverted mould and thus measuring the difference between the
height of the mould and that of the highest point of the specimen being tested).
NOTE:i)
The test is to be carried out at a place free from vibration or shock and within two
minutes of sampling.
ii)
Slump specimen which collapsed or sheared off laterally should be rejected and
another test should be carried out.
iii)
Annexure - V
DOC. NO. QPE - CL 04-51
REV. NO. R00
SHEET NO. 1 of 1
a) Age Test :
The age shall be calculated from the time of the addition of the water to the dry ingredients.
The testing shall be carried out at the age of 7 days and 28 days.
b) Number of Specimens :
Three specimen from different batches.
c) Procedure :
Specimens stored in water shall be tested immediately on removal from the water, in
testing machine. The load shall be applied without shock and increased continuously at
the rate of approx. 140 kg/ cm2/min, Until the resistance of the specimen to the increasing
load breaks down and no greater load can be sustained. The maximum load applied to the
specimen shall then be recorded.
d) Calculation :
Compressive Strength (kg / cm2)
Annexure - VI
DOC.NO. QPE-CL-04-51
REV. NO. R00
SHEET No. 1 of 1
BOUGHT OUT ITEMS
Check the following bought out items for their specifications / IS codes before use
i.
Teak wood
ii.
Grout Materials
iii.
iv.
v.
vi.
vii.
Rolling shutters
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
Asbestos rope
xv.
Mineral wool
xvi.
Vineertax
xvii.
xx.
xxi.
xxii.
Galvanised pipeline for water supply including fittings, C I pipes, RCC non-pressure pipes
Note :1) Customer may witness the tests at manufacturers' premises or at laboratory as and when
felt necessary.
SHEET
NO. OF QPI
CHECK
NO.
RESULTS
ACHIEVED
OK / NOT
OK
DRAWING /
DOCUMENT
REFERENCE
FORMAT OF
RECORD
CHECKED BY
SIGN. & DATE
REMARKS
ACCEPTED BY
SIGN. & DATE
Note : Any protocol made is to be numbered & mentioned in Format of Record column.
SYSTEM
SUB-SYSTEM
AREA
PROJECT
UNIT NO.
RATING
SHEET
FMT-QP-007 REV. 00
SHEETS
DATE OF INSPECTION
PSER
This method is for determining the quantity of water required for preparing a cement paste of
standard consistency. This can be performed by vicat apparatus.
Date of Testing
Reading recorded by analyst
Weight of sample
mould
_________________gms
Quantity of water
_________________ ml
Time of gauging
_________________ min.
Formula
Consistency
3 to 5 min.
5 to 7 from bottom of the mould
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
LOGSHEETNO. L-01
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
(VICAT APPARATUS)
Date of testing
Weight of sample
mould
_________________gms
Quantity of water
_________________ ml
min/sec
iii)
min. / sec.
Specification :
Initial (mins.) Min 30 min.
Final (mins.) Max 600 min.
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
LOGSHEETNO. L-02
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
(FINE AGGREGATE)
Date of testing
Weight of sample
_________________gms
___________________
Sl.
No.
Retained on
IS Sieve No.
1.
10 mm
2.
4.74 mm
3.
2.36 mm
4.
1.18 mm
5.
600 microns
6.
300 microns
7.
150 microns
8.
75 microns
Weight Retained
Type of Aggregate :
Percentage Weight
Retained
Cumulative %
Weight
Retained
Percentage Passing
IS Sieve Designation
Grading Zone I
Grading Zone II
Grading Zone IV
10 mm
100
100
100
100
4.75 mm
90 - 100
90 - 100
90 - 100
95 - 100
2.36 mm
60 - 95
75 - 100
85 - 100
95 - 100
1.18 mm
30 - 70
55 - 90
75 - 100
90 - 100
600 microns
15 - 34
35 - 59
60 - 79
80 - 100
300 microns
5 - 20
8 - 30
12 - 40
15 - 50
150 microns
0 - 10
0 - 10
0 - 10
0 - 15
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
LOGSHEETNO. L-03
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
SIEVE ANALYSIS
GRADING OF COARSE AGGREGATE
Date of testing
Weight of sample
Sl.
No.
Retained on
IS Sieve No.
1.
10 mm
2.
20 mm
3.
16 mm
4.
12.5 mm
5.
10 mm
6.
4.75 mm
7.
2.36 mm
_________________gms
Weight Retained
Percentage Weight
Retained
Cumulative %
Weight
Retained
Percentage Passing
IS Sieve Designation
40 mm
20 mm
16 mm
12.5 mm
10 mm
95 - 100
100
20 mm
30 - 70
95 - 100
100
100
16 mm
90 - 100
12.5 mm
90 - 100
10 mm
10 - 35
25 - 55
30 - 70
40 - 85
4.75 mm
0-5
0 - 10
0 - 10
0 - 10
2.36 mm
NAME
SIG. / DATE
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
LOGSHEETNO. L-04
RATING
FMT-QP-008 REV. 00
CUSTOMER
SHEET 1 / 1 SHEETS
DATE OF INSPECTION
PSER
Sl. Date
Cube
No
of
Identificati
. Casti on Mark
ng
Location / Structure :
Slu
mp
(mm)
Concrete
Date Age Weig
Quantity from
of
of
ht of
which
Testin Cub Cube
sampling done
g
e
NAME
Compression
Strength / mm2
Individual Average
SIGNATURE / DATE
Remarks
PROJECT
CHECKED BY
UNIT NO.
ACCEPTED BY
RATING
FMT-QP-009 REV. 00
CUSTOMER
SHEET
SHEETS