TPCIL/QA&I/ Dt 17-11-2012

To,

M/s. BGR Energy Systems Limited,

443, Anna Salai,

Teynam Pet , Chennai – 600018.

ATTN – Mr. D. Selvam

Dear Sir,

Sub – 2X660 Mw Super Critical Thermal Power Project – Krishna Patnam - Quality Issues at site.

This has w.r.t the discussions had with BGRESL on 02-11-2012 and 08-11-2012 at Krishnapatnam site
office on various issues. The following are our observations.

a) Augmentation of QC man power at site – TPCIL advised to depute SENIOR QUALITY person to
take care of site issues and to close at site level. Till to day we have not received the name of
senior Quality person posted at site.
b) CW Piping –
1) RT and UT procedures with Level- III review /certification not yet submitted even after several
reminders. The deployed NDT agency was not doing the work continuously at site. The RT
demonstration work also not completed. The NDT agency credentials not submitted so far.
2) Corrocoated pipes preservation and housekeeping works at coated pipes area not satisfactory.
The workers are walking and spoiling the coating of the pipes. Hence we decided to inspect the
coated pipes once again before actual trenching.
3) Presently THREE qualified welders were available at site. Needs to be increased.
c) Boiler Pressure Parts -
1) Field welding schedule –Extent of RT , pre heating Post weld Heat treatment for Boiler pressure
parts was discussed on 09-11-2012 in detail and agreed. So far the same was not submitted.
2) The Field welding schedule was not submitted to IBR for approval by BGRESL so far.
3) The welding procedures were completed for SA 106 Gr C/SA 335 P12/SA 213 T2 and SA213 T12
(TiG) . So far the welding procedures were not made available at site.
4) Pressure parts erection methodology not submitted. This is required for us to obtain the
required documents from DEC for submission to IBR authorities at site.
5) Weld map for field joints not yet submitted.
6) For all qualified welders, identity cards not issued.
7) NDT procedures with Level-III review/certification, Pre heat and post weld heat treatment
procedures not submitted.
8) Heat treatment equipments were not mobilized.
9) BARC approval for Pit room not yet submitted.
10) UT equipments and calibration blocks were not made available at site.
11) Welding joints history sheets, weld visual reports etc. formats shall be submitted immly.
12) Welding procedures for the balance materials to be established immly .
13) Action required for the completion of welding on the same day of fit up by increasing the IBR
welders. (Only three welders are available at site out of 11 welders qualified).
14) Welder job card not available with pressure part welders at site.

The above issues were highlighted at site level for several times and the actions were not taken
so far. The above issues were handed over to BGRESL during their visit on 02-11-2012 at site.

Pl. arrange to take the appropriate actions for the above issues immly. We appreciate your
immediate actions for the above.

Thanking you,

Very truly yours

N. Ramakrishna

Head- QA&I

Copy to - Mr. Alluri Nageswara Rao – HOP – TPCIL site.

Mr. William – Head- Project Management- TPCIL site.