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LEGEND:
P-Perform MTC-Manufacturer test certificate WPS-Welding procedure Specification
R-Review DPT- Dye Penetrant Testing PQR-Procedure Qualification Record
W-Witness NDT- Non Destructive Testing WPQ-Welder Performance Qualification
RW-Random witnessBGR Doc. No.: BGR-PPD-0208-EL-MQP-0494, REV 02, DATED: 12.03.15
VENDOR Doc. No.: RPECPL/BGR/OPGCL/QAP/STR/001, REV 02, DATED: 11.02.15
PREPARED BY
R.SHREEVATSAN
APPROVED BY
K.KALYANARAMAN
MANUFACTURING INSPECTION AND TEST PLAN
for structural materials for Equipment Mounting and Towers
REVIEWED BY
S.CHANDRASEKAR
BGR ENERGY SYSTEMS LIMITED
POWER PROJECTS DIVISION
443, ANNA SALAI, TEYNAMPET
CHENNAI - 600 018
PROJECT: 2 X 660 MW IB TPS , ODISHA POWER GENERATION CORPORATION LTD
Page 1 of 4
Contractor BGR Customer
1.0
Visuals & Dimensions MajorVisual/
MeasurementRandom Appvd. Drg./GTP P R R Mfg. TR/LAB TC
Mechanical Properties Major Verification 2/heat IS: 2062 P R R Mfg. TR/LAB TC
Chemical Properties Major Verification 1/heat IS: 2062 P R R Mfg. TR/LAB TC
Ultrasonic Test of Plate thickness ≥
25mmMajor Verification 100% ASTM A 435 P R R
Visuals & Dimensions MajorVisual/
MeasurementRandom Appvd. Drg./GTP P R R Mfg. TR/LAB TC
Mechanical Properties, Chemical
Properties and HardnessMajor Verification Sample
IS:1367-3 /IS:1367-
6P R R Mfg. TR/LAB TC
Hot Dip galvanizing Major Verification Sample IS:1367-13 P R R Mfg. TR/LAB TC
Visuals & Dimensions MajorVisual/
MeasurementRandom Appvd. Drg./GTP P R R
Mechanical Properties Major Verification Sample IS 4072/ IS 1079 P R R
Chemical Properties Major Verification Sample IS 4072/ IS 1079 P R R
Electro Galvanised ( Only for Spring
Washer )Major Verification Sample IS 1573 P R R
Visuals & Dimensions MajorVisual/
MeasurementRandom Appvd. Drg./GTP P R R Mfg. TR/LAB TC
Mechanical Properties Major Verification Sample IS:2062 P R R Mfg. TR/LAB TC
Chemical Properties Major Verification Sample IS:2062 P R R Mfg. TR/LAB TC
Hot Dip galvanizing Major Verification SampleAppvd. Drg./IS:
2629P R R Mfg. TR/LAB TC
1.1
Washers1.3
1.4
RATAN PROJECTS & ENGG. CO. PVT. LTD.
26, PRASANNA KUMAR TAGORE STREET,
KOLKATA – 700 006
VENDOR: RATAN PROJECTS & ENGG.CO.(P) LTD.
Raw Material / Equipment Items
NAME :
QUALITY ASSURANCE PLAN
Doc. No: RPECPL/BGR/OPGCL/QAP/STR/001
Project: 2X660 MW, IB TPS, BANAHARPALLI
CONTRACTOR: BGR ENERGY SYSTEMS LTD
Package/Equipment :
SWITCHYARD TOWERS & SUPPORTING STEEL STRUCTURALS
Foundation Bolts
Supplier TC
/ Internal
Test Report
RemarksFormat of
Record
Ref documents &
Acceptance std
Class of
Check
CLIENT : ODISHA POWER GENARATION CORPORATION LTD.
Date : 11.02.2015 P.O. NO. 3500006202, Date : 09.12.2014
Rev. No : 02
Inspecting AgencyItem/Component &
OperationCharacteristics Type of checkS.NO
1.2
NAME :
BGRESL
Quantum/
Frequency of
check
Structural/plates
SIGNATURE :
CUSTOMER
SIGNATURE : SIGNATURE :
NAME :
Bolts, Nuts
Page 2 of 4
Contractor BGR Customer
RATAN PROJECTS & ENGG. CO. PVT. LTD.
26, PRASANNA KUMAR TAGORE STREET,
KOLKATA – 700 006
QUALITY ASSURANCE PLAN
Doc. No: RPECPL/BGR/OPGCL/QAP/STR/001
Project: 2X660 MW, IB TPS, BANAHARPALLI
CONTRACTOR: BGR ENERGY SYSTEMS LTD
Package/Equipment :
SWITCHYARD TOWERS & SUPPORTING STEEL STRUCTURALS
RemarksFormat of
Record
Ref documents &
Acceptance std
Class of
Check
CLIENT : ODISHA POWER GENARATION CORPORATION LTD.
Date : 11.02.2015 P.O. NO. 3500006202, Date : 09.12.2014
Rev. No : 02
Inspecting AgencyItem/Component &
OperationCharacteristics Type of checkS.NO
Quantum/
Frequency of
check
1.5Welding Electrode (batch
certificate)Verification of batch certificate Major Verification Sample
Apprd. Drwg/
Related std
Supplier
TC/Internal
Test Report
P R R
1.6 Zinc Ingot Quality of Zinc Major VerificationSample per
Lot/Batch
IS:2629/IS:209/IS:1
3229MTC P R R
2
2.1Materials Marking, Cutting,
Drilling, PunchingVisual & Dimensions Major
Visual/Measur
ement100% Appvd. Drg./GTP P R ….
Match Marking will be done
in black Condition
2.2 Welding Control Verification of WPS/PQR/WPQ Major Visual 100% ASME SEC IX P R R
IF already approved
established procedure is
available, then review or
else witnessed by customer
2.3 Final Welding Visual & Dimensions Major Visual10%
Random
Mfg. Drg/ Data
SheetP R R
2.4 NDT DPT on Welds Major Visual 100% ASTM E165 Report P R R
Mfg.
record/In
process
Report
P W
In Process
Mfg.
Record/In
process
Report
2.4 Trial Assembly Visual & Dimensions _Tolerance for part
dimension ± 2mm and full
dimension ± 5mm
Major Measurement Appvd. Drg./GTP
BGR ESL
SIGNATURE :
OPGCL
SIGNATURE :
NAME :
1/ Type
NAME :
VENDOR: RATAN PROJECTS & ENGG.CO.(P) LTD.
SIGNATURE :
NAME :
Page 3 of 4
Contractor BGR Customer
RATAN PROJECTS & ENGG. CO. PVT. LTD.
26, PRASANNA KUMAR TAGORE STREET,
KOLKATA – 700 006
QUALITY ASSURANCE PLAN
Doc. No: RPECPL/BGR/OPGCL/QAP/STR/001
Project: 2X660 MW, IB TPS, BANAHARPALLI
CONTRACTOR: BGR ENERGY SYSTEMS LTD
Package/Equipment :
SWITCHYARD TOWERS & SUPPORTING STEEL STRUCTURALS
RemarksFormat of
Record
Ref documents &
Acceptance std
Class of
Check
CLIENT : ODISHA POWER GENARATION CORPORATION LTD.
Date : 11.02.2015 P.O. NO. 3500006202, Date : 09.12.2014
Rev. No : 02
Inspecting AgencyItem/Component &
OperationCharacteristics Type of checkS.NO
Quantum/
Frequency of
check
Surface preparation (Degreasing-
Pickling)Major Mechanical 100%
Appvd. Drg./IS:
2629Log Book P R ….
Quality of Zinc Material Major VerificationSample per
Lot
Appvd. Drg./IS:
2629MTC P R R
Temperature of Zinc Bath Major Visual ContinuousAppvd. Drg./IS:
2629Log Book P R ….
Surface Finish Major Visual 100%Appvd. Drg./IS:
2629Log Book P R ….
Zinc Coating Thickness Major MeasurementProcess
Check
Appvd. Drg./IS:
2629Log Book P R ….
3
3.1Individual Members of
Towers/StructuresVisual & Dimensions Major
Visual/
MeasurementRandom Appvd. Drg./GTP Report P W R
Visual & Dimensions, Marking &
RectificationMajor
Visual/
MeasurementRandom Appvd. Drg./GTP Report P W R
Surface Finish, Distortion Major Visual RandomAppvd. Drg./IS:
2629Report P W R
Adhesion Test Major
Pivoted
Hammer Test/
Knife Test
2 Sample
Per Lot IS: 2629 Report P W R
Zinc Coating Thickness Major Measurement2 Sample
Per LotIS: 6745 Report P W R
Mass of Zinc Coating Major Measurement2 Sample
Per LotIS: 2629 Report P W R
Uniformity of Zinc Coating Major Measurement2 Sample
Per LotIS: 2629 / IS: 2633 Report P W R
4 Packing and Transport …. …. ….
5 Final Documentation Review of documents Major Verification 100%As per approved
QAP
Document
PackageP R R
NAME : NAME :
OPGCL
SIGNATURE :
NAME :
VENDOR: RATAN PROJECTS & ENGG.CO.(P) LTD. BGR ESL
SIGNATURE : SIGNATURE :
Hot Dip Galvanizing
Final Inspection
3.2
2.5 Hot Dip Galvanizing
Included in the supplier Scope
Page 4 of 4