PRESSURE PARTS
(ERECTION)
FOR
PRESSURE PARTS
(ERECTION)
FOR
COPY No:
ISSUED TO:
FRT-FQA-002-REV 00
CONTENTS
SL. No
DESCRIPTION
NO. OF SHEETS
1 2. 3. 4. 5. 6
STATUS OF AMENDMENTS AUTHORISATION FOR DIFFERENT CATEGORIES OF CHECKS STATEMENT OF CHECKS DOCUMENTS REFERRED IN QUALITY PLAN LOGSHEETS : L-00 TO L-12 FEEDBACK ON FIELD QUALITY PLAN
1 1 14 1 20 1
FRT-FQP-003-REV 00
STATUS OF AMENDMENTS
SL. NO.
REMARKS
NIL
FRT-FQP-004-REV 00
CLASSIFICATION OF CHECKS
ACCEPTING AUTHORITY
HEAD/FQA
CRITICAL SCL FQE (QC ENGR.) ERECTION ERECTION (QC ENGR.) ERECTION ERECTION HEAD/QA
QAE-INCHARGE
FQE
QAE
FQE
LEGNDS:
QAE -QUALITY ASSURANCE ENGINEER FQE -FIELD QUALITY ENGINEER QC ENGR.-QUALITY CONTROL ENGINEER
NOTE 1. QAE shall witness 'A' category checks. He is also authorised to carry out surveillance in any of B and C category of checks at his discretion. 2. In case of non-conformity, accepting authority shall ensure disposition before accepting 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
STATEMENT OF CHECKS
NOTES: 1. For checks where log sheets are not called for, suitable records should be maintained in the form 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. In case of variation in parameters indicated in the characteristics column, the values mentioned in the drawings shall prevail.
4. The above sub-system covers Drum,Headers,Down comer pipes,Riser pipes/ Super heater connecting links,Panels,Cyclone inlet duct,Cyclone,Cyclone outlet chamber,Vortex finder,Circular to rectangular transition / Loop seal / Downchute panel,Buck stays and furnace guides,Coils and tubes,Primary super heater coil,Secondary and final super heater coil,Re heater , Economiser,,welding,Hardness survey,General and Hydraulic test.
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW PACKAGE: EPC CONTRACT No.: EBJ 072 & 073
QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS/ITEM
INSTRUMENT
1.0 1.1
DRUM Check the inspecting authority's stamp on drum and certificate. Readiness of structure for boiler drum erection.
V/R
100%
1.2
V/R
100%
Ground inspection of drum,its orientation. Ensure clearance between drum and structural members during hoisting. Drum suspension 'U' rod dimensions and freeness of nuts. Drum suspension supports alignment. Alignment of drum. Minimum projection of threads above the nuts in the drum suspension rods.
B B B B A A
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. :R02 PAGE No.: 03 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FORMAT FREQUENCY OF OF CHECK RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
1.9 1.10 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7
M V
A B
100% 100%
Assembly of drum internals. HEADERS: Check inspecting authority's stamp on headers and certificate. Identification of the headers. Cleanliness of headers. Bow in headers (Tolerance:1mm/M,Max.5mm for membrane panel headers and max.5mm for other headers. Header scarffing line(Tolerance:1mm max. ) Completion of supports. Alignment of headers and elevation,horizontality and distance from reference axes.
V/R
A
C
Drg./IBR certificate.
Shipping list/Drg.
V
V M Water level/Tape
-do-
B B
B
Drawing -do-do-do-
100%
100%
M
V M
B -doA
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION)OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 04 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FORMAT FREQUENCY OF OF CHECK RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
3.0 3.1 3.2 3.3 3.4 3.5 3.6 4.0 4.1 4.2 4.3 4.4
DOWN COMER PIPES(DC pipes): Identification of DC pipes. Cleanliness of the pipes. Orientation of DC pipes. Alignment of DC pipes(Tolerance: Verticality of DC pipes:1 mm/M,5 mm max.) Alignment of supports. Completion of seismic guides. RISER PIPES/SH CONNECTING LINKS: Identification of the pipes. Cleanliness of the pipes(Sponge test with compressed air). Alignment of pipes. Completion of supports.
M V V V
Tape
B C
B
B Tape/plumb bob B B B
Drawing.
-do-
M
V
-do-do-
V
V M V
C
B
100%
100% 100% 100%
B B
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 05 /14 CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT CLASS
5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6.0 6.1 6.2
PANELS(COMBUSTOR / STEAM COOLED WALL PANEL): Identification of panels. Width,diagonals&location of opening of the panels. (Tolerance:panel width:2 mm. Diagonal difference 5 mm max Cleanliness of the panels(sponge test with compressed air). Completion of supports. Completion of panel to panel joints. Verticality of panels. Alignment of Combustor / steam cooled wall panels. CYCLONE INLET DUCT : Elevation and Orientation of the inlet duct. Cyclone inlet duct distance w.r.t. Boiler axis.
C B B B B B A
-do-do-do-do-
M M
A B
-do-do-
100% 100%
FOR CUSTOMER USE
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 06 /14 CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT CLASS
Ensure the completion of all the supports. CYCLONE: Elevation and orientation of the cyclone top header. Elevation and orientation of the cyclone bottom header. Cyclone distance W.r.t. Boiler axis. Ensure: a)Before assembling the water cooled cyclone panel piece-I to IV,vortex finder should be placed at inside of the water cooled cyclone. b)After erection the water cooled cyclone,vortex finder should be temporary positioned at neck portion of the water cooled cyclone in such a way and support brackets at quartrant points,guide pipes should be located as per drawing and aligned to match with the support opening given in the vortex finder by means of support rods. After alignment,support brackets and guide pipes should be full welded with water cooled cyclone.
M V
A B
Drawing/Erection Drawing
100%
M M M
A B B
-do-do-do-
-do-
100%
-do-
100%
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 07 /14 CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT CLASS
c)After welding the vortex finder supports ,vortex finder should be replaced from its position and it should be placed at inside of the cyclone for neck portion refractory working. d)After completion of refractory work at neck portion,vortex finder should be placed at its original location and it supported with the help of support rods. The support rod should be welded with rear end of the guide pipe . e)Erection completion of all the supports at different elevation. f)Completion of welding. 8.0 8.1 8.2 8.3 CYCLONE OUTLET CHAMBER: Cleanliness of the panels(Air test). Elevation and orientation of the outlet chamber. Cyclone outlet chamber distance w.r.t. Boiler axis.
M V
Tape
A B
Drawing/Erection Drawing
100% 100%
-do-
100%
V V
B B
B
-do-do-
V
M M Water level/Tape Water level/Tape
B A
Drawing -do-
100% 100%
FOR CUSTOMER USE
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 REV. No. : R02 PACKAGE: EPC PAGE No.: 08 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
Ensure the completion of all the supports. VORTEX FINDER: Elevation and orientation of the vortex finder. Centerline of vortex finder w.r.t. Boiler Axis. Ensure the vortex finder is in level. CIRCULAR TO RECTANGULAR TRANSITION / LOOP SEAL / DOWNCHUTE PANEL: Cleanliness of the panels(sponge test with compressed air). Elevation and orientation of the panel. BUCKSTAYS AND FURNACE GUIDES: Identification of the components. Completion of the buck stay channel,stirrup angle with beams.
Drawing
100%
M M M
B A B
-do-do-do-
V M
Water level/Tape
B B
100% -do100%
V
V
C B
100% 100%
FOR CUSTOMER USE
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 09 / 14 CONTRACT No.: EBJ 072 & 073
CLASS QUANTUM/ FORMAT REFERENCE DOCUMENT/ FREQUENCY OF ACCEPTANCE STANDARD OF CHECK RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
Completion of attachment welds such as scalloped plates and lugs. Alignment of buck stay beams. Completion of corner joints. Completion of furnace guides. COILS AND TUBES: Identification of the coils. Cleanliness of the coils(sponge test with compressed air). Alignment of coils w.r.t. inlet and outlet headers. Pitch of economiser hanger tubes above R.H-II and distance between economiser hanger tubes and back pass front/rear wall.
V M V V
Tape
B B B
Drawing -do-do-
-do-
100%
C B B
Drg./Shipping list
100% 100%
Drawing
100%
12.4
-do-
100%
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST. REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW PACKAGE: EPC CONTRACT No.: EBJ 072 & 073
REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FORMAT FREQUENCY OF OF CHECK RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
PSH(PRIMARY SUPER HEATER COIL): Identification of PSH coils. Clearance between end coil assembly and back pass sidewalls. Individual pitches between coils. Clearance between coil ends and back pass front/rear wall. Pitch of economiser hanger tubes above PSH and distance between economiser hanger tubes and back pass front/rear wall. SECONDARY/FINAL SUPER HEATER: Identification of super heater assembly. Clearance between end coil assembly and combustor side walls. Individual pitches between coils. Location of the assembly w.r.t. furnace axis.
V M M M Tape Tape Tape C A B B
C B B A B
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 11 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
15.0 15.1
15.2 15.3
REHEATER: Identification of Reheater coils. Clearance between coil ends and back pass front/rear wall. Individual pitches between coils. ECONOMISER: Identification of economiser coils. Clearance between end coil assembly and Steam cooled wall panels. Individual pitches between coils. Clearance between coil ends and back pass front/rear walls. WELDING: Qualification of welders. Fitup of pressure parts.
C Tape Tape A B
M M V
M M M
16.0 16.1
16.2 16.3 16.4 17.0 17.1 17.2
C
Tape Tape Tape A
100%
100% 100% 100%
B A
V/R V/M
A A
100% 100%
FOR CUSTOMER USE
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 12 / 14 CONTRACT No.: EBJ 072 & 073
CLASS QUANTUM/ REFERENCE DOCUMENT/ FREQUENCY ACCEPTANCE STANDARD OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
17.3 17.4
Adoption of correct procedure,method and approved consumables. Completion of pre-heating,welding and post heating of weld joints.
V V
A A
100% 100%
Drg./ QAC/F/020 (Latest) Drg./CVL/PR/029 (latest)/CVL/PR/006 (Latest)/CVL/PR/014 (Latest)/CVL/PR/095 (Latest)/CVL/PR/009 (Latest) Drawing/QAC/F/020 (Latest) / CVL/PR/002A (Latest)
17.5
As per Drg.
17.6
Time-Temp. Recorder.
-do-
17.6
HARDNESS SURVEY : a) P91 welds. b)All other alloy steel welds in header and links. Identification of weld joints and maintenance of records indicating number of weld joint,heat treatment carried out,NDE results,acceptance and rejection/repair details.
M M V/R
A A A Drg./QAC/F/020 (Latest)
17.7
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 13 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
18.0 18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 18.9
GENERAL: Verticality and loading of suspensions. Cold compression of all springs and locking of the spring assembly. Completion of pressure parts attachment welds.
Closing of voids and cut-outs made during erection.
V V V V V V V V
B B
B B B B B
Locking of supports for hydraulic test. Servicing of valves. Completion of drain/vent valves. Ensure welding of metal temperature pads on superheater and re heater coils. Ensure ground survey by IBR for all pressure parts components.
100%
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
SUPPLIERS NAME & ADDRESS Cethar Vessels Limited 4,Dindigul Road, Tiruchirappalli-620 001
SL. NO
CUSTOMER: M/S SCL PROJECT: SHREE MEGA POWER 2X150MW FQP No. : QPE-PP-002 PACKAGE: EPC REV. No. : R02 PAGE No.: 14 / 14 CONTRACT No.: EBJ 072 & 073
CLASS REFERENCE DOCUMENT/ ACCEPTANCE STANDARD QUANTUM/ FREQUENCY OF CHECK FORMAT OF RECORD REMARKS/ HOLD POINTS (H)
CHARACTERISTICS
INSTRUMENT
HYDRAULIC TEST: Welding of insulation hooks/studs and attachments to pressure parts completion before hydraulic test. Seal welding of all site RT plugs. Ensure that the studs /nuts of blind flange are tensioned to the required torque.
Readiness of total system for hydraulic test.
V
V LPI kit Hydraulic stud tensioner
B
B
100%
100%
B
B
100%
V Pressure gauge
100%
L-10
Completion of air test of the system. Max.test pressure:2 kg/cm(g). Rectification of leak welds and details. Clearance of milestone activity. Completion of hydraulic test.
A A A
L-11 L-11
Pressure gauge
L-12
LEGEND: CLASS : A - CRITICAL, B - MAJOR, C - MINOR; A SHALL BE WITNESSED BY QAE OF CVL & CUSTOMER, B SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL & CUSTOMER, C SHALL BE WITNESSED BY QC ENGR.(ERECTION) OF CVL. TYPE : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
REVIEWED BY
APPROVED BY
APPROVAL SEAL
FRT-FQP-007-REV 00
Reference Document
Erection Manual-Pressure parts. Procedure for Liquid Penetrent Examination Procedure for Radiographic Examination Procedure for Magnetic Particles Examination. Procedure for Post Weld Heat treatment Procedure for Visual Inspection. Procedure for Ultrasonic Examination. Heat Treatment Parameters List of Approved Welding Consumables
Document / Procedure No
SMP/Erec/002(Latest). CVL/PR/006 (Latest)
Issuing Authority
CONS. QA&C
CVL/PR/095(Latest)
QA&C
CVL/PR/014 (Latest)
QA&C
CVL/PR/002A (Latest)
QA&C
NOTE:CVL will submit Hydraulic test procedure before hydraulic test for customer approval.
FRT-FQP-009-REV 00
CHECK NO.
FORMAT OF RECORD
REMARKS
Note: Any protocol made is to be numbered & mentioned in Format of Record column.
PROJECT UNIT NO. RATING FRT-FQP-010-REV 00 SYSTEM SUB - SYSTEM AREA DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 00 SHEET : 1/1
LA
CL OF DRUM
R
LEGEND: LA-Arm Length R-Radius of curvature As measured Left(C1) Axis 1 Axis-2 Right (C2) Axis 1 Axis-2 20 mm 20 mm Tolerance
SL.NO
Description
As per Drg.
01 02
SIGN. &DATE
DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 01 SHEET : 1 / 1
I A G
II B J
D1
D2
DRUM AXIS
BOILER AXIS
H C
I D
IV
III
REFERENCE DRG.NO................................................. 1.Disposition of Drum axis from centre line of furnace (Tolerance:1 mm/ M;Max.5 mm) 2.Elevation of drum suspension support beam(EL)
LHS As per drg. Actual 3.spacing of washer plate with respect to longitudinal axis of boiler & drum axis. (Tolerance :1 mm /M ; Max. 3 mm)
RHS
Tolerance 5 mm
4. Diagonal difference between washer plate locations. (Tolerance : Max. 5 mm) 5.Orientation of rocker plate: Actual :
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER
D1=_____ mm D2=_____ mm
D1~D2=________ mm As per Drg.___________ from drum axis. I______ II______ III______ IV________
SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 02 SHEET : 1 / 2
DRUM ALIGNMENT
CL OF FURNACE
``
I
BOILER AXIS
II
DRUM AXIS
EL B
EL ` `
LHS
IV
III
RHS
Reference Drawing No: 1.Elevation of Drum As per Drg: (Tolerance -Elevation:5 mm ;Cumulative of I&II,III&IV not to exceed 8 mm) Actual :ELI = ELII = ELIII = ELIV =
2.Spacing of Drum Axis with reference to centre to centre line of furnace. As per Drg.________ mm (Transverse axis-Tolerance:1mm/M; Max.5 mm) Actual:A=_________ mm B=_________ mm 3.Axial disposition of drum centre with respect to longitudinal axis of boiler. Actual__________ mm (Tolerance: 5 mm) Towards LHS/RHS 4.Verticality of drum suspension rod(U-Rod) (Tolerance:10 mm) 5.Contact of 'U' rod with drum: All dimensions are in mm.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 02 SHEET : 2 /2
EL 1
SIGNATURE&DATE
DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 03 SHEET : 1 / 2
EL 1
SIGNATURE&DATE
DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 03 SHEET : 2 / 2
1
FURNACE AXIS
LEFT
FURNACE
FRONT
FRONT
BACK
REAR
REAR
PASS
BOILER AXIS
RIGHT
RIGHT
Elevation at
Front wall L M R
Rear wall M R F
COMBUSTOR ALIGNMENT E
LEFT
A D1
FRONT
C D2
REAR
G
Elevation Combustor Top (Near roof) As per Drg. Actual A B
RIGHT
H
D E F G H D1 D2
Combustor As per Drg. middle(Elevati Actual on:18 m) As per Drg. Combustor Bottom Actual
Tolerance:Furnace width & depth : +10mm or-15mm; Furnace diagonal difference : 20 mm max.
F D2
FRONT
D1
FURNACE AXIS
C
REAR
BOILER AXIS
RIGHT SIDE
Elevation Back pass top (Near roof) As per Drg. Actual As per Drg. Actual Above Economiser As per Drg. Actual As per Drg. Actual
D1
D2
Above RH-II
Below Economiser
Tolerance:Back pass width & depth : +10 mm or -15 mm; Back pass diagonal difference : 20 mm max.
All dimensions are in mm.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 05 SHEET : 2 / 2
PITCH OF COILS
As per drawing:_________ mm Tolerance:10 mm
Measured values. A Y1 B
LEGEND: Y1 Spacing between Economiser hanger tubes. A-spacing between back pass front wall and economiser hanger tubes. B-spacing between back pass rear wall and economiser hanger tubes. All dimension are in mm
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 06 SHEET : 2 / 2
Measured values
Measured values
Measured values
REMARKS:
AIR TEST OF BOILER REQUIREMENTS: Design pressure Working pressure Test pressure Reference document Circuits included in the test : : : : : kg/cm (g) kg/cm (g) kg/cm (g)
OBSERVATIONS: Date of test Test pressure Test witnessed by Details of failure noticed Details of rectification REMARKS: : : : : : kg/cm (g)
Air test of boiler at the test pressure of ...........kg/cm (g) carried out on ................and found satisfactory. The boiler is cleared for Hydraulic test.
NAME PROJECT UNIT NO. RATING FRT-FQP-011-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGN. &DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 11 SHEET : 1 / 2
SL. NO
LOCATION
FAILURE AT
REMARKS
NOTE :Failure at :1.Butt weld 2.Seal weld 3.Attachment weld 4.Hand hole plate weld 5.Thermowell weld 6.Cuts & gouges
NAME PROJECT UNIT NO. RATING FRT-FQP-012-REV 00 INSPECTED BY CLEARED BY CUSTOMER SIGNATURE&DATE DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 11 SHEET : 2 / 2
SIGN. &DATE
DOC. NO. : QPE-PP-002 REV. NO. : R02 LOG SHEET NO. : L - 12 SHEET :1 / 1
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:
To Head/FQA, CVL, Tiruchirappalli. DOC. NO. : QPE-PP-002 REV. NO. : R02 SHEET :1/1