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FIELD QUALITY PLAN

Suppliers Name and Address:


M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 1 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

1 a)

Setting up of FQA laboratory within Ten weeks of NOA Avialablility of requisite laboratory set up and equipment in good working condition well before commencement of concerned activity Submission of QA & QC manpower deployment schedule based on agreed L-2 network . Availability of QA& QC manpower based on deployment schedule . Availability of construction equipment in working condition Sampling for testing of buliding materials by third party within 15 days of LOA Submission of schedule of tests to be done monthly / quaterly and maintenace of the same on a computer connected to LAN of NTPC for monitoring.

Physical

One time

As per section VI Bid doc no: CS -0260135 R-2 Part - B Sub section-III E-06

SR

Functioning of laboratory equipment in proper working condition to be verified on monthly basis.

1 b)

Physical

Monthly Do

SR

1.01 a

Physical

One time

As per technical specification and post bid mintues of meeting dated 22 and 23 Jan 2009 As per technical specification and post bid mintues of meeting dated 22 and 23 Jan 2009 Post bid mintues of meeting dated 22 and 23 Jan 2009 Post bid mintues of meeting dated 22 and 23 Jan 2009 Post bid mintues of meeting dated 22 and 23 Jan 2009 SR

1.01 b

Physical

Monthly

1.02

Physical

Monthly

SR

1.03

Physical

Once per source

SR/TR

The test report along with the Recommendation from NCB ballabgarh/ CSMRS shall be submitted to NTPC

1.04

Physical

Monthly

SR

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation.

DOC. NO.:

Manufacturer / Sub-supplier Signature

Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

For NTPC USE REVIEWED BY APPROVED BY APPROVAL SEAL

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 2 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

2 2.1

Nature of soil/rock

As required

Visual

EXCAVATION AND FILLING Random As per Contractors scheme for excavation/appd. Drg. -do-

SR

2.2

Initial ground level

2.3 2.4 2.5 2.6

Dimensions of excavated pit. Final pit/bed level. As required Side slope during As required excavation Excavation in Hard Rock(if applicable) a) Receipt & Storage of Explosive b) Blasting Operation. Compressor / Drilling Machine

Digital Theodolite / Total Station As required

Measurement

100.00

SR

B B B

Measurement Measuement Measurement

100.00 100.00 Random

-do-do-do-

SR SR SR

A A

Physical Physical

100.00 100.00

Indian Explosive Act 1940 IS:4081

SR SR

Agency employed shall have to be approved from NTPC Site Engr. Incharge. Blast pattern design has to be carried out from an approved agency

2.6 b)

Excavation in Rock (with Blasting) (if applicable)

a) Submission of blasting methodology b) Submission of detailed blasting scheme c) Documentation for all statutory laws required for blasting operations d) Deployment of approved Govt. specialised agency for controlled blasting operations e) Storage and accounting of explosives f) Blasting operations

A A A

Physical Physical Physical

Before starting of blasting operation do do

IS: 4081, Technical Specification IS: 4081, Technical Specification IS: 4081, Technical Specification

SR SR SR

Physical

do

IS: 4081, Technical Specification

SR

Compressor/ Drilling Machine As required

B A

Physical Physical

100% do

IS: 4081, Technical Specification IS: 4081, Technical Specification

SR SR

g) Monitoring of vibrations During Blasting.

Physical

do

IS: 4081, Technical Specification DOC. NO.:


For NTPC USE REVIEWED BY

SR

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

APPROVED BY

APPROVAL SEAL

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 3 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

2.7 2.8 2.8.1 Fill (Suitability of borrow material)

Excavation in Hard Rock (Blasting Prohibited)

-do-

Physical

100.00

As per approved drawing/ scheme

SR

Grain size analysis

Set of seives Hydrometer etc Mechanical luquid limit device, Grooving tools, Evaporating disc , Spatula, Pallate knives, Balance, oven container etc - do -

Physical

2.8.2

Liquid & plastic limit

Physical

One in every 2000 cum for each type and source of fill materials subject to a min. of 2 samples One in every 2000 cum for each type and source of fill materials subject to a min. of 2 samples

IS:2720 (Pt.IV) & NTPC Specifications

SR/TR

Applicable only in case backfilling is required to be done using borrowed earth brought from outside plant boundry - do -

IS:2720 (Pt.V) & NTPC Specifications

SR/TR

2.8.3

Shrinkage limit

Physical

2.8.4

Free Swell Index

Measuring cylinder etc

Physical

One in every 5000 cum for each type and source of fill materials subject to a min. of 2 samples One in every 5000 cum for each type and source of fill materials One in every 5000 cum for each type and source of fill materials

IS:2720 (Pt.VI) & NTPC Specifications

SR/TR

- do -

IS:2720 (Pt.XL) & NTPC Specifications

SR/TR

- do -

2.8.5 I

Chemical Analysis Organic Matter

Oven, chemical, balance, volumetric flask, burettes, pipettes, conseal flask, set of seives etc

Physical

IS:2720 Pt.XXII & NTPC Specifications

SR/TR

- do -

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

DOC. NO.:

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

For NTPC USE REVIEWED BY APPROVED BY APPROVAL SEAL

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 4 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

ii

Calcium carbonate

iii iv 2.8.6

pH value Total soluble sulphate

Reagent & indicator, burette, flask etc As required As required

Physical

-do-

Part XXIII of IS-2720

SR/TR

Applicable only in case bachfilling is required to be done using borrowed earth brought from outside plant boundary - do - do -

B B B

Physical Physical Physical

2.8.7

Standard proctor Test to Proctor determine optimum needle moisture content and max. apparatus etc dry density of fill Moisture content of fill As per IS: before compaction 2720 Degree of compaction fill Dry density by core cutter method Core cutter, Balance etc

Part XXVI of IS-2720 -doPart XXVII of IS-2720 One in every 2000 cum IS 2720 (Pt.VII) for each type and source of fill materials One in every 2000 cum for each type and source of fill materials Once every 500 sqm area for each compacted layer subject to a minimum of one sample -doIS 2720 (Pt.II)

-do-

SR/TR SR/TR SR/TR

Physical

SR/TR

2.8.8 i

Physical

IS 2720 (Pt. XXIX)

SR/TR

ii iii

2.8.9 2.8.10

Dry density in place by sand Sand replacement method replacement appartus etc Relative density (Density Balance, Index) oven etc Dry Density by proctor Proctor needle penetration needle appartus etc Sand As per IS2720,383 Stone As per IS2720,383

Physical

IS 2720 (Pt. XXVIII)

SR/TR

A B

Physical Physical

-doRandom checks to be carried out for each compacted layer Random Random

IS 2720 (Pt. XIV) Standard practice

SR/TR SR/TR

Test for sand Test for soil

B B

Physical Physical

IS-2720 ,383 IS-2720,383 DOC. NO.:


For NTPC USE REVIEWED BY

SR/TR SR/TR

Applicale where Sand and Stones are used as a Fill Material

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

APPROVED BY

APPROVAL SEAL

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 5 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

3 3.01 3.01.01

CAST-IN-SITU CONCRETE MATERIALS Cement a) Ensure that cement is stored in weather proof covered storage on raised platform. b) If cement is stored more Vicat than 60 days in godown of appartus, contractor same shall be compression retested for comp. Strength testing & setting time. machine B Visual 100% covered storage Covered storage, weather tight on raised platform. SR/LB Each consignment of cement obtained shall be duly correlated with manufacturesr's test certificate. for setting time, compressive strength and C3A content .One sample from each lot shall be tested for setting time and compressive strength. Acceptance norms shall be as per relevant Indian standard.

Testing

At Random

IS;1489 Part (I & II) IS: 269, IS:455 IS:8112, IS:12269

Test Report

3.01.02 I

Coarse Aggregate Moisture content Balance, sieve(confor ming to IS:460-1962) & oven etc As per IS Code B Physical Once for each stack of IS:2386 Part-III 100 Cu.M. or part there IS : 456 of Except during IS : 383 monsoon when this has to be done every day before start of concreting Once for each source & IS: 2386 Part-III, for every change of IS:383 source( Once in twelve weeks or change of source whichever is earlier) One per 100 cum., or IS: 2386 Part-I, part thereof/change of source whichever is earlier Once per source/ on every change of source IS: 2386 Part-II, SR/LB Accordingly water content of the concrete will be adjusted

ii

Specific gravity, density, voids, absorption

Physical

IS:456,

SR/LB/ Test Report

These tests will be carried out white establishing design mix and the results to be intimated to NTPC.

iii

Particle, size & Shape-Sieve analysis, , flakiness index, elongation index, angularity number Deleterious materials & organic impurities

iv

Soundness

Sieves, balance, oven thickness gauge, metal Balance sieves ( confirming to IS-460-1985 etc Reagents (sodium sulphate or magnesium sulphate) etc

Physical

IS:383

SR/LB

-do-

Physical

IS:383

SR/LB/ Test Report

Experts opinion regarding suitability of the aggregates shall be obtained from NCB, Ballabhgarh.

Physical

-do-

IS: 2386 Part-V, IS:383

SR/LB/ Test Report

-do-

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

DOC. NO.:
For NTPC USE REVIEWED BY APPROVED BY APPROVAL SEAL

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 6 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

3.01.03 i ii iii iv

Fine Aggregate Bulkage, moisture content Mortar making properties Silt, Clay content and organic impurities All other tests similar to coarse aggregates as mentioned above. Accelerated Mortar Bar Test Oven, Balance etc As per IS Code As per IS Code B B B B Physical Physical Physical To be done every day IS: 2386 Part-III IS:383 before start of work Once per source& for on IS: 2386, IS:383 every change of source Once per source& for on IS: 2386 Part-II, IS:383 every change of source Refer S.No. 3.01.02 IS-2386, IS-383 SR/LB/TR SR/LB/TR SR/LB/TR SR/LB/TR Volume of sand and weight of water shall be adjusted as per bulkage & moisture content. Acceptance criteria as per IS:383 Acceptance limit as per relevant IS code Flackiness index, elongation index,angularity number, crushing strength are not to be carried out for fine aggregates Test applicable for coarse and fine aggregates to be carried out at NCB Bllabhagarh

vi

vii

Petrographic examination

viii

Crushing value abrasion value and impact value

Scales, weights,sieve s, glass, gradients mixing bowl, trovel , container, length comperator etc Screen, Microscope, hand lens etc As per IS Code

Physical

-do-

ASTMC 1260

SR/LB/ Test Report

Physical

-do-

IS: 2386 Part-VIII, IS:383

SR/LB/ Test Report SR/LB/ Test Report

Test applicable for coarse and fine aggregates to be carried out at NCB Bllabhagarh Test applicable for coarse aggregates

Physical

-do-

IS:383, IS-2386 Part IV

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

DOC. NO.:
For NTPC USE REVIEWED BY APPROVED BY APPROVAL SEAL

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS REV. NO.: 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 7 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

3.01.04 i

Water Test for acidity & alkalinity Chemical by using neutralization of Reagent, water using indicator and Buret, conical test for chloride and flask, pipette sulphate content etc Tests for ascertaining limit As per IS of solids Code B Testing Once per season for every change of seasonand for each change of source. Once per season for every change of seasonand for each change of source. Once per season for every change of season and for each change of source. One sample every 2 hrs. from every mixing plant Min. 4 Trial Mixes for each grade of concrete to be carried out . IS:3025, IS:456 SR/LB/TR

ii

Physical

IS:3025, IS:456

SR/LB/TR

iii

Tests for pH Value

ph meter

Testing

IS:3025, IS:456

SR/LB/TR

3.02.01 i ii

Concrete Workability - slump test Trial mix (Cubes compressive strength) Mix Design Slump cone etc As required B A Physical Physical IS:456/NTPC Tech. Spec. IS: 516 & IS:456, IS:10262/ NTPC Tech. Spec. SR/LB/TR SR/LB/ Test Report For trial mix min. of 6 cubes for each mix, 3 specimen shall be tested at 7 days remaining 3 shall be for 28 days comp. Strength. Mix design shall carried out at NCB Ballabhgarh/ CSMRS N . Delhi Min. of 6 cubes for each mix, 3 specimen shall be tested at 7 days remaining 3 shall be for 28 days comp. Strength.

iii

Crushing strength (works Tests cubes)

As required

Physical

iv

Water cement ratio

v vi vii viii

Cement content Admixtures for Concrete Water Tightness Test for Water Retaining Structures Dimensions and visual examination of finished structure

Chemical reagent, buret, conical flask, pipette etc As required As per IS Code As per IS Code Measuring tapes etc

Physical

One set of 6 cubes per IS:516, IS:456, NTPC Tech. Spec. SR/LB/ 50 CuM or part thereof Test Report for each grade of concrete per shift whichever is earlier. At random at the time of As per IS:1199 and approved design SR/LB batching. mix.

B B A B

Physical Testing Test Physical

At random at the time of batching. Once per Lot 100 .00 % 100 .00 %

IS:1199 and approved design mix. IS:456 and appd. Design mix. IS:3370 (Tanks and Revision) As per Tech. Specification./Appd. Drg./IS-456 DOC. NO.:
For NTPC USE REVIEWED BY

SR/LB Test Report Inspection Report -doAdmixture of appd. Brand and tested quality shall be used.Manufacturers TC required.

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

APPROVED BY

APPROVAL SEAL

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

29/03/05 8 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

3.02.02 i

Concrete conveying, placing & compaction Calibration of Batching Plant As required A Review of calibration certificate To be calibrated at the time of starting and subsequently once in three months, and shall confirm to IS:4925 100. 00 % 100. 00 % 100. 00 % At Random At Random 100. 00 % IS 4925 relevant IS and technical specifications Calibration Certificate Batching plant should be computerised. Calibration of batching plant shall be by NPL traceable weights.

ii iii iv v vi vii

viii

Transportation of concrete Placement of concrete Check for placement Compacting Curing Cleanliness, provision of chute and arrangement for transportation & placement of concrete. Check slope of fan deck slab Check slope of the cold water basin TEST/CHECK ON RCC STRUCTURE IN HARDENDED Dimensional check on finished structures & Dimensional tolerances Water Tightness Test of liquid retaining structure/ tanks Schmidt Hammer Test

As required As required As required

B B B B B C

Physical Physical Physical Physical Physical Visual

As per construction/erection SR As per construction/erection SR As per approved construction SR Check for segregation as per IS 456 SR Check for period of curing as per IS SR Before clearance for concreting Inspection Report

Construction methodology to be approved one week prior to start of work

ix

Lvl. Inst./ Digital theodolite Lvl. Inst./ Digital theodolite

Physical/ Measurement Physical/ Measurement

100. 00 %

NTPC tech . Specs./Approved drgs.

-do-

100. 00 %

NTPC tech . Specs./Approved drgs.

-do-

3.02.03

Measuring tape etc As per IS code

Measurement

Approved Drawing

As per IS:456/ Tech. Specification.

SR/LB

ii

Test

100. 00 %

IS:3370/ Tech. Specification

SR/LB

iii

Rebound Hamer Test if required by NTPC Engineer in-charge

Strength Test

At Random on identified Relevant IS elements of structure and Tech.Specifi cations

SR/LB

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

DOC. NO.:
For NTPC USE REVIEWED BY APPROVED BY APPROVAL SEAL

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 9 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

3.03

REINFORCEMENT STEEL(TMT & HYSD BARS) Physical, Chemical properties A Review of TCS Each consignment IS : 1786, IS:432 (Part-I), IS:1566 Mfr. TCS For steel procured by contractor the manufacturer's test certificate(MTC) is required. In absence of MTC, testings shall be carried out on jointly drawn out sample. Consignment shall be considered in lots of 50MT.For underground structures , the type of reinforcement steel used shall be as approved by the employer based on the type of soil water chemical environment. To be checked at site. Steel collected from source should be free from excessive rust. To be stored as per Technical Specs.

ii iii

Tolerance Freedom form cracks surface flaws, Lamination. (Visual Examination). Placement of Reinforcement Steel Check for bar bending schedule with necessary laps. Spacers & Chairs Check for cover, spacing of bars Check for bending of bars Check for spacers and chairs after the reinforcement cage is put inside the formwork Lapping of bars Check all joints, Crossing

As required As required

B C

Measurement Visual

At Random 100 .00 %

IS : 1852, IS: 432, IS:1786 & Tech IS: 1852, IS:432, IS:1786

SR/LB SR/LB

3.03.01 I

As required

Visual & Measurement Visual & Measurement Visual & Measurement Visual & Measurement

100 .00 %

Approved Drawings

SR

ii iii iv

Measuring tape etc As required Measuring tape etc

B C C

100 .00 % 100 .00 % 100 .00 %

Approved Drawings Approved Drawings Approved Drawings

SR SR SR

v vi

As required As required

C B

Measurement Visual

100 .00 % Random

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

IS : 456/ Drawings & approved bar Approved drawing/bar bending schedule DOC. NO.:
For NTPC USE REVIEWED BY

SR SR

Crossing of the bars are to be tied up properly with right gauge of annealed wire .

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

APPROVED BY

APPROVAL SEAL

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 10 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

3.04 3.04.01 i ii

STAGING AND FORMS Materials and accessories Soundness of staging, shuttering and scaffolding Connection between individual scaffolding units and safe slenderness ratio. Two independent safety measures against collapse. Concrete strength during climbing process. Hoisting for personnel and materials Alignment/Shape Check form's seam marks and water tightness Embedded part Position and level of embedded parts Position depth and size of bolt hole Location verticality of pipe sleeve/opening of bolt hold Welding / tieing of embeddment to reinforcement Pre-cast concrete Workmanship free from visual defects Visual B Physical 100. 00 % Tech. Spec. Register The precast units shall be free from defects like honeycombing, reinforcement exposure and should have good finish. All relevant tests like workability, cube test shall be carried out as per IS 456-2000 Same as applicable to cast in situ concrete.Min. grade of concrete to be used is as per technical specs. As required As required As required As required B B B B Dimensional Dimensional Dimensional Dimensional 100. 00 % At random At random At random As per drawing/ Technical Specifications. As per drawing/ Technical Specifications. As per drawing/ Technical Specifications. As per drawing/ Technical Specifications. SR SR SR SR As required As required As required B B C Visual Visual Visual Once Once Fortnightly As per relevant IS As per manufacturer's spec.and as per 3696,4014, 4990 As per National Safety council & relevant IS Codes I.e. IS:14687& IS:3696 SR SR SR

iii iv v vi 3.05 i ii iii iv

As per IS provision As required As required As required

B C B B

Physical Testing Visual

For each lift of shuttering Fortnightly

As per provisions and tolerances As per manufacturer recommendation & safety codes As per approved drawings As per approved drawings

SR SR SR/LB SR/LB

Measurement For each lift of shuttering Physical Random

3.06 I

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

DOC. NO.:
For NTPC USE REVIEWED BY APPROVED BY APPROVAL SEAL

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 11 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

ii

Dimension of finish structure As required

Measurement

100. 00 %

As per IS:456/NTPC Tech. specification.

SR

iii

Load Test

As required

Physical

Random

IS:456/ As decided by NTPC Site Engr. Incharge. As per approved drawing

Inspection Report do

iv

Placement of precast members & fill support members Brick Masonry Test on Bricks Dimensions, soundness, colour, compressive strength, water absorption, warpage efflorescence. Test on Mortar Masonry construction Workmanship, verticality and alignment Painting of concrete surfaces / Plastered Masonry a)Super structure (RCC Works)

As required

Physical

Random

If the material already tested of the cast-in-situ concrete and part of the same is used for precast concrete, further testing is not required, otherwise testing is required for every 50 Cum. Of Concrete. These tests shall also be carried out, in case of doubt regarding grade of concrete and poor quality. Placement has to be checked for correct horizontal and vertical alignment of the fill support members

4 4.01 i)

Brick Masonry, & allied works

As required

Measurement/ As per relevant IS Code/ Physical Test One Sam ple for 10,000 Nos. or part thereof

IS: 1077, IS:2212/ Relevant IS Code. IS 12894

Inspection Report

Efflorescence shall be checked at each source.The sand used for masonry work shall conform to IS:2116

ii) iii)

As required

Visual/ Physical

100. 00 %

IS 2212, IS 1905 As per Technical Specifications

SR/LB

4.02

Visual

100. 00 %

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

As per Tech Spec./ Drawing/and relevant IS Code. DOC. NO.:


For NTPC USE REVIEWED BY

SR/LB

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

APPROVED BY

APPROVAL SEAL

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 12 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

5 a) Galvanising A Visual/Review of Mfr. TC

PAINTING OF STEEL One per lot

NTPC Tech. Specs./Mfr. TC

SR/LB/MfrT C

5.1

Painting Material

b) Painting with one coat of red oxide zinc chromate primer. c)Two coats of synthetic enamel Cement Paint a) Oil Bound distemper

Elcometer

Visual/ Measurement Visual/ Measurement Visual Review of MFr.TC

100. 00 %

NTPC Tech Spec.

SR/LB

All mild steel parts in the cooling towers shall be hot dip galvanised.. All gratings and hand railings and ladders and chequred plates shall also be hot dip galvanised unless otherwise specified. Random to be checked by FQA.DFT as per Tech . Specs/Approved drawings -do-

Elcometer/ As required As required As required

B B B

100. 00 % 100. 00 % Random for each Lot

NTPC Tech Specs. IS: 5410 as per Tech Spec/ IS:428/As per Tech Specs./ Correlated Mfr. TC

SR

SR/LB

These shall be procured from accredited vendors acceptable to Engineer- In - Charge duly supported by batch /consignment wise correlated manufacturers test certificate. Surface preparation and application shall be as per tech. Specs. Painting material & its application method can be obtained from any manufacturer who has been granted licence by CERI, Karaikudi.

6 I

SPECIAL ITEMS Coating of inside of cold water basin and desludging channel with tar extended two component coating system. a)Material b)Laying As reqd. As reqd. A B Review of Mfr. TC Physical Once per Lot 100. 00 % As per Tech Specs, and relevant IS. Tech. Specs., Relevant IS Mfr TC SR/LB The laying of coating shall be as per relevant IS code /As per manufacturer's recommendations. The DFT shall be as per Tech spec & appd drawing Low hydrogen electrode as per NTPC approval shall be used. TR SR Earthing required as per IS

II

Earthing Mat a) Weld sizes & length b) DP Test c) Earth test

Visual/Tape DP Kit Earthing test kit

B A A

Visual/Tape Physical

100. 00 % 10% at random 100. 00 %

As per Tech Specs. Free from defect Relevant IS DOC. NO.:


For NTPC USE REVIEWED BY APPROVED BY

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.

APPROVAL SEAL

FIELD QUALITY PLAN


Suppliers Name and Address: M/sGAMMON INDIA LIMITED , "GAMMON HOUSE" , VEER SAVARKAR MARG, PRABHADEVI , MUMBAI - 400025

PROJECT: PACKAGE: CONTRACT NO.

VTPP (3 x 500MW) COOLING TOWERS PACKAGE NTECL/C&M/IDCT(CS-0260-135 R-2)-FC-NOA/0809/0123 DATE :26/02/2009 NTECL/C&M/IDCT(CS-0260-135 R -2)-SC-NOA/0809/0124 DATE :26/02/2009 M/s GAMMON INDIA LTD.
Format of Record 9 D* Remarks 10

QP NO.: 01 ITEM : CIVIL WORKS Rev. No : 00 DATE: SUB-SYSTEM : PAGE:


Class of check 4

13.03.09 13 of 13
Type of Check 5 Quantum of Check 6 Reference Document 7

CONTRACTOR
Acceptance Norms 8

Sl. No 1

Activity and Operation 2

Characteristics / Instruments 3

7 a

All bought out items to be procured from the approved vendor and on approval of Quality plans by NTPC Submission of list of BOI and their vendors for each of the bought out item identified,within two months of LOA for approval Materials Bitumen Impregnated board PVC water stops Expanded polystyrene board Bitumen sealing compound Two part Polysulphide sealant

Verification of TC and/or Testing Physical

Bought out Items 100. 00 %

NTPC Tech. Spec. /BOQ

SR / LB

One time

Preaward minutes of meeting dated 27 & 28.12.2004

The TC submitted should bear proper identification or correlation with the batch of material supplied and same shall be brought out in the challan/ consignment note . To be submitted to CQA for approval with a copy to site .

8 a I

Expansion Joints in concrete A A A A A Verification of MfTC Verification of MfTC Verification of MfTC Verification of MfTC Verification of MfTC Once per Lot Once per Lot Once per Lot Once per Lot Once per Lot As per manufacturer's TC , technical specification,IS:1838 As per manufacturer's TC , technical specification,IS:12200 As per manufacturer's TC , technical specification,IS:4671 As per manufacturer's TC , technical specification,IS:1834 As per manufacturer's TC , technical specification,IS:1835 DOC. NO.:
For NTPC USE REVIEWED BY APPROVED BY APPROVAL SEAL

SR / Mfr.TC SR / Mfr.TC SR / Mfr.TC SR / Mfr.TC SR / Mfr.TC The bitumen sealing compound shall be of Grade-A

LEGEND: D* Records, indentified with Tick () shall be essentially included by supplier in QA documentation. Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB

Manufacturer / Sub-supplier Signature

A shall be witnessed by NTPC FQA, B shall be witnessed by ntpc erection / construction deptt. and C shall be witnessed by erection supplier (A & B check shall be NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log book

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings.