ID No.

FIELD QUALITY PLAN

FOR

EOT CRANE
(105/15/2x15T)

(ERECTION)

FOR

BELLARY THERMAL POWER PROJECT

(1X500MW)
(M/s Karnataka Power Corporation Ltd.)

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - SOUTHERN REGION
QUALITY DEPARTMENT
CHENNAI - 600 035

DOC. No: QPE-NB-154

REV. No: R00 / 03-05
 FIELD QUALITY PLAN
FOR

EOT CRANE
(105/15/2x15T)

(ERECTION)

FOR

BELLARY THERMAL POWER PROJECT

(1X500MW)
(M/s Karnataka Power Corporation Ltd.)

PREPARED BY
M/s WMI Cranes Limited, Mumbai

REVIEWED BY
(M Dharmasivam, Dy.Manager / Quality, BHEL-PSSR, Chennai)

APPROVED BY
(V Kandhsamy, Sr.DGM / Quality, BHEL-PSSR, Chennai)
QPE-NB-154 ID No. DATE OF ISSUE
DOCUMENT No.
R00 / 03-05
CONTROLLED / No. OF ISSUED BY
COPY No: INFORMATION PAGES:
COPY 21

ISSUED TO:

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - SOUTHERN REGION
QUALITY DEPARTMENT
CHENNAI - 600 035
 QP No. : QPE-NB-154

CONTENTS REV. No.: R00

PSSR-Quality PAGE 1 OF 1

Sl.No. Description No. of Pages

1.0 Status of amendments 01

2.0 Field Quality Plan for

EOT Crane (105/15/2x15T)

Erection

For

BELLARY TPP - 1 x 500 MW

(M/s Karnataka Power Corporation Ltd.)

2.1 Statement of checks 05

2.2 Documents referred in Quality Plan 01

2.3 Log Sheets: L-00-L-05 09

3.0 Feedback on Field Quality Plan 01

******

FMT-QP-003 Rev.00
 QP. No.: QPE-NB-154

STATUS OF AMENDMENTS REV. No.: R00

PSSR – Quality PAGE 1 OF 1

S l. Reference of Sheet(s) Amendment No. Remarks

No. Amended & Date

NIL

FMT-QP-016 Rev. 00
 QP No. : QPE-NB-154
STATEMENT OF CHECKS REV. No.: R00
PSSR-Quality PAGE 1 OF 5
Capacity / Type : 1 X 500 MW
System : --
Sub System : EOT CRANE (105/15/2x15T)
Area : ERECTION

 For checks where log sheets are not called for, suitable records should be maintained in
the form of log book / protocols.

 As an evidence of having carried out the work satisfactorily, a general-purpose log sheet
L-00 shall be maintained for all the checks.

 The above sub-system covers Crane, Trolley complete with Hoist and Cross Travel drive,
Long Travel drives, Electrical Controller- receipt of material, Installation, Testing &
Commissioning and Inspection of Gantry Girders.

 Abbreviations used in the column “Type of check” are:

R : Record Verification

M : Measurement

V : Visual

FMT-QP-005 Rev.00
 SUPPLIER‟S NAME &
FIELD QUALITY PLAN CUSTOMER:M/s KPCL
ADDRESS
WMI Cranes Ltd. SYSTEM: EOT CRANE FQP No. : QPE-NB-154 PROJECT: BELLARY TPP-1x500 MW
Vi llage Road,
SUB SYSTEM: REV. No. : R00 PACKAGE: EPC
Bhandup (West)
Mumbai-400 078 AREA: ERECTION PAGE No.: 2/5 CONTRACT No.: TDBT1EPC/E
TYPE QUANTUM / FORMAT REMARKS/
REFERENCE DOCUMENT/
SL.NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF OF HOLD
ACCETANCE STANDARD
CHECK CHECK RECORD POINTS (H)
1 Unloading from Trucks / Trailors / site transport / site V C 100% Safe receipt of Log
storage (Visual check for damage during transit and Materials, no Book
appropriate preservation, storage at site). damage, Packing
Note

2 Receipt / Checking of Material (Visual inspection for V C 100% 1) Boxes in packed

damage to cases and loose material and quantity condition
check) 2) Loose parts as
per despatch
challans
3) CHP / M.D.C.C /
Packing Note

3 Joint Inspection of Gantry i.e. Span / Diagonal / Level / M Tape / Plumb / A 100% GA Drawing of L-01
Height / Head Room Height / Side Clearance etc. as Piano Wire / Crane, Gantry
per the standard Thread Drawing, IS 7215

4 Erection & alignment of rail (LT) M Tape and A At the Gantry Rail Drawing Protocol
a) Straightness of gantry rails Spring interval of 10 and IS 3177 /
b) Level and elevation of gantry rails (top level of Balance Mtr IS 7215 for LT Span
girder)
c) Distance between rails (Tolerance: ± 6 mm)
d) Diagonal of rails (Tolerance: 5 mm)
e) Shift in centre line of rail w.r.t. centre line of web
crane girder (Tolerance: ± 10 mm)
f) Bolting of rails and tightening Torque wrench

LEGEND: CLASS #: A= CRITICAL, B= MAJOR, C= MINOR; FOR CUSTOMER USE

„A‟ SHALL BE WITNESSED BY FQA OF BHEL & CUSTOMER,
„B‟ SHALL BE WITNESSED BY ERECTION/ CONSTRUCTION DEPT. OF BHEL & CUSTOMER AND
„C‟ SHALL BE WITNESSED BY ERECTION OF BHEL.
MANUFACTURER MAIN SUPPLIER: TYPE @ : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
M/s WMI BHEL-PSSR
SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL
 SUPPLIER‟S NAME &
FIELD QUALITY PLAN CUSTOMER:M/s KPCL
ADDRESS
WMI Cranes Ltd. SYSTEM: EOT CRANE FQP No. : QPE-NB-154 PROJECT: BELLARY TPP-1x500 MW
Vi llage Road,
SUB SYSTEM: REV. No. : R00 PACKAGE: EPC
Bhandup (West)
Mumbai-400 078 AREA: ERECTION PAGE No.: 3/5 CONTRACT No.: TDBT1EPC/E
TYPE QUANTUM / FORMAT REMARKS/
REFERENCE DOCUMENT/
SL.NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF OF HOLD
ACCETANCE STANDARD
CHECK CHECK RECORD POINTS (H)
5 Erection of end carriages / Bogies and Girder V C 100% GA Drawing. Protocol
Proper placement and bolting

6 Erection of Bogies connection (Proper placement and V C 100% GA Drawing Protocol

bolting)

7 Erection of platform, LT machinery, Cabin and other V C 100% GA Drawing Protocol

structural items
1) Proper fitment
2) Proper bolting of respective parts

8 Crab Assembly V C 100% Crane Assembly Protocol

Drawing

9 Erection of Crab and Trolley (Proper placement) V C 100% GA Drawing Protocol

10 Check for free movement of Trolley V C 100% Protocol

11 Clearance Check M Tape C 100% GA Drawing L-02

12 Gear box alignment with motor M B 100% Drawing L-03

13 Check on assembled crane dimensional and crane M Tape and B 100% GA Drawing Protocol
clearance scale

14 DSL fixing, location, spacing and alignment M Tape B 100% Drawing Protocol

LEGEND: CLASS #: A= CRITICAL, B= MAJOR, C= MINOR; FOR CUSTOMER USE

„A‟ SHALL BE WITNESSED BY FQA OF BHEL & CUSTOMER,
„B‟ SHALL BE WITNESSED BY ERECTION/ CONSTRUCTION DEPT. OF BHEL & CUSTOMER AND
„C‟ SHALL BE WITNESSED BY ERECTION OF BHEL.
MANUFACTURER MAIN SUPPLIER: TYPE @ : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
M/s WMI BHEL-PSSR
SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL
 SUPPLIER‟S NAME &
FIELD QUALITY PLAN CUSTOMER:M/s KPCL
ADDRESS
WMI Cranes Ltd. SYSTEM: EOT CRANE FQP No. : QPE-NB-154 PROJECT: BELLARY TPP-1x500 MW
Vi llage Road,
SUB SYSTEM: REV. No. : R00 PACKAGE: EPC
Bhandup (West)
Mumbai-400 078 AREA: ERECTION PAGE No.: 4/5 CONTRACT No.: TDBT1EPC/E
TYPE QUANTUM / FORMAT REMARKS/
REFERENCE DOCUMENT/
SL.NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF OF HOLD
ACCETANCE STANDARD
CHECK CHECK RECORD POINTS (H)

15 Cable laying and wiring connection V C 100% Wiring Diagram / Protocol

Cable Schedule

16 Electrical Checks
a) Insulation Test V/M Megger A 100% IS 3177 /
b) Control Circuit and Earthing V/M Megger A 100% Wiring Diagram and Protocol
c) Operation of limit switch V A 100% GA Drawing

17 Ensure that the wiring & ferruling of control panels are V B 100% Wiring Diagram
done properly.

18 Performance of contactor‟s sequence operation for V B 100% Wiring Diagram

CT, LT & Hoist motions at no-load & full load.

19 Working of the following control devices for CT, LT & V B 100% Wiring Diagram
Hoist motions at no-load & full load.
a) Contactors & timers
b) Controllers and
c) Push button switches

20 Working of the following protective devices for CT, LT V B 100% Wiring Diagram
& Hoist motions at no-load & full load.
d) Circuit interlocks
e) Brakes and
f) Limit switches
LEGEND: CLASS #: A= CRITICAL, B= MAJOR, C= MINOR; FOR CUSTOMER USE
„A‟ SHALL BE WITNESSED BY FQA OF BHEL & CUSTOMER,
„B‟ SHALL BE WITNESSED BY ERECTION/ CONSTRUCTION DEPT. OF BHEL & CUSTOMER AND
„C‟ SHALL BE WITNESSED BY ERECTION OF BHEL.
MANUFACTURER MAIN SUPPLIER: TYPE @ : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
M/s WMI BHEL-PSSR
SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL
 SUPPLIER‟S NAME &
FIELD QUALITY PLAN CUSTOMER:M/s KPCL
ADDRESS
WMI Cranes Ltd. SYSTEM: EOT CRANE FQP No. : QPE-NB-154 PROJECT: BELLARY TPP-1x500 MW
Vi llage Road,
SUB SYSTEM: REV. No. : R00 PACKAGE: EPC
Bhandup (West)
Mumbai-400 078 AREA: ERECTION PAGE No.: 5/5 CONTRACT No.: TDBT1EPC/E
TYPE QUANTUM / FORMAT REMARKS/
REFERENCE DOCUMENT/
SL.NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF OF HOLD
ACCETANCE STANDARD
CHECK CHECK RECORD POINTS (H)

21 No-load test performance testing of all equipments are V B 100% Wiring Diagram
free from noise / vibration

22 Speed and current measurement at full load for CT, M Tacho-meter A 100% IS 3177 / L-04
LT & Hoist motions Stop watch Wiring Diagram and
Ammeter GA Drawing

23 Deflection test M Tape A 100% IS 807 L-05

24 Overload test at 125% of rated load performance M Voltmeter A 100% IS 3177

testing for CT, LT & Hoist movements Ammeter

LEGEND: CLASS #: A= CRITICAL, B= MAJOR, C= MINOR; FOR CUSTOMER USE

„A‟ SHALL BE WITNESSED BY FQA OF BHEL & CUSTOMER,
„B‟ SHALL BE WITNESSED BY ERECTION/ CONSTRUCTION DEPT. OF BHEL & CUSTOMER AND
„C‟ SHALL BE WITNESSED BY ERECTION OF BHEL.
MANUFACTURER MAIN SUPPLIER: TYPE @ : V- VISUAL, R- RECORD VERIFICATION, M- MEASUREMENT, P- PHYSICAL & T- TEST.
M/s WMI BHEL-PSSR
SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL
 QP NO. : QPE-NB-154
DOCUMENTS REFERRED IN
REV.NO.: R00
QUALITY PLAN
PSSR-Quality PAGE 1 OF 1

SL.NO. Reference Document Issuing Authority

1 GA Drawing of Crane, IS7215 WMI Cranes

2 Drawing, IS-3177 WMI Cranes

3 Electrical Schematic Diagram WMI Cranes

FMT-QP-017 REV.00
 RECORD OF QUALITY CHECKS
PSSR-Quality

DRAWING /
RESULTS
SHEET CHECK DOCUMENT FORMAT OF INSPECTED BY CLEARED BY
ACHIEVED REMARKS
NO. OF FQP NO. REFERENCE RECORD SIGN. & DATE SIGN. & DATE
OK / NOT OK

Note: Any protocol made is to be numbered & mentioned in “Format of Record” column.

QP NO. : QPE-NB-154
SYSTEM SUB-SYSTEM AREA
PROJECT REV. NO. : R00
UNIT NO. LOG SHEET NO. : L- 00
RATING PAGE 1 OF 1
FMT-QP-007 REV. 01
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
STEEL GANTRY

D E

Gantry Centre Span = B

B(B)

NOTE:
1. Dimensions A, B, C are to be mentioned by BHEL
2. Starting point is to be mentioned by BHEL
3. One permanent Reference Line on either side of Gantry to be given by BHEL
4. Dimension D and E are to be given every 5 Mtr. along the Gantry
5. Water Level at every 5 Mtr. along the Gantry is to be mentioned by BHEL.

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-01
RATING CUSTOMER PAGE 1 OF 3
FMT-QP-008 REV.00
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
CENTRE DISTANCE OF RAIL

1. Customer:
2. Job No. :
3. Kg Load :

Y Z

SPAN

Column Water
Span Diagonal Variation Remarks
No. Level

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-01
RATING CUSTOMER PAGE 2 OF 3
FMT-QP-008 REV.00
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
GANTRY GIRDER / LT RAIL WATER LEVEL

Column 10
Water Level Water Level Water Level

Column 9

Column 8

Column 7

Column 6

Column 5

Column 4

Column 3

Column 2

Column 1

A B
Note:
1) Water Level to be checked between Column No. A-A1, A1-A2,… so on
2) Water Level to be checked between Column No. B-B1, B1-B2,… so on
3) Water Level to be checked between Column No. A-B, A1-B1,… so on

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-01
RATING CUSTOMER PAGE 3 OF 3
FMT-QP-008 REV.00
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
CRAB CLEARANCE

WORK ORDER NO.:

VENDOR :

CAPACITY :

SPEED IN M/Min. :

HEIGHT OF LIFT IN MM HOOK APPROACH

CABIN SIDE DSL SIDE

REQUIRED

ACTUAL

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-02
RATING CUSTOMER PAGE 1 OF 1
FMT-QP-008 REV.00
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
GEARBOX ALIGNMENT WITH MOTOR

WORK ORDER NO.:

VENDOR :

CAPACITY :

TOP TOP

LEFT RIGHT LEFT RIGHT

BOTTOM BOTTOM

AXIAL RADIAL

ALLOWABLE DEVIATION: 1 mm

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-03
RATING CUSTOMER PAGE 1 OF 1
FMT-QP-008 REV.00
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
CURRENT MEASUREMENT

WORK ORDER NO.:

VENDOR :

CAPACITY :

POWER SUPPLY :

NAME OF CURRENT IN AMPS

THE NO LOAD FULL LOAD OVER LOAD (20%)
HOIST STARTING WORKING STARTING WORKING STARTING WORKING

MAIN HOIST
HOIST LOWER

AUX. HOIST
HOIST LOWER

CROSS HOIST
TRAVEL LOWER

LONG HOIST
TRAVEL LOWER

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-04
RATING CUSTOMER PAGE 1 OF 2
FMT-QP-008 REV.00
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
SPEED MEASUREMENT

WORK ORDER NO.:

VENDOR :

CAPACITY :

SPEED IN M/Min.

MAIN HOIST AUX. HOIST CROSS LONG

HOIST LOWER HOIST LOWER TRAVEL TRAVEL

REQUIRED

ACTUAL

MAIN HOISTCREEP AUX. HOIST CREEP CROSS LONG

TRAVEL TRAVEL
HOIST LOWER HOIST LOWER CREEP CREEP
REQUIRED

ACTUAL

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-04
RATING CUSTOMER PAGE 2 OF 2
FMT-QP-008 REV.00
 INSTRUMENT REGN.NO.

DATE OF INSPECTION

DRAWING / DOCUMENT REF.

PSSR-QUALITY
DEFLECTION TEST

WORK ORDER NO.:

VENDOR :

CAPACITY :

DEFLECTION IN MM WITH FULL LOAD:

DEFLECTION IN MM WITH OVER LOAD (125%):

ALLOWABLE DEFLECTION:
(REF.: IS 3177)

NAME SIGNATURE & DATE QP. NO.:QPE-NB-154

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-05
RATING CUSTOMER PAGE 1 OF 1
FMT-QP-008 REV.00
 FEEDBACK ON FIELD QUALITY PLAN
PSSR - QUALITY

In the Field Quality Plan for (FQP), following Checks / Log sheets may be added / rewritten /
deleted (cannot be carried out / not required) due to reasons as mentioned below:

Sheet No. Check No. /

Proposed Change / Reasons / Remarks
Of FQP Log Sheet No.

From: To
PROJECT Head (Quality) DOC.NO. QPE-NB-154
PS-SR, Chennai
UNIT NO. REV. NO. R00

RATING PAGE 1 OF 1
FMT-QP-018 Rev 00