TOUR REPORT FOR SITE VISIT FROM 25th TO 27th APRIL 2022 IN CONNECTION WITH

SURVEILLANCE CHECK & FQP IMPLEMENTATION FOR THE ONGOING FGD PROJECTS AT RTPS
(2X600MW) & DSTPS (2X500MW) [EPC: L&T].

A team of QC&I Engineers, comprising of the DCE (E)/HQ, SE (E)/RIO-Trichy, and SDE (C)/HQ
visited RTPS & DSTPS for carrying out the above-mentioned work from 25 th to 27th APRIL, 2022.
A detailed walk-down survey on the FGD construction site was done with the Quality and
Construction wing of L&T and DVC.

It will not be out of place to mention that the equipment of FGD system will be operated in
highly erosive / corrosive environment on a continuous basis. Special type of materials (Like
Absorber Tank Liners, Flue Gas Liners, Chimney Liners etc.) / equipment will be used to take
care of corrosion / erosion and other potential hazards, safety etc.

Erection and commissioning of critical equipment / system like Absorber Tanks, Mist
Eliminators, Chimney Liners, RC Pumps, Wet Limestone Grinding Mills, and Limestone
Dewatering Systems will be of a great challenge while enforcing Quality checks during erection
of the equipment / system by strictly adhering to the Project Timeline.

The concern was raised to respective EPC Project team and Quality wing in presence of DVC
erection team to achieve the goal of defect free erection & commissioning by identification of
risk and mitigation measures while enforcing quality checks during erection & commissioning.

The visit details/observations & checks carried out and areas identified for taking improvement
measures are detailed in Annexure-I which is broadly categorized in two different fronts viz. 1)
DVC internal resource deployment for immediate strengthening of site FQA and 2) Action
points related to the EPC.

Based on the detailed observation of QC&I Engineers team as attached in Annexure-I, you are
kindly requested to take improvement measures / corrective actions.

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 ANNEXURE-I

RTPS:

1. Booster Fan: The static parts of Booster Fan have been erected over respective
foundations. The erection of part flue duct is seen in progress. The biplane dampers for
both the units are uninstalled.

2. Chimney: The Chimney RCC Windshield with RCC Roof casting for U#1 is completed. The
erection of intermediate floor girders at U#1 was seen completed. The power packs for
lifting of U#1 flue has reached site and due to be placed shortly as intimated by L&T.
QC&I team checked the twist & CL of under construction U#2 RCC windshield. The
measured value found within acceptance limit.

3. Absorber Tank: Erection is in progress both U#1 &2. However, Absorber Tank for U#1 is
in advance Stage. The welding of bottom clad plate of Absorber Tank for U#1 and
welding of C276 strip over joint is seen in progress. Absorber Tank for U#2 is
QC&I Team witnessed the Vacuum Box Test over a finished joint of bottom Clad Plate
and found the result satisfactory.
Mist Eliminator: Erection of the Mist Eliminator is yet to start. The MoC of Mist
Eliminators is Polysulfone which is having very high strength and high heat resistance
and welding is practically impossible / difficult. There had been several failure histories
of Mist Eliminators globally in FGD application due to erection defects. It was discussed
and advised to L&T and DVC Site team that during Erection of Mist Eliminator extra
measures and vigil are to be maintained. In order to achieve good quality of Erection,
Erection checks/ Procedure is to be gathered from the respective manufacturers along
with Quality Control measures to be taken during erection for risk mitigation so that
equipment can be erected with proper fitment / tolerances towards attaining desired
life.

4. FRP Lining & FRP Lamination: The bottom of columns with foundation bolt, joints of
columns to beams and beams to side cladding inside absorber were found unladed with
C276. M/s. L&T claimed to cover the same with FRP Lining & FRP Lamination over CS
Plate at joint portion.
M/s. L&T was requested to send the FRP lining materials details and application
procedure to DVC for review.

5. Borosilicate lining procedure: It was advised to DVC and L&T site Team to collect the
detailed Erection Procedure from the Manufacturer so that the erection tolerances are

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 well within the limit (3 mm Radial Tolerance) to avoid liquid re-entrainment (Acid Rain)
during running of the FGD system.

As gathered, there had been a failure / peel off in primer / adhesive layer during
erection of Borosilicate in recent ongoing FGD Project in India due to suspected poor
bonding. The EPC, M/s L&T may be advised to prepare comprehensive risk mitigation
and control measures during erection of Borosilicate Lining System (Primer, Adhesive,
Borosilicate Blocks).

It was advised to L&T & DVC Site team to give focused attention during erection of
Borosilicate Lining System and to ensure that all erection works of related to
Borosilicate Lining are done under the strict supervision and guidance of Manufacturer
representative (M/s. ZES/China) considering the works will be continued round the
clock.
6. Crusher House: The Crusher House major structural erection is seen completed. The
RCC slabs at Head Pulley of LC-1A/B, VFS & Cr. Deck slab with main platform has been
casted. The Crushers were seen placed over RCC decks.

7. SILO: The LS Bulk silo erection seen in progress. The ring girder for one number silo is
erected, other one at fabrication. The placement & tack welding of SS liner inside Silo
hopper seen in progress. On discussion, it was understood that the WPQ for welder for
SS to MS plate has not been carried out at RTPS (as on 26 th Apr’22), although plug
welds of SS liner were seen carried out (ref. Pic-1).

Fig. 1

8. Fabrication Yard & Consumables Store:

a) The Titanium plates seen rolled/bent and kept covered with Tarpaulin Sheet at
fabrication yard. Titanium plates kept over wooden planks and separated from CS

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 plates. Prior to rolling of Titanium plates, the MS rollers were covered with
aluminum coil. However, the same seen covered by merely Tarpaulin Sheet may
prove inefficient.
b) The Flue Can fabrication seen in progress. Outer primer is made after completion of
final welding of shell plate. However, inside surface primer would be made post
erection. M/s. L&T was requested to furnish abrasion & application procedure for
Borosilicate primer, adhesive & blocks.
c) It was observed that Flue Can Parts were fabricated & painted and were kept in
open yard. There had been considerable presence of dust/coal dust wave during our
visit. EPC should take a control measure plan / precautionary measure from the
manufacturer immediately or well before the start of carrying out primer job in open
yard and storage thereby.
d) Consumable’s store: Elevated platforms for storing of electrodes and room heater
found.

9. Material Storage at site – The storage of supplied materials of FGD Project were
reviewed at site. The stores were visited by QC&I team. After a complete visit at the
stores of FGD Project, most of the received material were stored in the covered area.
However, it emerged that there is some need for improving the storage of materials as
per storage guidelines/policy at site before the onset of monsoon. L&T & DVC-RTPS
were informed to take care of the critical items like DG Set, RC pumps, Pulley, C&I items
(viz. DCS Panels, etc.) which must be stored under covered area.

10. Lab & Batching Plant: The team visited the batching plant & Lab of L&T RTPS and
checked the calibration details of the instruments/equipment used. The developed RT
films at RTPS were randomly checked. The marking of joints & preservation of records
seems organized.

11. Documents Verification: QC&I Team verified the important documents like
WPS/PQR/WPQ, Registers/Records, etc. maintained at site. Record keeping was found
to be well maintained. QC&I team suggested some improvements reg. keeping the
history of repairs and traceability of the same.

QC&I Team informed L&T & DVC-RTPS that All the erections are to be done as per
approved FQP. Site FQA to enforce 100 % witness for all Class-A checks and surveillance
checks to all Class-B checks. During start of erection of any mechanical equipment, civil
GA should be matched with the mechanical GA of equipment & the protocols should be
jointly signed by Civil & mechanical engineers along with the representatives of EPC.

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 Also ensure the availability of all the erection drawing, field welding schedule, WPS,
Erection procedure etc. well in advance before start of activity as per approved FQP.

During erection checks all the fitments, tolerances are to be recorded and jointly signed
in the site Register by DVC and L&T. EPC (L&T) will also ensure the submission of QA
Dossier with proper indexing as per FQP on completion of the respective job.

12. Safety: L&T was also advised to ensure the safety measures of hanging mechanism for
safe erection of Borosilicate Lining System, etc. and also to ensure the safe & proper
platforms for carrying out welding jobs, erection jobs & inspection jobs at elevated
areas of Chimney & Absorber tank, etc. at site. QC&I team randomly checked the
documents of Rope Guide Hoist used in the construction at site and found it to ok.

13. Number of Welders for C276, Titanium, SS: During site visit, very few numbers of C-276
welders were noticed. Considering tight Project Schedule, huge volume of Welds,
Fatigue of Welders, Welding NDT Check, Day and Night Shifts of Welding,
Representatives of L&T Quality at site was advised to immediately strengthen the
number of welders for Absorber Tank welding. Already, vertical position welding &
stiffener welding has started up for Absorber Tank for U#1. To ensure defect free
erection of Absorber Tank, M/s. L&T has to immediately increase the welder’s strength
for absorber tank. There should be sufficient nos. of Welders in pool for Absorber Tank
welding so that welding joint defect due to welders’ fatigue can be eliminated which is
very common in Absorber tank Welding. QC&I Team asked L&T to furnish the complete
details of Welders requirement for C276, Titanium, SS Vs. available number of welders
at RTPS at present. QC&I Team also informed L&T to submit the Welders’ experience
certificate/credentials esp. for critical welding areas viz. C276, Titanium, SS. It was also
informed to submit the credentials of RT/UT Agencies engaged by L&T at RTPS.

14. ANST Level-II Inspectors: Considering the quantum of welding work & RT involved,
number of ANST Level-II inspectors may be increased as currently only one ASNT Level-II
inspector is available at site.

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DSTPS:

1. Booster Fan: The Booster fan static part seen placed over foundation. Biplane damper
installation for none of the unit done.
2. For majority of duct support structures, bulk silo structures, BRU system the civil
foundation has not been completed yet. L&T cited high depth of foundation as reason of
delay in civil foundation.
3. The tack welding of bottom clad plate of Absorber#1 seen in progress. The Civil
foundation for Absorber#2 yet to finish.
4. The RCC Roof casting of chimney#1 completed. The welding of Titanium plate flue can
have been commenced in fabrication yard. M/s. L&T was advised to take precautionary
measure to avoid painting/ priming during dusty wind to avoid ingress of dust over
coated surface.
5. The internal platforms of Cr. House yet to be casted along with cr. Deck. Only deck
sheeting has been done.
6. As civil foundations for most of the structures are incomplete, many of the equipment’s
were seen lying open on road side with tarpoline covered.
7. The team visited the borosilicate primer store, which has been kept temperature
controlled.
8. The consumable store was visited and proper stacking of consumable were noticed.
9. The team visited the batching plant and Lab of DSTPS. The civil & structural
documentation of L&T RTPS were surveil lanced and found generally in order.
10. However, the WPS with supported PQR for all types of welding envisaged and WPQ of all
welders were found readily unavailable there. M/s. L&T was requested to compile the
WPS with supported PQR and plant wise WPQ with accepted welders and sent it to DVC.

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TOUR NOTE FOR SITE VISIT ON 15th & 16th FEBRUARY 2022 IN CONNECTION WITH THE KTPS
FGD SYSTEM.

The works of FGD System installation for Koderma TPS (2X500MW) plant was awarded to M/s.
Thermax Limited, Pune-711026, Maharashtra. The said FGD system installation consisting of
various Civil, Structural, Mechanical, Electrical and C&I activities is presently being executed at
Koderma TPS by M/s. Thermax Ltd.

The team visited Koderma TPS FGD site from 15th to 16th February 2022 in respect of progress of
work and quality thereof.

OBSERVATIONS:

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1. The visit commenced from the Booster Fan foundation of FGD System and it was seen
that grouting work in BUF#1B has been completed and grouting work of BUF#2B was
going on. It as reported by the DVC site authority that UPV Test had been carried out in
Booster Fan foundation #1A/B, Booster fan Pedestal #1A/B and RCC Ball Mill Pedestal#
1/2.
It was found that only two persons are engaged in grouting activities & simultaneous
drilling and grouting activities were not being carried out at site. M/s. Thermax was
advised to engage additional man power to carry out simultaneous drilling as well
grouting activities at site.
2. Chimney casting work for U#1 was being carried out at EL +138.0 M. Chimney casting of
U#2 was at hault for scarcity of sand at site at EL +45.0 M.
As the concrete shell casting of U#1 would be completed shortly, M/s. Thermax was
advised to tie up with DVC approved vendor to procure deck sheet shuttering for RCC
Chimney roof at (+)142.0M. The same shall also be needed for Chimney RCC roof of U#2
and RCC Roof & Platforms of Crusher House.
3. M/s. Thermax was advised to prepare complete Bar Bending Schedule (BBS) for all civil
structure and place immediate order over DVC’s approved vendor to expedite the
procurement of reinforcement steel and avoiding shortfall of same at site.
4. Owing to existing plant pipeline very near alongside LS conveyor line, additional
structural supports were being engaged to facilitate excavation for BRU/ LS Conveyor &
Crusher.
The BRU and Crusher foundation works were in progress. M/s. Thermax advised to
expedite crusher house works as the same is quite high duration activity.
5. Most of the civil foundations except BRU, Crusher house & Lime Stone (LS) Conveyor
have been constructed above FGL. M/s. Thermax was advised to expedite the work of
BRU, Crusher House & LS Conveyor foundation to complete the same upto minimum
above FGL before the next monsoon.
6. The team visited Batching plant of Thermax. The Civil Lab was found to consist of
primarily Compression Testing machine, Sieves for Gradation of Aggregates, Electric
Oven, Core Cutter Test Apparatus, Vicat Apparatus, Proctor Test apparatus etc. The
calibration records of the same were reviewed and found generally in order.
7. The team verified the Cube test register, pour card register, Coarse & Fine aggregate
test registers etc. The documents were found alright.
8. To assess the strength of concrete, a cube of grade M25 at the end of 26Days was taken
from the curing tank and after some time was crushed in compression testing machine.
The compressive strength of the cube was observed as 31.6MPa which is satisfactory.
9. The team visited the fabrication yard of Thermax. The fabrication, testing equipment’s
were found satisfactory.

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 10. M/s. Thermax was advised to write the casting date over exposed concrete surface of
the specific structures after stripping, for ensuring the required curing time.

(P. Manna) (B. Sarkar)

SDE(C), QC&I DCE (C), QC&I
DVC, Kolkata DVC, Kolkata

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