A PRESENTATION

ON
TECHNICAL EXAMINATION
OF
CHP PACKAGE

04/17/24
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  Major Areas/Items of CHP

 Civil Works:
 Track hopper & tunnel up to pent house

 Crusher house/Transfer Points

 Foundation works

 Structural Works:
 Conveyor gallery & its supports/trestles

 Conveyor gallery superstructure

 Crusher House/Transfer points

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  Mechanical Works – Conveyor system

 Technological structure

 Conveyor belts

 Drive system – Motor, Gear Box, Fluid coupling,

Gear coupling & Hold Back

 Pulleys – Drive, Tail, Snub, Bend & GTU

 Idlers/Rollers

 Skirt boards/chutes

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  Mechanical Works – Major equipments

 Wagon tipplers

 Plough feeders/Grizzly feeders/Belt feeders

 Crushers – Primary & Secondary

 Stacker & Reclaimer

 Trippers

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  Electrical Works

 Control desk/mimic, PLC & control equipments

 MCC & Transformers

 LT Cables

 Belt protections

 Lighting

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 Scope of work in the package

 Design, Engineering, Manufacture, Shop fabrication,

assembly, testing and inspection at manufacturer’s
works, packing, dispatch, transportation, transit
insurance, delivery to site, receipt, unloading,
handling, storage at site, comprehensive insurance
for storage cum erection and in plant transportation at
site, fabrication at site, installation (including
associated civil, structural, electrical and allied
works), completion of facilities, performance
guarantee testing of all equipments and handing over
to the employer and furnishing of spares as per
specification and scope defined in the bidding
documents.
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VIGILANCE OBSERVATIONS
DURING EXAMINATION

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 Use of unapproved make structural steel:
 Structural steel sections without manufacturer stamp were
used by the contractor for fabrication work.

 Record showed that part material of this lot not having

manufacturer stamp was sent back as the same was not
accepted.

 Remaining material used in fabrication was accepted

based on testing got done by site officials without
considering any commercial implication.

 This was done in spite of the fact that there existed

substantial difference in price between the steel
manufactured by NTPC approved manufacturers and other
local suppliers i.e. M/s Raipur Re-rollers/M/s Abhishek
Steel from whom the above mentioned steel sections were
04/17/24
procured.
 Use of unapproved electrodes in fabrication
work

 As per contract provision, the approval of NTPC

was to be specifically obtained by the contractor for
all the welding consumables.

 During inspection of the work at site, use of

unapproved electrodes make ‘Super Weld’ was
observed.

04/17/24
  Width of conveyor walkway not as per the
specifications

 The following was stipulated under relevant clause

of technical specifications for conveyor walkway -

The floors of outdoor conveyor galleries

shall be designed and constructed as
follows – Clear side and central walkways
for double streams conveyors shall be 800
mm and 1100 mm wide respectively. The side
walkway for single conveyors shall be 800
mm width one side and 1100 mm on the other
side.

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 A cable tray of size 150 mm X 75 mm was found
erected in the side walkway along with the supports
of the conveyor throughout gallery leaving the
clearance less by 75 mm than the stipulated figure.
 This arrangement was found to be as per drawing
which is in deviation to the requirement of the
specification.
 In order to accommodate the cable trays for control
cables of conveyor protection in the walkways, width
of the walkways should have been designed
accordingly so that a clear walkway of 800 mm could
have been maintained as per the specification
requirements.
 As the deviation applies to the full length of the
conveyor system of the CHP, it had a substantial
cost implication.
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 Discrepancies in cable laying
 The following were observed -
1. Cable 3C X 150 sq mm of length 1900 mtrs was laid
without cable tray.
2. Tagging of cables was not done.
3. Dressing of the cables was not done and cables were
hanging from the supports and the trays at many
places.
At location TR-2 trestle (400 mtrs) - earthing was not
done.
At location TR-28 TR 01 A/3 (40 mtrs) - earthing was
not done.
At location TR-18 to TR-8 (40 mtrs) - earthing not
done
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 Non-conformance to the drawing for pre-cast
slabs of cable trench

 As per relevant drawing, the lugs of 25X6 mm MS flat

with splitting at one end were to be used for edge
protection angle of pre-cast slab and cable trench.

 The agency was found to be using 10 mm

reinforcement rod as lugs for pre-cast slabs edge
protection angle in place of MS flats.

04/17/24
  Non Conformance to the specification for
painting

 Non-conformance to painting specifications is

generally observed specially with respect to
 Surface cleaning/preparation
 Records maintained for different coats of painting
i.e. primer coat, intermediate coats & final finish
coat.
 Total DFT of paint.

 Paint should also be randomly checked w.r.t.

approved make, paint type & storage/shelf life
etc.
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  Testing of samples

 The following samples of various items were jointly

taken by the representatives of Execution & FQA
departments and the Agency -
 Conveyor belt (from conveyor number 30A/ 30B)
 Cable tray (150 mm ladder type)
 Conduit pipe (25 mm dia)
 XLPE cables (3Cx240 Sq mm & 3Cx185 Sq mm)

The testing of these samples was got done as per

the relevant standards.

04/17/24
 Non-conformance to the specification for Dust
Suppression System on Stacker-Reclaimer

 The relevant clause of Technical Specifications for

Stacker Reclaimer states -
“Stacker/Reclaimer shall have
effective dust suppression system so
that dust generation during
stacking/reclaiming can be minimized.”

 Neither the same was installed nor was the

provision for the same kept in the drawing.

04/17/24
 Reduction in scope of the work of road, road light
and drains

 As per the relevant clause of Technical Specification,

the following was included in the scope of contractor -

 Concrete paved access to various CHP buildings from

the nearest road.

 Road along Conveyor 30A/B.

 Road lighting along Conveyor 30A/B.

 These works were not completely provided by the

Agency.
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  CHP being the lump sum contract, the construction
of entire road all along the Conveyor 30 A/B along
with the road light and associated drain work was in
the scope of the agency. However due to site
conditions the above work could not be done
throughout the length of the conveyor and hence
resulted in scope reduction.

 A rebate on account of the above deviations/scope

reduction with respect to the specifications was
worked out & recovered from the agency.

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