Digitally signed by

V Srinivasa Rao
Date: 2010.05.11
19:39:40
GMT+05:30
Reason: CAT I
Location:
NTPCEOC
 Sheet1

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MANUFACTURER'S NAME &
ADDRESS MANUFACTURING QUALITY PLAN PROJECT : NTPC MAUDA STPP (2X500 MW)

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REVA INDUSTRIES LIMITED ITEM : DOUBLE GIRDER EOT CRANE UPTO – 45T PACKAGE :
PLOT NO.-28, SECTOR-25 LOAD NO. :
NIT FARIDABAD-121004 DOC NO. : 2630/QAP MAIN SUPPLIER : FLOWMORE (P) LTD
HARYANA
REV : 01 DATE : 24.03.10 CONTRACT NO. :

33
-1
61
95
SL. COMPONENT/ TYPE OF REFERANCE ACCEPTANCE FORMAT OF
CHARACTERISTICS CLASS QUANTUM OF CHECK Agency Remarks
No. OPERATION CHECK DOCUMENTS NORMS RECORD
1 2 3 4 5 6 7 8 9 10 11
M C/N D M C N
Plates & Structural / Dimensional Conformity MA Measurement 100% Approved Drawing / Datasheet/ -- - P V -
Test will be Carried
Raw Material for Hoist, Chemical MA Chemical 1/ Lot Manufacturing Drawing Lab TC √ P V V out in absence of Mill
Girder End carriage (IS:2062 Gr. A OR B)
1.1 Mechanical MA Mechanical 1/ Lot Lab TC IR √ P V V TC
TISCO/ISCO/SAIL
UT > 25 Mm Thick Plates MA UT 100% ASTM A 435 ASTM A 435 UT REPORT √ P V V only Corrected TC

Gears, Pinion, Shafts Chemical Approved Drawing / Datasheet/ There is no

Chemical & Mechanical MA 1/ Size Lab TC IR √ P V V
Mechanical Manufacturing Drawing mechanical
1.2
NDT> (For diameter / thick properties specified
MA Ultrasonic Test 100% ASTM A 388 NOTE-3 UT REPORT √ P V V DIN 17210
above 4 0mm)
Gear Box Housings/
Tensile MA Tensile 1/Heat P V V
1.3 Sheave/ Pulley Approved Drawing / Datasheet TC √
Hardness MA Hardness 100% P V V
Seamless Tube Acid etching test MA Chemical HEAT Approved Drawing/ Data Sheet Lab TC √ P V V
for Rope Drum Flattening test MA Mechanical HEAT Approved Drawing/ Data Sheet Lab TC √ P V V
1.4 Chemical MA Chemical 1/ Size Approved Drawing/ Data Sheet Lab TC √ P V V
Mechanical MA Mechanical 1/size Approved Drawing/ Data Sheet LabTC √ P V V
Soundness MA UT>25mm THK. ASTM A-388 NOTE-3 Lab TC √ P W V
Wheels Chemical MA Chemical 1/lot Lab TC √ P V V
1.5 Mechanical MA Mechanical 1/lot Approved Drawing/ Data Sheet Lab TC √ P V V
Hardness MA Hardness 100% IR √ P V V
Hooks Chemical MA Chemical 1/lot -- Mfr. TC √ P V V
Approved Drawing/ Data Sheet
1.6 Mechanical MA Mechanical 1/lot -- Mfr. TC √ P V V
Soundness MA Ultrasonic Test 100% -- ASTM A 388 IR √

W
NOTE-3 P W V
LEGEND : * RECORDS, IDENTIFIED WITH '' TICK'' SHALL BE DOC.No. :
ESSENTIALLY INCLUDED BY SUPPLIER IN QA
DOCUMENTATION ** M:MANUFACTURER/ SUB SUPPLIER
C:MAIN SUPPLIER,N:NTPC, P:PERFORM ,'W: WITNESS and
Manufacturer/ Sub V: VERIFICATION AS APPROPRIATE, ''CHP'' NTPC SHALL
Main Supplier INDICATED IN COLOUM ''N'' AS "W"
supplier FOR NTPC USE
REVIEWED BY APPROVED BY
SIGNATURE

Page 1
 Sheet1

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MANUFACTURER'S NAME &
ADDRESS MANUFACTURING QUALITY PLAN PROJECT : NTPC MAUDA STPP (2X500 MW)
REVA INDUSTRIES LIMITED ITEM : DOUBLE GIRDER EOT CRANE UPTO – 45T PACKAGE :
PLOT NO.-28, SECTOR-25 LOAD NO. :
NIT FARIDABAD-121004 DOC NO. : 2630/QAP MAIN SUPPLIER : FLOWMORE (P) LTD
HARYANA
REV : 01 DATE : 24.03.10 CONTRACT NO. :
SL. COMPONENT/ TYPE OF REFERANCE ACCEPTANCE FORMAT OF
CHARACTERISTICS CLASS QUANTUM OF CHECK Agency Remarks
No. OPERATION CHECK DOCUMENTS NORMS RECORD
1 2 3 4 5 6 7 8 9 10 11
M C/N D M C N
Wire Rope Dimensional Conformity MA Measurement Random -- Mfr. TC √ P V V

1.7 Breaking Load MA Review of TC Verify -- Approved Drawing/ Data Sheet Mfr. TC √ P V V
Tensile MA Review of TC Verify -- Mfr. TC √ P V V
Type/Construction MA Review of TC Verify _ Mfr. TC √ P V V
Brake Verification of Type, Rating
1.8 MA Review of TC 100% -- Approved Drawing/ Data Sheet Mfr. TC √ P V V
& Routine TC
Verification of Routine Test
1.9 Motor MA Review of TC 100% -- Approved Drawing / datasheet / IS 325 Mfr. TC √ P V V
Certificate
Cables Type, rating, Routine Test Verify/Review of
1.10 MA 100% -- Approved Drawing/ Data Sheet Mfr. TC √ P V V
Report TC
Verification of Make &
1.11 Bearings MA Verify 100% -- Approved Drawing/ Data Sheet Compliance √ P V V
Model No.
Control Transformer,
Limit switch, Relay Verification of Make &
1.12 etc. MA Verify 100% -- Approved / Mfg. drg./ Annex A for BOLs Compliance √ P V V
Model No.

II INPROCESS INSPECTION
WPS, PQR Visual &
PQR CR 100% -- ASME SEC IX ASME SEC IX QW 482, 483 √ P V V
Mechanical
2.1 Refer Note 2
Welder Qualification Approved WPS,
WPQ CR -Do- 100% -- ASME SEC IX QW 484 √ P V V
ASME SEC IX
LEGEND : * RECORDS, IDENTIFIED WITH '' TICK'' SHALL BE DOC.No. :
ESSENTIALLY INCLUDED BY SUPPLIER IN QA
DOCUMENTATION ** M:MANUFACTURER/ SUB SUPPLIER
C:MAIN SUPPLIER,N:NTPC, P:PERFORM ,'W: WITNESS and
V: VERIFICATION AS APPROPRIATE, ''CHP'' NTPC SHALL
Manufacturer/ Sub
Main Supplier INDICATED IN COLOUM ''N'' AS "W"
supplier FOR NTPC USE
REVIEWED BY APPROVED BY
SIGNATURE

Page 2
 Sheet1

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MANUFACTURER'S NAME &
ADDRESS MANUFACTURING QUALITY PLAN PROJECT : NTPC MAUDA STPP (2X500 MW)
REVA INDUSTRIES LIMITED ITEM : DOUBLE GIRDER EOT CRANE UPTO – 45T PACKAGE :
PLOT NO.-28, SECTOR-25 LOAD NO. :
NIT FARIDABAD-121004 DOC NO. : 2630/QAP MAIN SUPPLIER : FLOWMORE (P) LTD
HARYANA
REV : 01 DATE : 24.03.10 CONTRACT NO. :
SL. COMPONENT/ TYPE OF REFERANCE ACCEPTANCE FORMAT OF
CHARACTERISTICS CLASS QUANTUM OF CHECK Agency Remarks
No. OPERATION CHECK DOCUMENTS NORMS RECORD
1 2 3 4 5 6 7 8 9 10 11
M C/N D M C N
Gears/Pinion after Visual
machining Visual & Dimensional MA 100% - Manufacturing Drawing IR − P V V
Measurement
2.2 Hardness MA Hardness 100% - DO IR √ P V V
MPI on wheels, Gear No Relevant W

C
Y
B
%
0
10
& Pinion MPI MA MPI 100% - ASME 709 IR √ P V
Indication
Hook

W
Proof Load MA Load Test 100% - IS 15560/IS 5749 IR √ P V V
2.3 DPT Before & After Proof 100% ASTME 165 /

W
MA DTP 100% No Linear Indication IR √ P W V
load BY C IS 3658
Welding of Main Visual MA Visual 100% - Good appearance of weld IR √ P V V
Girder & End Carriage RT FILMS WILL
DPT on Root Run of Butt

M
T
S
A
MA DP test 100% - IR √ P V V BE REVIEWED
Weld after BG ASM E 165 /
No Linear Indication BY NTPC
2.4 DPT on final weld of Butt 100% IS: 3658 DURING LOAD
MA DP test 100% IR √ P W V
weld & Fillet Weld BY C TEST
ASME SEC VIII DIV – CHP

*
v/w
RT On Butt Weld MA RT Note 4 & 5 ASME SECTION V IR √ P V V
I UW 51/52

random
areas at
doubtful
NTPC on
checked by
may be
weldment
final
*DP test on
Gear Box
Gear Ratio, Back MA Measurement 100% -- Approved Drawing / Datasheet / Mfg std IR √ P V V
No load test on
Lash(contact &
2.5 Hoisting gear box for 4
pattern)sound NO LEAKAGE OF OIL, Vib- 75 microns
hours in each side MA Visual 100% 10% By c IR √ P w V
level,vibration,oil leakage max noise 85 db max @ Distance of 1m
III FINAL INSPECTION
LEGEND : * RECORDS, IDENTIFIED WITH '' TICK'' SHALL BE DOC.No. :
ESSENTIALLY INCLUDED BY SUPPLIER IN QA
DOCUMENTATION ** M:MANUFACTURER/ SUB SUPPLIER
C:MAIN SUPPLIER,N:NTPC, P:PERFORM ,'W: WITNESS and
V: VERIFICATION AS APPROPRIATE, ''CHP'' NTPC SHALL
Manufacturer/ Sub
Main Supplier INDICATED IN COLOUM ''N'' AS "W"
supplier FOR NTPC USE
REVIEWED BY APPROVED BY
SIGNATURE

Page 3
 Sheet1

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MANUFACTURER'S NAME &
ADDRESS MANUFACTURING QUALITY PLAN PROJECT : NTPC MAUDA STPP (2X500 MW)
REVA INDUSTRIES LIMITED ITEM : DOUBLE GIRDER EOT CRANE UPTO – 45T PACKAGE :
PLOT NO.-28, SECTOR-25 LOAD NO. :
NIT FARIDABAD-121004 DOC NO. : 2630/QAP MAIN SUPPLIER : FLOWMORE (P) LTD
HARYANA
REV : 01 DATE : 24.03.10 CONTRACT NO. :
SL. COMPONENT/ TYPE OF REFERANCE ACCEPTANCE FORMAT OF
CHARACTERISTICS CLASS QUANTUM OF CHECK Agency Remarks
No. OPERATION CHECK DOCUMENTS NORMS RECORD
1 2 3 4 5 6 7 8 9 10 11
M C/N D M C N
Assembly of Crane & Completeness &
MA Visual 100% Approved drawing/ Datasheet √ P W W CHP
Hoists Correctness
3.1 CRITICAL
Dimensions MA Measurement 100% Dim. Rep. √ P W W
DIMENSIONS Approved drawing/ Datasheet/IS807
Span, level MA Measurement 100% 100% Dim. Rep. √ P W W
Motor Current, Speed
L
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N
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FL
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TES
SWL
AND
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D
LOA
NO

IS 3177
HEET.
DATAS
VED
APPRO
NG /
DRAWI
VED
APPRO
2
3.

during Hoisting & CT at CR Measurement 100% 100% IR √ P W W

D
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L
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N
&

SWL
Inching operation,
TION,
OPERA
H
SWITC
LIMIT
TEST,
OCK
INTERL
TION,
OPERA
G
INCHIN

interlocking, limit switch CR Performance 100% 100% IR √ P W W

operation
Lifting from mid-
3.3 Overload Test Holding capacity CR 100% 100% Approved Drawing / Datasheet / IS 3177 IR √ P W W
air
Control Panel High Voltage MA HV for 1 min. 100% 100%
Apprd. Drwg. / Manufacturer’s Circuit
3.4 Insulation resistance MA IR 100% 100% IR √ P W W
Diagram
Functional Test MA Functional 100% 100%
Degree of protection by
Paper should not go easily √ P V V
paper insertion method
3.5 Painting Visual MA Visual 100% --
DFT MA Measurement Rndm -- Approved painting Schedule - P V -
Strip test MA Strip test Rndm --
1. All materials shall be as per approved drawing.
2. NTPC approved WPS & Welders to be deployed. If already qualified for other projects then previously approved WPS & PQR record shall be verified during final inspection.
3. For Ultrasonic Test Normal Beam Probe of 20 mm / 25 mm Diameter and 2MHz frequency shall be used. Using this probe the Back wall Echo is set to 100% of FSH in sound area. At this sensitivity setting any defect
echo more than 20% of FSH is not acceptable. Also the loss in Back wall echo 20% of FSH is not acceptable.
4. The Radiography on Girder Welds shall be 100% for the joints exposed to tensile stresses and 25 % of the joints exposed to Compressive stresses. RT film shall be reviewed by NTPC.
T
R

5. For radiographic Welding all films shall be offered with co relation for Verification during Final Inspection.
N
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LEGEND : * RECORDS, IDENTIFIED WITH '' TICK'' SHALL BE DOC.No. : ………………………… Rev : 0
ESSENTIALLY INCLUDED BY SUPPLIER IN QA
DOCUMENTATION ** M:MANUFACTURER/ SUB SUPPLIER
C:MAIN SUPPLIER,N:NTPC, P:PERFORM ,'W: WITNESS and
V: VERIFICATION AS APPROPRIATE, ''CHP'' NTPC SHALL
Manufacturer/ Sub INDICATED IN COLOUM ''N'' AS "W"
Main Supplier
supplier FOR NTPC USE
REVIEWED BY APPROVED BY
SIGNATURE

Page 4
 Approved in CAT-I with comments as marked.
MANUFACTURER
NAME & ADDRESS: - ANNEXURE ‘A’ PROJECT NTPC MAUDA (2X500MW)

M/S REVA INDUSTRIES SOURCE OF

PRODUCT: EOT CRANES UP TO 45T
LIMITED BOUGHT OUT ITEMS
PLOT NO. 28,
SECTOR 25, MAIN SUPPLIER M/S FLOWMORE LIMITED
FARIDABAD - 121004 PAGE 1 OF 1
SUB CONTRACTOR M/S REVA INDUSTRIES LTD.

STEEL : SAIL \ IISCO\ TISCO \ MUKAND

MOTORS : CROMPTON – AHMED NAGAR / LHP- SOLAPUR / ABB – FARIDABAD, BANGALURU/

BBL – MUMBAI / SIEMENS – MUMBAI / KIRLOSKAR – HUBLI , BANGALURU/
MARATHON – KOLKATA
BRAKES AND RECTIFIER

A) EM DISC : ELECTROMAG / PETHE / EMCO LENZE

B) EHT BRAKE : SPEED-O-CONTROL, MUMBAI

GEAR BOX : OWN MAKE – 100 % IN HOUSE FACILITY

WIRE ROPE : USHA MARTIN / FORT WILLIAM / BOMBAY WIRE ROPE

HOOKS : HERMAN – MOHATTA & KARACHIWALA UP TO 15T / SMRITI FORGING UP TO 150T

COUPLING : OWN MAKE – 100 % IN HOUSE FACILITY

LIMIT SWITCHES : BCH / SPEED-O-CONTROL, MUMBAI

CONTACTOR & OLR : SIEMENS/L & T / TELEMECANIQUE/ABB

FUSES : SIEMENS/L &T / GEPC

FLEXIBLE CABLE : UNIVERSAL/ POLYCAB/NICCO / FINOLEX / KEI .

BEARING : SKF / FAG / NTN / NBC(NEI) / TIMKEN

PUSH BUTTONS : : VAISHNO / L&T / SIEMENS / TELEMECANIQUE

PUSH BUTTON : L & T / SIEMENS / VAISHNO

STATION (PENDANT)

INDICATING LIGHT : SIEMENS / VAISHNO

TRANSFORMERS : LOGICSTAT / INDCOIL

TPN SWITCHES : C & S/L & T / SIEMENS

VVVF DRIVE : L & T / YASKAEA (YASKAWA)

MANUFACTURER/ MAIN SUPPLIER NTPC

SUB SUPPLIER
Submission
For Approval For Review Revision

AUTHIRISED
SIGNATURE