LAFARGE

QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations 1.0 RAW MATERIAL 1.1 Physical & Chemical Properties Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement ( Contract no : SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Strl / Tech.str Fabrication & Erection) Equipment: Q.C.P ref: QP for strl&tech. Str. Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no. Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection

VC

1&2

CC No 1

1.2

U.T.on above 40mm Thickness Plates

VC

1&2

CR No 1

IS-2062,IS-8500,IS-1162,IS-3502 BDS 878 : 1978, BDS 1355 : 1992 Grades as per approved drgs. Review of Mill TC's for chemical mechanical properties ASTM A 435 / AWSD1.1 Review of Mill T.C No surface Defects Inspection Report

1.3

Visual Examination

VC

CR No 1

2.0

IN PROCESS INSPECTION Marking and cutting

DIM

CR No 2

Approved drg.

3.0 3.1

FITUP Ensure Proper fit up before welding DIM 1 CR No 2 Approved drg.

3.2

Check that Gap for all

DIM

CR No 2

- Do -

Page 1 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations fillet weld,as per standard. 4.0 4.1 Pre heating and PW HT Ensure Preheating and PW HT as per approval WSP/ Tech.spcc Welding Welding procedures and Welders Qualification test. VC VC Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement ( Contract no : SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Strl / Tech.str Fabrication & Erection) Equipment: Q.C.P ref: QP for strl&tech. Str. Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no. Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection

CR No 3

Approved WPS/Protocol Tech.spec. (Thermo challk)

5.0 5.1

CR No 4

ASME IX / Approved Record Test WPS

5.2 Ensure welding consumables are used as per approval electrodes list 5.3 Ensure proper storage backing and Handing of Electrodes Ensure proper Sequence of welding Non Destructive Testing (SHOP AND SITE WELDS) Butt Welds

VC

CR No 4

List of Approved Electrodes

VC

CR No 4

As per manufacturer's recommendations Technical Specification

5.4 6.0

VC

CR No 4

6.1

Page 2 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases a b (i) (ii)
o

Project: Lafarge Cement ( Contract no : SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Strl / Tech.str Fabrication & Erection) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection DP RD / US RD / US Item No. Interventions Participants 1 1&2 1&2 Date Report no. CR No 5 CR No 5 CR No 5 Remarks Remarks AWSD1.1/ Tech.Sepc. AWSD1.1/ Tech.Sepc. AWSD1.1/ Tech.Sepc. Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment: Q.C.P ref: QP for strl&tech. Str. Date 31.05.03 Revision 0

Manufacturing Operations Operations DPT on root Run after back gauging Radiography or ultrasonic test on compression zone Butt welds at fabrication shop. R.T or UT on tension zone Butt welds at fabrication shop. Fillet welds Check size and visual defects Dye penetration test

6.2 a) b)

VC + DIM VC

1 1

CR No 5 CR No 5

Approved drawing ASWD 1.1 and Tech. Specn. No liner and round indications ASME sectron IX/WSD 1.1

c)

MACRO Eich. Examination on production test coupon Check individual structure for Dimensional tolerances, match mark length, camber, sweep marking of holes for fitment etc. as per Technical Specification IS 7215 Check cleaning & painting & dry

MT

1&2

CR No 6

7.0

DIM

CR No 7

IS-7215 , BNBC Part 6 : 10.11.2.7 /Approved drg.

8.0

VC + DIM

CR No 8

Tech. Spec./ Appd. Drg.

Page 3 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations film thickness,including final coat. 9.0 Shop Assy ( trial assy) before despatch for Erection ERECTION Documents Reviews, completeness of tests Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement ( Contract no : SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Strl / Tech.str Fabrication & Erection) Equipment: Q.C.P ref: QP for strl&tech. Str. Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no. Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection

DIM

CR No 9

Approved drawing

10.1

VC

1&2

CR No 10

Appd. Q.P/Appd. Drg./ Tech. Specn

10.2 a)

HSFG/HT Bolts tightening Ensure HSFG bolts are tightened by part turn method at Reqd. torquee Welding and NDT Checking of Erection tolerances as during Erection of steel structures as per IS-12843/appd. Drg

VC

CR No 10

Tech. Spec./ Appd. Drg.

10.3 10.4

VC DIM

1&2 1

CR No 10a CR No 10 IS-12843 , BNBC Part 6 :10.11.3 /Apprd. Drg.

10.5

Touch up painting

VC

CR No 11

Tech. Specification

Page 4 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations I Excavation a) Nature of soil / rock b) Initial Ground Level c) Dimensions of Excavated pit d) Final Pit / Bed level e) Side slope during excavation II a) b) Filling with earth Suitability of fill material Grain size Analysis Liquid limit & Plastic Limit ( Test for soil) Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1&2 1 1 1&2 1&2 Date Report no. CR CR CR CR CR No No No No No 1a 1a 1a 1a 1a Site register - Do - Do - Do - Do Observations:

Date 31.05.03

Revision 0

2-Lafarge/Insp. agency Type Of Inspection VC DIM DIM DIM DIM

Remarks Remarks

Completed

MT MT

1 1

CR No 1b CR No 1b

IS 2720/BNBC - 1993 Part 6 : 3.4 One in every 5000 M3 for each type and each source of fill material subject to a minimum of 1 sample One in every 9000 M3 for each type and each source of fill material

c)

Shrinkage Limit

MT

CR No 1b

d) e)

Free Swell Index Chemical Analysis i) Organic Matter ii) Calcium Carbonate iii) Ph. Value iv) Total Soluble sulphate

MT CA CA CA CA CA

1 1 1 1 1 1

CR CR CR CR CR CR

No No No No No No

1b 1b 1b 1b 1b 1b

Page 5 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases III.
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection MT Item No. Interventions Participants 1 Date Report no. CR No 1b Remarks Remarks IS 2720 Part VIII BNBC - 1993 Part 6 : 3.12.5.2,3.4 Once in every 5000 M3 for each type and each source of fill malt IS 2720 Part II BNBC - 1993 Part 6 : 3.12.5.2,3.4 One in every 5000 M2 for each type and each source of fill material Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

Date 31.05.03

Revision 0

Manufacturing Operations Operations STANDARD PROCTOR TEST TO DETERMINE OPTIMUM MOISTURE CONTENT AND DRY DENSITY OF FILL.

IV.

Moisture Content of fill before companction

MT

CR No 1b

V.

COMPACTION TEST IS 2720 Part xxix/ BNBC 1993 Part 6:3.4 , 6 : 3.12.5.2 a) for foundation filling one for every 25 found. For each compacted layer. However each layer for loca- tion of important & heavily loaded

a)

DRY DENSITY BY CORECUTIER METHOD OR DRY DENSITY INPLACE BY SAND DISPLACEMENT METHOD

MT

CR No 1b

Page 6 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks found. testing on fill shall be tested For Plinth b) for each filling one for every 5000M3 for each compacted layer IS 2720 Part xiv / BNBC Part 6:3.4 , 6: 3.12.5 As above (a) & (b) Random on each compacted layer Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

Date 31.05.03

Revision 0

Manufacturing Operations Operations

b)

FOR COHESIONLESS SOILS ( SAND FILLING) Relative Density (Density Index) Dry Density By proctor Needle penetration PILING FOUNDATION Setting out Pile points

MT

CR No 1b

c) VI . a)

MT

CR No 1b

DIM

1&2

Sketch

BNBC Part 6 : 3.11 IS : 2911 (Part I /Sec 2 ) -1979 BNBC Part 6 : 3.11.5 IS : 2911 (Part I /Sec 2 ) -1979 BNBC Part 6 : 3.11.3 IS : 2911 (Part I /Sec 2 ) -1979

b)

Check load bearing capacity at time of test piles Check installation procedure

MT

1&2

CR No 1c

c)

DIM

1&2

CR No 1c

Page 7 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases d)
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection VC + DIM Item No. Interventions Participants 1&2 Date Report no. CR No 1c Remarks Remarks BNBC Part 6 : 3.11.4 IS : 2911 (Part I /Sec 2 ) -1979 Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

Date 31.05.03

Revision 0

Manufacturing Operations Operations Check pile concreting

1.0 1.1

CEMENT Received from supplier -

SC (Review of T.C.S)

1&2

CR No. 2

Setting time and Compressive strength 1.2 If stored for more than 3 months of original receipt, test for following : - Setting time and Compressive strength MT 1&2 CR No. 2

IS:269-1989, IS:4031-1988 One for each batch & test inhouse at random IS : 269 - 1989, IS : 4031 1988 One sample from each lot of 250MT or part thereof

CR No. 2

1.3

Ensure that cement is stored in covered storages on raised platform REINFORCING STEEL Physical and Chemical properties of reinforcement steel for each consignment / lot

VC

2.0 2.1

SC (Review of T.C.S)

1&2

CR No. 3

IS : 1786 - 1985 IS : 432 , BDS 1313

Page 8 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations 2.2 Visual examination to ensure free from cracks, surface flaws and Dimensional check 2.3 Cutting, bending placing of reinforced steel bars and lapping WATER Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1 Date Report no. CR No. 3 Observations:

Date 31.05.03

Revision 0

2-Lafarge/Insp. agency Type Of Inspection VC and DIM

Remarks Remarks IS : 1786 - 1985 Site register and approved drg.BDS 1313 Drawing / Bar bending schedule Site register

Completed

DIM

CR No. 3

3.0

3.1

Water is free from excess acid. alkali or salt & harmful subst- ances

CA

CR No 4

IS : 456 1978, IS : 3025,BNBC Part 5 : 2.4.4 IS: 516 - 1959 Once per source or after monsoon - Do - Do -

3.2 3.3 4.0 4.1

Permissible limits of solids PH Value FINE AGREEGATES Sieve analysis, Particle size and shape

CA CA

1 1

CR No 4 CR No 4

MT

CR No. 5

IS : 383 - 1970, IS : 2386 1963 Part - I , BDS 285 : 1963 Once for 2000 Cum or change of source whichever is earlier

Page 9 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations 4.2 Silt and Clay content,deleterious materials, soundness,acid/alkali reactivity, mortar making properties Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1 Date Report no. CR No. 5 Observations:

Date 31.05.03

Revision 0

2-Lafarge/Insp. agency Type Of Inspection VC

Remarks Remarks IS : 2386 - 1963, IS : 383 Part - 2,5,6 and 7 BDS 281 : 1963 Once per source (to be repeated if source is changed) IS : 383 - 1970, IS : 2386 1963, IS : 383 BDS 284 : 1963 Once in 20 weeks or change of source whichever is earlier IS : 383 - 1970Site register/ IS : 2386 - 1963 and Log Book Part - 3 BDS 284:1963 To be done everyday before start- ing work IS : 2386 - 1963 & IS:383 Test certificate Part - 5 and 8 BDS 243 :1963 Once per source

Completed

4.3

Specific gravity, water absorption bulk density and voids

MT

CR No. 5

4.4

Bulkage and moisture content & Silt content

MT

CR No. 5

4.3

Petrographic examination

MT

CR No. 5

5.0 5.1

COARSE AGGREGATE : Sieve analysis, Particle size & shape MT 1 CR No. 5 IS : 2386 - 1963 IS : 383 Part - I BDS 285 :1963

Page 10 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks One sample per 1000cum Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

Date 31.05.03

Revision 0

Manufacturing Operations Operations

5.2

Specific gravity,and water absorption, bulk density and voids

MT

CR No. 5

IS : 2386 - 1963 and IS : 383 Part - 3 BDS 243 :1963 Once in 20 weeks change of source whichever is earlier IS : 2386 - 1963 and IS : 383 Part - 2,4,5 & 7 BDS 279:1963 ,BDS 243 :1963 BDS 283:1963 Once per source

5.3

Crushing value, impact value, soundness, reacting with acid/ alkali, flakiness indes, deleterious materials

MT

CR No. 5

5.4

Moisture content

MT

CR No. 5

IS : 2386 - 1963 and IS : 383 Part - 3 BDS 243 :1963 One sample per 1000cum / change of source which ever is earlier During rains everyday before start of work IS : 2386 - 1963 andcertificate Test IS : 383 Part - 2 BDS 243 :1963

5.5

Petrographic examination

MT

CR No. 5

Page 11 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks Once per source Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

Date 31.05.03

Revision 0

Manufacturing Operations Operations

6 6.1

CONCRETE Crushing strength Sample casting , curing & testing

MT

1&2

CR No 6

IS: 456 - 1978 IS: 516 - 1959 As per clause 14.2.2 of IS: 456-1978 ASTM C 39 - 86 IS : 1199 - 1959 IS : 456-1978 BDS 1044 : 1983, ASTM C 172 - 90 One sample every four hours from each mixer IS : 1199 - 1959 , BNBC Part 5 : 5.6.3 IS : 1199 - 1959 , BNBC Part 5 : 5.6

6.2

Workability (slump and compaction factor test )

MT

CR No 6

6.3 6.4 7 7.1

Water Cement ratio Cement content BRICKS Check for dimension, soundness colour, warpage and efforescence

MT MT

1 1

CR No 6 CR No 6

VC+ DIM

CR No 7

IS : 1077 - 1992 IS : 3495 - 1992 BDS 1249 : 1989 A set of 20 bricks

Page 12 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks min.for each lot of 10000 or part thereof Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

Date 31.05.03

Revision 0

Manufacturing Operations Operations

7.2

Compressive strength

MT

1&2

CR No 7

IS : 1077 - 1992 IS : 3495 - 1992 BDS 1249:1989, BNBC Part 4 : 4.3.2 A set of 20 bricks min.for each lot of 80000 or part thereof IS : 1077 - 1992 IS : 3495 - 1992 BDS 1249 -1989

7.3

Water absorption

CA

CR No 7

8 8.1 8.2 8.3

EMBEDDED PARTS Position and level of embedded parts Position, depth and size of bolt holes Location, verticality of pipe sleeves/opening for bolt hole Welding / tieing of embedment to reinforcement DIM DIM DIM 1 1 1&2 CC No 1 CC No 1 CC No 1 Drawing / Specification - Do - Do -

8.4

VC

CC No 1

- Do -

Page 13 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations 9 FORM WORK : SHUTTERING 9.1 9.2 Check for material Position, dimension and verticality of form work before concreting CHECK FOR JOINTS : To avoid loss of liquid the joints should be leak proof as for as possible STAGING : Checking for durability, strength soundness, joints, adequacy of its foundation, specific level CONCRETING : Quantity of cement and aggregates Water cement ratio Cleanliness, provision of chute and arrangement for transport- ation and placement of conc. MASONRY CONSTRUCTION Strength of stone Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no. Observations:

Date 31.05.03

Revision 0

2-Lafarge/Insp. agency Type Of Inspection

Remarks Remarks

Completed

VC DIM

1 1

CC No 2 CC No 2

- Do - Do -

9.3

VC

1&2

CC No 2

- Do -

9.4

VC

CC No 2

- Do -

10 10.1 10.2 10.3

MT MT VC

1 1 1

CR No 8 CR No 8 CR No 8

Appro. Conc. mix Design Appro. Conc. mix Design Appro. Conc. mix Design

11 11.1

MT

CR No 9

Relevant I.S / BDS 1249:1989

Page 14 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases 11.2 11.3 12 12.1 12.2 12.3
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for Civil Works) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection VC VC Item No. Interventions Participants 1 1 Date Report no. CR No 9 CR No 9 Specification Specification Remarks Remarks Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment:
Q.C.P ref:QP FOR CIVIL WORKS

Date 31.05.03

Revision 0

Manufacturing Operations Operations Proper jointing, providing sufficient bond stone Proper mixing of cement mortar TESTING ON HARDENDED CONCRETE Rebound Hammer test Load test on structures Core test ( if required)

MT MT MT

1&2 1&2 1&2

CR No 10 CR No 10 CR No 10

IS : 13310 / BNBC Part 6 : 5.12 IS:456./ BNBC Part 6 : 5.12 IS:456./ BNBC Part 6 : 5.12

Page 15 of 64

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 1

1 of 1

Check list for Receipt and Storage of Materials

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Checks ITEM. Quantity. Purchase Order no. BBU no. Delivery Challens no. MDCC Reference Number. Visual Examination. Verification report no. / CHP no. Shortage. Damages. Storage - Location. Stroage - Type - outdoor / indoor. Accs. Storage- location. Storage- Type- outdoor/indoor (Accs). Special Storage Instruiction. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 2 1 of 1

Check List for earthing Pre-erection

SL NO. 1 2 3 4 5 6 7 8 9 10 Checks Area. Location. Drawing No. Size of the grid materials. Type of earthing pit. Method of joining the meterial. Availability of all materials as per BOM and drawings. Earth grid marking and trench excavation as per drawing. Check for obstruction / crossing Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 3 1 of 1

Check List for Earthing - Erection

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Checks Area. Location. Drawing No. Size of the grid materials. Type of earthing pit Overlap and Welding Application of bitumen 2 coats over welding. Buried depth of earth, material,back filling,compaction. Treated / untreated earth electrode installation. Earth pit made as per drawing. Charcoal & salt filled in alternate layers. Filling of earth. Connection of earth pit grid. Connection of chamber / fixing of cove.r Welding of risers. Pit Numbering. Earth resistance by earth tester. Additional earth pits requirement Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 4 1 of 1

Check List for Power Transformer / DG SET Pre-erection

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Checks Area. Location. Voltage grade. Capacity. Type. Vector group. Type of cooling. Make. Sl. No. Year of manufacturing. Availability of instruction manual and drawings. Availability of all materials as per BOM and drawings. Completion of foundation as per civil drawing. Rails fixing as per drawings Remarks Observation

Note :

To be followed as per applicability

PREPARED BY ( L &T)

APPROVED BY (LAFARGE) CR No 5

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION

31.05.03

1 of 1

Check List for Power Transformer/ DG SET Erection

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Note : Checks Area. Location. Voltage grade. Capacity. Type. Vector group. Type of cooling. Make. Sl. No. Year of manufacturing. Placement of transformer on plinth. IR value of windings. Lifting scheme & arrangement. Bushing assembly. Cleaning of bushing Size and condition of sealing gaskets. Level of oil. Mounting of radiators. Other accessories mounting. Earthing connection. Vaccum and oil filling ( check BDV&PPM on oil samples before filling and filteration ). Neutral earthing. Bleeding of transformer. Locking of wheels / provide stopper. Completion of fire protection wall. Completion of oil soak pit. Completion of fencing and gate. Earthing the gate / fence. Fixing of danger board. Completion of illumination. Providing fire-fighting equipment. Providing emergency stop. Completion cabling and bus duct installation. Completion and removing of unwanted mat. Remarks To be followed as per applicability PREPARED BY ( L &T) APPROVED BY (LAFARGE) Observation

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 6 1 of 1

Check list for Control Desk, Relay Panel, Thyrister Panel, Switchgear/MCC/PLC Pre-erection
SL NO. 1 2 3 4 5 6 7 8 9 Checks Area. Location. Tag No. Voltage grade. No. of verticals. No. of transport sections. Details of loose items supplied. Availability of all materials as BOM and drawing. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 7 1 of 1

Check list for Control Desk, Relay Panel, Thyrister Panel, Switchgear/MCC/PLC Erection
SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Checks Area. Location. Tag No. Voltage grade. Fabrication of base frame and primer coating. Alignment and levelling of base frame. Grouting of base frame. Erection of panels sequence wise. Alignment of panels. Tightening of inter panel bolting. Inter panel wiring. Inter panel earthing. Mounting of accessories. Fixing of danger board. Mounting of shock hazard chart in the room. Mounting of fire extinguishers. Cleaning of panels. Earth grid connection. Rubber mat laying. Plugging of unused holes. Tighting of all terminals / connections. Check continuty & IR. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 8 1 of 1

Check list for Tray and Tray Support Pre-Erection

SL NO. 1 2 3 4 5 6 7 8 9 Checks Area. Location. Drawing No. Availability of materials. Fabrication of tray supports. Fixing of insert plates. Painting of supports. Marking of location of support. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 9 1 of 1

Check list for Tray and Tray Support

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Checks Area. Location. Drawing No. Alignment of supports. Span of the support. Full welding of supports. Application of two coat of painting Alignment and fixing of coupler plates trays Anchoring of trays to the support. Applying of paint to the welding portion. Cable route tray interconnection. Numbering of trays. Earthing of trays. fixing of cable supports below panel / near equipment. Remarks.

Erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 10 1 of 1

Check list for Illumination Installation - Pre Erection

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 Checks Area. Type of wiring. Size / type of conduit. Size / type of wire. No. of fixture / make / voltage / grade. Type of layout of fixture. Ref. Of drawing number. 3 phase / 1phase distribution. No.of wires in conduits. Location of switch. Clearance for starting work. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 11 1 of 1

Check list for Illumination Installation - Erection

SL NO. 1 2 3 4 5 6 Checks Area. Marking of the location of the fixture. Fixing of JB's. JB no.-----------------JB NO. Fixing of spacers. Mounting of lighting panel. IR Value R to E Y to E B to E Lighting fixture tag no / location no. Assemble. Measure IR value. Operation. Wire pulling as per circuit. Circuit no. IR value. Circuit loop test after connecting wires. Grounding of coduit, fixture,LDB's. Connection of cables to MLDB / LDB's. IR value of the MLDB / LDB. Load current, terminal voltage of each circuit. On circuit. ------------------Off circuit. --------------Remarks. Observation

9 10 11 12

13

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 12 1 of 1

Check list for Bus Duct Pre-Erection

SL NO. 1 2 3 4 5 6 7 8 9 10 Checks Area. Location. Tag no. Make of bus duct. Voltage grade. Connection between---------Alignment. Fixing of insert plates. Supports. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 13 1 of 1

Check list for Bus Duct Erection

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Checks Area. Location. Cleaning of Duct. Positioning. Tightening of section interconnection bolts. Assembling of bus bar sections / links. Connection of earth bus links. Connect the earth Bus Bar to grid. Vacuum cleaning of the duct. IR value measurement & continuty. Closing of covers / check proper gasketting. Sealing of wall crossing. Painting of the supports and duct. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 14 1 of 1

Check List for Battery Pre-erection

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 Checks Area. Tag no. Capacity. Make. No of cells. Type. Input voltage range. Output voltage range. Provision of ventilation. Epoxy coating of room. Clearance from the authority for installation. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 15 1 of 1

Check List for Battery Erection

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Checks Area. Tag no. Capacity. Make. No of cells. Type. Cleaning of the battery room. Assembling of battery stand. Painting of battery stand. Alignment as per layout drawing Layout drawing no. Assembly and alignment of cells. Interconnection of cells. Fixing of cell tag no / identification no on the stand. Connection of battery to charger / DCDB. Cleaning of battery room. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED

CR No 16

CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03 1 of 1

Check list for Battery Charger, ACDB, DCDB.

SL NO. 1 2 3 4 5 6 7 8 9 10 11 Checks Area. Tag no. Make. Capacity. Input voltage. Output voltage. Type. Sl. Number. Ref. Drawings. Clearence for installation. Remarks.

Pre-erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 17 1 of 1

Check list for Battery Charger, ACDB, DCDB.

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Checks Area. Tag no. Make. Capacity. Input voltage. Output voltage. Fabrication of base frame. Fixing, alignment of painting. Grouting of base plates. Alignment of panels. Fixing of foundation bolts and tightening. Mounting of accs. Inter panel wiring. fixing of earth bus link. Tightening of all terminals. Plugging of unused holes. Vacum cleaning of panel. Installation of rubber mats. Connection of cables - power / control. Panel earthing to the station grid. IR & continuity. Remarks.

Erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 18 1 of 1

Check List for Cabling & terminations

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 Checks Area. Availability of route drawing and cable schedule. Location. Routing. Completion of tray route / trench / depth of trench. Completion of tray numbering. Completion of sand bed laying in trench. Size of cables / tag no. IR value of the cable. No. of runs. Cable mounting on shaft and drum stand. Laying manual / mechanical. Remarks.

Pre-erection.
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 19 1 of 1

Check List for Cabling & terminations

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Checks Area. Location. Clamping of cables. Laying of sand bed in trench. Back filling. Fixing of cable route marker. Sealing of cables laid / balance in drum. Identification of cable by aluminium tags. IR value after laying / countinuty check. Identification of cores. Ferruling of cores. Glanding / Lugging. For HT cable termination kit fixing. Crimping. Cable supporting / clamping. Grounding of screen stone end for signal cables. Fixing of cable tags below the panel / equipment. removing of unwanted materials. Remarks.

Erection.
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 20 1 of 1

Check List for Motors

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Checks Area. Location. Voltage grade HT / LT / DC. Voltage. Make. Srl. No. RPM. Wattage. Completion of foundation. Clearence from authority for installation. Alignment of base plate. Level of the base plate. Grouting of base plate. Remarks.

Pre Erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 21 1 of 1

Check List for Motors

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Erection
Observation

Checks Area. Location. Voltage grade HT / LT / DC. Voltage. Make. Srl. No. RPM. Wattage. Alignment of motor centerline and coupling centerline. Tightening of foundation bolts. Alignment of motor centerline and coupling centerline (final) IR value of motor. P I for HT motor. Winding resistance. Clearing for cabling / termination. Clearence for earthing connection. Clearence for control cabling and termination. Mounting of aux. Devices. Remarks.

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 22 1 of 1

Check List for Junction Boxes installation.

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Checks Area. Location. Tag no. Drawing No. Clearence for Installation. Availability of material. Box Frame mounting. Length of box frame. Working space available. Safe distance from HOT line. Mounting of JB. Tightening of bolts. Mounting of canopy. Plugging of unused holes. Grouting of JB. Remarks.

Pre Erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 23 1 of 1

Check List for Junction Boxes Installation.

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Checks Area. Location. Tag no. Drawing No. Clearence for Installation. Availability of material. Box Frame mounting. Length of box frame. Working space available. Safe distance from HOT line. Mounting of JB. Tightening of bolts. Mounting of canopy. Plugging of unused holes. Grouting of JB. Remarks.

Erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 24 1 of 1

Check List for Vibration Monitor

SL NO. 1 2 3 4 5 6 7 Checks Area. Location. Tag no. Drawing No. Clearence for Installation. Availability of material. Remarks.

Pre Erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 25 1 of 1

Check List for Vibration Monitor

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 Checks Area. Location. Tag no. Drawing no. Completion of Testing / Calibration. Mounting of Box frames for Grouting / Welding. Mounting of Instruments. Mounting of Box frames for Grouting / Welding. Mounting of accessories. Cabling. Grounding. Remarks.

Erection
Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 26 1 of 1

Check List for Limit Switch, Pull Cord, Belt Sway,Zero Speed - Pre Erection
SL NO. 1 2 3 4 5 6 7 Checks Area. Location. Tag no. Drawing no. Clearence for installation. Availability of material. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC.(FOR LAFARGE)

ELECTRICAL & INSTRUMENTATION 31.05.03

CR No 27 1 of 1

Check List for Limit Switch, Pull Cord, Belt Sway,Zero Speed - Erection
SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 Checks Area. Location Tag no. Drawing no. Competing of Testing / Calibration. Mounting of Base frames for Grouting / Welding. Mounting of Instrument. Tightening of Bolts and alignment. .Mounting of accessories. Cabling. Grounding. Remarks. Observation

PREPARED BY ( L &T)

APPROVED BY (LAFARGE)

LARSEN & TOUBRO LIMITED CRUSHING SHOP & LBC FOR LAFARGE
ELECTRICAL & INSTRUMENTATION 31.05.03

CK-LST 1 of 1

CHECK LIST INDEX

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 DOCUMENT NO. CR No 1 CR No 2 CR No 3 CR No 4 CR No 5 CR No 6 CR No 7 CR No 8 CR No 9 CR No 10 CR No 11 CR No 12 CR No 13 CR No 14 CR No 15 CR No 16 CR No 17 CR No 18 CR No 19 CR No 20 CR No 21 CR No 22 CR No 23 CR No 24 CR No 25 CR No 26 CR No 27 CHECK LIST FOR ELECTRICAL RECEIPT EARTHING - PRE ERECTION EARTHING - ERECTION TRANSFORMER/DG SET - PRE ERECTION TRANSFORMER/DG SET - ERECTION SWITCHGEAR - PRE ERECTION SWITCHGEAR - ERECTION TRAY AND SUPPORT, G I PIPES - PRE ERECTION TRAY AND SUPPORT, G I PIPES - ERECTION ILLUMINATION - PRE ERECTION ILLUMINATION - ERECTION BUSDUCT PRE ERECTION BUSDUCT ERECTION BATTERY PRE ERECTION BATTERY ERECTION BATTERY CHARGER, ACDB, DCDB, PRE ERECTION BATTERY CHARGER, ACDB, DCDB, ERECTION CABLING & TERMINATION PRE ERECTION CABLING & TERMINATION ERECTION MOTOR PRE ERECTION MOTOR ERECTION JUNCTION BOX PRE ERECTION JUNCTION BOX ERECTION VIBRATION MONITOR PRE ERECTION VIBRATION MONITOR ERECTION LIMIT SWITCHS,PULLCORD, BELT SWAY,ZSS- PRE ERECTION LIMIT SWITCHS,PULLCORD, BELT SWAY,ZSS- ERECTION PAGES 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PREPARED BY(L& T)

APPROVED BY(LAFARGE)

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases A) 1) a) I) ii) iii) b) I) ii)
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment: Q.C.P ref: QP for Electrical Erecn Date 31.05.03 Revision 0

Manufacturing Operations Operations PRE-ERECTION & ERECTION PRE- ERECTION TRANSFORMER / DG SETS Availability of instalation Drg / Manual, Tools & Tackles, Test Report Foundation & Layout Name Plates Detailes CONTROL DESK / THYRISTER PANEL / SWITCHGEAR / MCC / PLC Availability of instalation Drg / Manual, Tools and Test Equipment's(as applicable), Test Reports. Civil foundation, if any & embedments of Chanels/Plates & Bolts.

VC DIM VC

1 1 1

CR No 04 CR No 04 CR No 04

VC VC

1 1

CR No 06 CR No 06

Page 44 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations c) CABLE i) Bending Redius, Check IR ii) Redius iii) IR iv) Layout Drawings / Cable Schudle v) Tools & Tackles vi) Proper Rollers vii) Jacks viii) Direction & Rotation d) i) e) i) ii) f) i) ii) g) I) EARTHING General Physical Inspection Illumination Availability of all items alongwith type and ratings Layout Drawings, Tools & tackles CABLE TRAY AND SUPPORT General Physical Inspection Straightene, allgnmint BUS DUCT Availability of all items alongwith type and ratings Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Equipment: Q.C.P ref: QP for Electrical Erecn Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1 1 1 1 1 1 1 1 Date Report no. Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection DIM VC VC VC VC VC VC VC

CR No18 CR No18 CR No18 CR No18 CR No18 CR No18 CR No18

VC

CR No 02

VC VC

1 1

CR No 10

VC VC

1 1

CR No 08 CR No 08

VC

CR No 12

Page 45 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Equipment: Q.C.P ref: QP for Electrical Erecn Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1 Date Report no. CR NO 8 Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection VC

Manufacturing Operations o N phases Operations h) G I PIPES i) Availability of all items alongwith type and ratings I) I) j) I) k) (a) I) ii) iii) iv) v) (b) I) ii) iii) iv) v) ACDB & DCDB Availability of all items alongwith type and ratings JUNCTION BOXES Availability of all items alongwith type and ratings MOTORS HT Foundation Availability of installation Drg./Manual Motor Name Plate Details Shaft & terminal box position to idetify correct Motor IR Value of the Motor LT Foundation Availability of installation Drg./Manual Motor Name Plate Details Shaft & terminal box position to identify correct Motor IR Value of the Motor

VC

CR No 16

VC

CR No 22

VC VC VC VC SC VC VC VC VC SC

1 1 1 1 1 1 1 1 1 1

CR CR CR CR

No No No No

20 20 20 20 BY INSTRUMENT

CR No 20 CR CR CR CR No No No No 20 20 20 20

CR No 20

Page 46 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases (C) I) ii) iii) iv) v) l) I) ii)
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment: Q.C.P ref: QP for Electrical Erecn Date 31.05.03 Revision 0

Manufacturing Operations Operations DC MOTORS Foundation Availability of installation Drg./Manual Motor Name Plate Details Shaft & terminal box position to idetify correct Motor IR Value of the Motor Limit Switches,Pull cord,Belt Sway & Speed Switches etc. All Items & their Ratings / Size Layout Drg. ,Tools & Tackles, Test Equipment if any VIBRATION MONITORING SYSTEMS Identification Foundation Base Plate Fixing & Grouting Mounting & Alignment Testing of Foundation Block

VC VC VC VC SC

1 1 1 1 1

CR CR CR CR

No No No No

20 20 20 20

CR No 20

VC VC

1 1

CR No 26 CR No 26

m) I) ii) iii) iv) v)

VC VC VC VC VC

1 1 1 1 1

CR CR CR CR CR

No No No No No

24 24 24 24 24

Page 47 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations 2) ERECTION a) TRANSFORMER/ DG SETS I) Mounting , Leveling & Alignment ii) Termination, Connection & Cable entry iii) Control & Protection Wiring iv) Oil Level / oil Leakage v) BDV & PPM vi) IR b) I) i) ii) iii) iv) c) I) ii) iii) iv) CONTROL DESK, THYRISTER PANEL, SWITCHGEAR / MCC / PLC Mounting & Base Channel Level & Alignment Tightness Of Bolts & Clams, interbolting ( if applicable ) Position of chequered plates to cover trench / opening IR Value of MCC, Bus Bar, Control Transformer CABLE Physical Inspection of Cable Laying of Cable as per Routing / Schedule Proper dressing & clamping of Cable Cable Jointing & Termination / IR value. Jointing Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Equipment: Q.C.P ref: QP for Electrical Erecn Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no. Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection

DIM VC SC VC SC SC

1 1 1 1 1&2 1&2

CR CR CR CR CR CR

No No No No No No

05 05 05 05 05 05

Not Applicable for DG

DIM VC VC SC

1 1 1 1&2

CR No 07 CR No 07 CR No 07 CR No 07

VC VC VC SC

1 1 1 1&2

CR CR CR CR

No No No No

19 19 19 19

Page 48 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations by experinced jointer only v) Tagging & marking vi) Sealing through floor / wall opening vii) Proper ferruling & termination and sealing d) I) e) I) ii) iii) f) I) ii) iii) iv) v) vi) vii) EARTHING General Physical Inspection ILLUMINATION Mounting of lighting fixture Identification, Electrical,Continuty,Permanent earthing cable termination & connection IR Value & function of switches, Control Gear etc CABLE TRAY AND SUPPORT Fixing , Grouting of Inserts Span of Support Welding , Coating of Painting Tightening of Coupler plates Tray Numbering Completion of cable Routes Grounding Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Equipment: Q.C.P ref: QP for Electrical Erecn Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1 1 1 Date Report no. CR No 19 CR No 19 CR No 19 Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection VC VC VC

VC

CR No 03

VC VC SC

1 1 1

CR No 11 CR No 11 CR No 11

VC DIM VC VC VC VC SC

1 1 1 1 1 1 1

CR CR CR CR CR CR CR

No No No No No No No

09 09 09 09 09 09 09

Page 49 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations g) BUSDUCT I) Cleaning, Alignment ii) Support iii) Assembling iv) Coupler / Flexible Fixing v) Vaccum Cleaning vi) Earthing h) I) ii) iii) iv) I) I) ii) iii) iv) v) vi) vii) GI PIPES Radius of bend Edge of Pipes Alingnment, level, Support Plugging open end ACDB , DCDB Foundation Completion Alignment Inter panel Connection Earth , Earthgrid Wiring of components Cabling Blanking of unused holes Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Equipment: Q.C.P ref: QP for Electrical Erecn Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1 1 1 1 1 1 Date Report no. CR CR CR CR CR CR No No No No No No 13 13 13 13 13 13 Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection VC VC VC VC VC VC

DIM VC VC VC

1 1 1 1

CR CR CR CR

NO NO NO NO

9 9 9 9

VC VC VC VC VC VC VC

1 1 1 1 1 1 1

CR CR CR CR CR CR CR

No No No No No No No

17 17 17 17 17 17 17

Page 50 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control Manufacturing Operations o N phases Operations j) JUNCTION BOXES I) Idetification ii) Alignment of Frame iii) Mounting of JB iv) Mounting Of Accessorious v) Blanking of unused holes Vi Connectioning of Cables vii) Connecting Of Earthing k) (a) I) ii) iii) iv) v) vi) vii) viii) MOTORS HT Cleanliness, Mounting of Motor, level & Alignment Terminal marking & Earthing Electrical connection with cable, Termination / Connection Protection Devices & Fuses RTD / BTD Connection ( as applicable ) IR Value Motor & Space Heater Continuty of Space Heater Free running of Shaft Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) Documents

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Equipment: Q.C.P ref: QP for Electrical Erecn Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1 1 1 1 1 1 1 Date Report no. CR CR CR CR CR CR CR No No No No No No No 23 23 23 23 23 23 23 Remarks Remarks Completed Observations: Date 31.05.03 Revision 0 CR- Control Report CC-Conformity certificate

2-Lafarge/Insp. agency Type Of Inspection VC VC VC VC VC VC VC

VC VC SC VC VC SC SC SC

1 1 1 1 1 1&2 1&2 1

CR No 21 CR No 21 CR No 21 CR No 21 CR No 21 CR No 21 CR No 21 CR No 21

CONTINUITY CHECK

PARAMETER CHECKING BY INSTRUMENT.

Page 51 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases b) I) ii) iii) iv) v) vi) vii)
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment: Q.C.P ref: QP for Electrical Erecn Date 31.05.03 Revision 0

Manufacturing Operations Operations LT Cleanliness, Mounting of Motor, level & Alignment Terminal marking & Earthing Electrical connection with cable, Termination / Connection Protection Devices & Fuses IR Value Motor & Space Heater Continuty of Space Heater Free running of Shaft

VC VC SC VC SC SC SC

1 1 1 1 1 1 1

CR No 21 CR No 21 CR No 21 CR CR CR CR No No No No 21 21 21 21

c) I) ii) iii) iv) v) vi) vii) viii)

DC Cleanliness, Mounting of Motor, level &Alignment Terminal marking & Earthing Electrical connection with cable, termination / connection Carbon brushes in Holder / Cleanliness of Commutator Protection Devices & Fuses IR Value Motor & Space Heater Continuty of Space Heater Free running of Shaft

VC VC SC VC VC SC SC SC

1 1 1 1 1 1 1 1

CR No 21 CR No 21 CR No 21 CR No 21 CR CR CR CR No No No No 21 21 21 21

Page 52 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control N phases
o

Project: Lafarge Cement (Contract no: SUR 500-3)

Plant department: Crushing Shop & Long Belt Conveyor (Field quality plan for electrical works.) Documents CR- Control Report CC-Conformity certificate Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Item No. Interventions Participants Date Report no. Remarks Remarks Completed Supplier: Part designation: Drawing No. Specification Ref. Observations: Equipment: Q.C.P ref: QP for Electrical Erecn Date 31.05.03 Revision 0

Manufacturing Operations Operations

l) I) ii) iii) m) I) ii) iii) iv) v) vii) viii) ix)

LIMIT SWITCHES, PULL CORD, BELT SWAY & SPEED SWITCHES As per Drawings / Specification / Manufacturer's Recommendation Proper mounting & positioning, Cable Entry, Termination & connection Operation VIBRATION MONITORING SYSTEM Alignment Cable connection Earthing Identification Taging Cable Taging Mounting & Alignment Tighting of Foundation Block Calibration

VC VC VC

1 1 1

CR No 27 CR No 27 CR No 27

VC VC VC VC VC VC VC DIM

1 1 1 1 1 1 1 1&2

CR CR CR CR CR CR CR CR

No No No No No No No No

25 25 25 25 25 25 25 25

Page 53 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases A 1) 2) Manufacturing Operations Operations PRE-ERECTION OF CONVEYOR SYSTEM & EQUIPEMENT Available of Drg. Manual, tools & tackles test reports. Name plate det. Layout check & Foundation check Dimension level, Orientation, marking of reference points & foundation bolts Erection scheme (if applicable) ERECTION CONVEYING SYSTEM Comprising of Technological structures, Belt , Idlers, Pulleys, Plummer block with bearing, Gear box, coupling, breaks, screws, take up components counter weight & chutes STRINGERS , SUPPORTS & DRIVE BASE FRAME Contour Alignment Centre distance Leveling Squareness of holes Weld quality Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract no : SUR 500-3 )

Plant department: Crushing Shop & Long Belt Conveyor ( Field quality plan for Mech. Equipment Erection) Equipment: Q.C.P ref: QP for MECH EQPT. Date 31.05.03 Observations: Revision 0

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no.

1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Remarks Remarks

Completed

VC VC + DIM

1 1 CR No 1

3) B 1) i)

SC VC + DIM

1&2 1 CR No 2

2) i) ii) iii) iv) v) vi)

DIM DIM DIM DIM DIM VC

CR No 3

Page 54 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases Manufacturing Operations Operations Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract no : SUR 500-3 )

Plant department: Crushing Shop & Long Belt Conveyor ( Field quality plan for Mech. Equipment Erection) Equipment: Q.C.P ref: QP for MECH EQPT. Date 31.05.03 Observations: Revision 0

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no.

1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Remarks Remarks

Completed

3) i) ii) iii) 4) i) ii) iii) 5) i) ii) 6) i) ii) iii) 7)

IDLERS Mounting, alignment spacing of idlers,proper tightening of bolts & nuts troughling angle of idlers Free rotation of idler rolls PULLEYS Mounting of pulley frame Alignment of plummer block, bearing, pulley & proper tightening of bolt and nut Lubrication of bearing & Free rotation BELTING Mounting of Belt drum & Belt lapping Splicing & Vulcanisation of belt joint GEAR BOX Mounting on frame / Base levelling & alignment Flushing & filling of gear box with oil Tightening of Base bolt FLUID COUPLING

VC + DIM

CR No 4

VC

CC No 1

VC VC + DIM VC

1 1 1

CR No 5 CC No 1

VC + DIM VC + DIM

1 1&2

CR No 6 CC No 2

VC + DIM VC VC

1&2 1 1

CR No 7 CC No 3 CC No 3

Page 55 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases i) ii) iii) 8) i) 9) i) ii) 10) i) Manufacturing Operations Operations Axial run out of input & out shaft Radial run out of Input & Out shaft Distance bet. Input & Output shaft GEARED & OTHER COUPLINGS Mounting & Alignment BRAKES Mounting & Alignment Adjustment / Setting FINAL INSPECTION Free running of Gearbox,fluid coupling Geared coupling, Brake & Pulley, Assy. TAKEUP ARRANGEMENT, SCRAPER, COUNTER WEIGHT ETC Mounting, Squareness with centre line & levelling Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract no : SUR 500-3 )

Plant department: Crushing Shop & Long Belt Conveyor ( Field quality plan for Mech. Equipment Erection) Equipment: Q.C.P ref: QP for MECH EQPT. Date 31.05.03 Observations: Revision 0

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants 1&2 1&2 1&2 Date Report no. CR No 7 CR No 7 CR No 7

1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection DIM DIM DIM Remarks Remarks

Completed

DIM

1&2

CR No 7

VC + DIM VC

1 1

CR No 8 CR No 8

VC + DIM

1&2

CC No 4

11) i)

VC + DIM

CR No 9

Page 56 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases Manufacturing Operations Operations Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract no : SUR 500-3 )

Plant department: Crushing Shop & Long Belt Conveyor ( Field quality plan for Mech. Equipment Erection) Equipment: Q.C.P ref: QP for MECH EQPT. Date 31.05.03 Observations: Revision 0

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no.

1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Remarks Remarks

Completed

12) i) ii) iii)

CHUTE, SKIRT BOARD, FLAP GATE WITH ACTUATOR Fitment & Squareness with centrline, proper tightening of bolt & nut, levelling Travel of flap gate Limit switches for travel & its adjustability (for flap gates) MONORAIL HOISTING ARRANGEMENT Fitment & alignment smooth operations MAINTENANCE VEHICLE Squareness of wheels Levelling of vehicle Check vibration during free run test Tightening of bolts, nuts and other loose fittings

DIM VC VC

CR No 10

13) i) 14) i) ii) iii) iv)

VC

CC No 5

VC DIM VC VC

Page 57 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases 15) i) ii) iii) iv) v) Manufacturing Operations Operations APRON FEEDER Squareness Centering Levelling Coupling & drive alignment To be tested for normal functioning of all accesories & controls CRUSHER Pad levels Centering of frame Level. bearing surface of frame Levelling of rotor shaft Alignment with drive NO LOAD TEST OF INDIVIUAL SYSTEM Check speed, vibration, effectiveness of speed control by hydraulic & coupling leakage Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract no : SUR 500-3 )

Plant department: Crushing Shop & Long Belt Conveyor ( Field quality plan for Mech. Equipment Erection) Equipment: Q.C.P ref: QP for MECH EQPT. Date 31.05.03 Observations: Revision 0

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no.

1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Remarks Remarks

Completed

VC+DIM DIM DIM DIM RT

1 1 1
1

CR N0 11 CC N 0 6

1&2

16) i) ii) iii) iv) v) 17) i)

DIM DIM DIM DIM DIM

1 1 1 1 1&2

CR N0 12

RT

1&2

CC N 0 7

Page 58 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases 18) a) i) ii) b) i) ii) iii) iv) c) i) ii) d) i) Manufacturing Operations Operations D.E SYSTEM, VENTILATION & FIRE FIGHTING, DETECTION & ALARM SYSTEM EQUIPMETNS Completeness of system as per approved dwg Run out & alignment of fans, pumps with drives PIPING Dimensional & pipe route layout Welding checks Proper location of valves / strainers & fittings Hydraulic test of piping system DUCTS & GRILLS Routing / layout Leakage while the system is on trial operation PAINTING OF MS PARTS To be checked for completeness and uniformity of coating BAG FILTER Condition of Bags Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract no : SUR 500-3 )

Plant department: Crushing Shop & Long Belt Conveyor ( Field quality plan for Mech. Equipment Erection) Equipment: Q.C.P ref: QP for MECH EQPT. Date 31.05.03 Observations: Revision 0

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no.

1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Remarks Remarks

Completed

VC + DIM VC + DIM

1 1&2

CC N 0 8 CR N 0 13

VC + DIM DP VC SC

1 1 1 1&2

CR N 0 14

CC N 0 7

VC RT

1 1&2

CR N 0 15 CC N 0 7

DIM

1&2

CC N 0 7

e)

VC

CC N 0 7

Page 59 of 64

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases f) i) Manufacturing Operations Operations CONTROL ROOM Control room ventilation shall be checked for proper pressurisation and effectiveness of the gravity loaded back draft dampers BELT WEIGHER Fitment & alignment Display in totaliser & rate flow indicator Calibration with zero to rated load MAGNETIC SEPARATOR /METAL DETECTOR IR & HV of magnet before erecn. Fitment & alignment Running of magnetic separator belt. Break down voltage check for oil. Sample load lifting capacity test at given height Throwing of reject to ramp iron chute Functional check for accessories like temparature indicator oil level indicator etc Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract no : SUR 500-3 )

Plant department: Crushing Shop & Long Belt Conveyor ( Field quality plan for Mech. Equipment Erection) Equipment: Q.C.P ref: QP for MECH EQPT. Date 31.05.03 Observations: Revision 0

CR- Control Report CC-Conformity certificate Supplier: Part designation: Drawing No. Specification Ref. Item No. Interventions Participants Date Report no.

1.Contractor (L&T) 2-Lafarge/Insp. agency Type Of Inspection Remarks Remarks

Completed

RT

1&2

CC N 0 7

19) i) ii) iii) 20) i) ii) iii) iv) v) vi) vii)

DIM VC SC

1 1 1&2

CR N 0 16 CR N 0 16 CC N 0 8

VC DIM RT MT RT RT RT

1 1 1 1

1 1 & 1 & & &

2 2 2 2

CR N 0 17 CR N 0 17 CC N 0 9 CC N 0 9 CC N 0 9 CC N 0 9 CC N 0 9

NOTE:- GENERAL - A.COMMISSIONING PROCEDURES WILL BE SUBMITTED AS PER CLASUSE NUMBER 10.2.VIII 4) UNDER SECTION 3 OF SPECIAL CONDITION OF THE CONTRACT B.PERFORMANCE GUARANTEE TEST PROCEDURES WILL BE SUBMITTED AS PER 11.2.1 UNDER SECTION 3 OF SPECIAL CONDITION OF THE CONTRACT

Page 60 of 64

STORAGE TYPE/CONDITION LAFARGE CRUSHING SHOP & LBC PKG (MECHANICAL ITEMS)
ANENXURE - I SL.NO ITEM STORAGE TYPE II REMARKS

BELTING

BELTING STORAGE AREA SHALL BE SUCH THAT BELT ROLLS ARE PROTECTED FROM DIRECT SUNLIGHT & RAIN

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

IDLERS PULLEYS GEAR BOXES APRON FEEDER CRUSHER FLUID COUPLING GEARED & FLEXIBLE COUPLING PLUMMBER BLOCK BEARING ROD GATES BELT VULCANISER AIR CONDITIONERS CHAIN PULLEY BLOCK ELECTRIC HOIST PUMPS, VALVES, STRAINERS, NOZZLES, VENTILATION SYSTEM, EQUIPMENT ETC. PIPE FITTINGS, TECH. STRUCTURE AND MISC. FABRICATED ITEMS PRECOATED SHEETS METAL DETECTOR BELT WEIGHER MAGNETIC SEPARATOR BRAKES SCRAPPER - EXTERNAL - INTERNAL

III II II II II II II III I III II I II II II III III II II II II II II

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases 1 A Interventions C-Witness Point A-Hold point Participants Documents

Project: Lafarge Cement (Contract No :SUR500 - 3)

Plant department: Crushing Shop & Long Belt Conveyor (Mech & Elect. Storage Quality Plan) Equipment: Q.C.P ref:Storage Quality plan Supplier: Part designation: Drawing No. Specification Ref. Item No. Type Of Inspection Participants Interventions Date Report no. Remarks Remarks Observations: Date 31.05.03 Revision 0 CR- Control Report CC-ConformIty certificate

1.Contractor (L&T) 2-Lafarge/Insp. agency Manufacturing Operations Operations

MATERIAL RECEIPT MECHANICAL ITEMS Equipments (Conveying) such as Belting, Idlers, Pulleys, Gear Boxes, Crusher, Fluid couplings, Geared couplings, Flexible coupling, Plummer blocks, Bearing, Apron feeder, Scraper, Belt vulcaniser Electric Hoist, Pumps, Air-conditioner, Chain pulley block, Metal detector, Magnetic separator etc. VC 1 CR NO - 1

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Item No. Type Of Inspection Participants Interventions Date Report no. Remarks Remarks Manufacturing Operations Operations Part designation: Drawing No. Specification Ref. Observations: 31.05.03 0 Plant department: Crushing Shop & Long Belt Conveyor (Mech & Elect. Storage Quality Plan) Documents CR- Control Report CC-ConformIty certificate Supplier: Equipment: Q.C.P ref:Storage Quality plan Date Revision

B i) ii) iii) iv) v)

Fabricated and other items Rod gates Piping, Valves,(For DE System, SW System, CW System & PW System ) Ventilation system Technological structures and misc. fabricated items Pre-coated sheets MATERIAL STORAGE VC VC VC VC VC 1 1 1 1 1 CR NO - 1 CR NO -1 CR NO - 1 CR NO -1 CR NO -1

Refer annexure -I for storage Type

A B

Check up for Storage type and condition Check during storage period for all items as per Annex-I

VC VC

1 1

CR NO - 2 CR NO -2

A I)

For Electrical Receipt & Storage Storage type I, for the following thyristor pannel, PLC pannel, Lighting fixures, Anemometer controldesk, Control panel, Mimic panel & Annunciation panel conveyor switches, Limit switchs & Proximity switches. Cable joining kits & Termination kits. Tilt switches P.A System ultrasonic level detector Vibration monitoring system Instrumentation like pressure gauges, Switches, Load Cell etc. Receipt Document Check physical condition on receipt Storage Storage type-II for the following H.T switch gear, DC Motor, power & Lighting transformer HT Load brake Switch, MCC pannel, Distribution boards Junction box, Local control stations, HT Fuses, Bus duct, Hooter, all cables stall torque motor, LT Motor current collector, Geared motor, Electrical Actuators, HT Motor Receipt

VC

CR NO -2

A 1 2 B II

VC VC VC

1 1 1

CR NO -1 CR NO -1 CR NO -2

For Electrical items storage type mentioned against the items

LAFARGE
QUALITY CONTROL PLAN ( Q.C.P ) CA - Chemical Analysis RT - Running Test MT - Mechanical Test ( Sample) VC - Visual Checking DIM- Dimensional Checking TT - Thermal treatment DP - Die penetrant MP - Magnetic particle test US - Ultra Sonic Test RD - Radiography SC - Specific Control No phases 1 2 B III Document Check physical condition on receipt Storage Storage type-III for the following Lighting poles & Mast, Cable trays Receipt Document Check physical condition on receipt Storage VC 1 CR NO -2 Interventions C-Witness Point A-Hold point Participants 1.Contractor (L&T) 2-Lafarge/Insp. agency Item No. Type Of Inspection Participants VC VC 1 1 Interventions Date Report no. CR NO -1 CR NO-1 Remarks Remarks Manufacturing Operations Operations Part designation: Drawing No. Specification Ref. Observations: 31.05.03 0 Plant department: Crushing Shop & Long Belt Conveyor (Mech & Elect. Storage Quality Plan) Documents CR- Control Report CC-ConformIty certificate Supplier: Equipment: Q.C.P ref:Storage Quality plan Date Revision

A 1 2 B

VC VC VC

1 1 1

CR NO -1 CR NO-1 CR NO -2

Type I storage : All side covered storage (i.e,TOP & SIDE COVER) storage on raised platform and in packed condition. Type II storage : Top covered storage area , storage on raised platform either in packed condition or taurpaulin covered. Type III storage:Open storage on a raised Platorm with tarpaulene cover