FIELD QUALITY PLAN - CIVIL WORKS

I~ Document No.:

Revision No.
I -S012-C-FQ-02

1
TCE.5146A-CV-570-032

Dated I24":Apr-09 CGfiL

rn.'ltt~tAjMlIfflt P<\t.V1H'; lmltl\d

AUTHORIZATION FOR CHECKS AND NONCONFORMITY DISPOSITION

Class of Check Agency Inspection Authority Accepting Authority Disposition Authority

IPL Performer! FQA Engineer IPL Site Engineering In charge Engineering Center! Head (Design)
CRITICAL (A)
FQA Engineer in association with Executing
CGPL Head of Section Head! Engineering
Department

IPL Performer IPL FQA Engineer Engineering Centerl Head (Design)

MAJOR (8)
Head of Section! CGPL
CGPL Erection Engineer Head Quality
Representative

IPL Performer Performer Head of Section

MINOR (C)
CGPL ---------_..._...... -_.._ Site in charge

LEGENDS:
A=Critical , B=Major , C=Minor ; 'A' shall be witnessed by CGPL FQAI FQC, 'B' shall be witnessed by CGPL Erection I Construction deptt. 'C' shall be witnessed by IPL (A
check shall be CGPL HOLD POINT stage ); SR-Site Register, TR-Test Report, MTC- Manufacturer's Test Certificate, LB- Log Book, IPL: The Indure Pvt. Ltd.
GENERAL NOTES:
All measuring devices and instruments mounted on equipments to be used at field laboratory as well as field must be calibrated from Govt.l NABL Approved
1
Third Party Agency! Laboratory.

2 Field calibration, if any must be witnessed by CGPL & same should be HOLD point.

3 Non Destructive Testing of welding points as per Field Welding Data Sheet.

4 Wherever log sheet is not called for, suitable record shall be maintained in logbook I protocol.

S In case of nonconformity, accepting authority shall ensure disposition of nonconformity before acceptance & disposition shall be reflected in log sheet! protocol.

6 CGPL Technical speCification and CGPL approved documents relevant to the product shall be applicable.

7 CGPL shall witness 'A' category checks. CGPL is also authorized to canry out surveillance in any of B & C category of checks at their discretion.

8 CGPLlIPL shall ensure that instruments with valid calibration are used for measurement.

9 Quantum of check should be 100% as mentioned in QAP ! Reference documents.

10 In case of conflict with TCE Technical SpeCification, the priority should be Approved Field Quality Plan

 4000 MW ULTRA MEGA POWER PLANT PROJECT AT

FIELD QUAUTY PLAN CIVIL WORKS PROJECT:
MUNDRA

~
THE INDliRE PRIVATE LIMITED I -5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

QP No. TCE.5146-CV-570-032 CONTRACT NO: CGPL\UM08\VJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi - 110 048 MAIN
Rev 01 DA TE: 24. 04.09 MIs THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK
1 2 3 4 5 6 7 8 9 10

A General Requirements

Submission of QA & Before

As per Site As per CGPL approved
a QC manpower - A Physical commencement of
Mobilzation Plan Site Mobilization Plan
SR
deployment schedule work

Availability of QA &
QC manpower based As per Site As per CGPL approved
b
on deployment - B Physical Monthly
Mobilzation Plan Site Mobilization Plan
SR
schedule.

Availability of
Construction As per Site As per CGPL approved
c
Equipment in working - B Physical Monthly
Mobilzation Plan Site Mobilization Plan
SR
condition

Submission of
As per techincal specs.,
schedule of tests to As per Technical
d
be done to CGPL for - B Physical Monthly
Specifications
Drawings and approved SR
Methodology
monitoring

B Excavation and Filling

1 Excavation

As per Approved
a Nature of Soil As Required B Visual Random SR
Scheme

Digital
Approved
b Initial ground Level Thedoloite I B Measurement 100% SR
Drawings
Auto Level

1 OF 11
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FIELD QUALITY PLAN CIVIL WORKS PROJECT:
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THE fNDlIRE PR'VATE LIMlTED 1-5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

QP No. TCE .5146-CV-570-032 CONTRACT NO: CGPL\UM08\vJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi - 110 048 MAIN
Rev 01 DATE: 24. 04.09 MIs THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK

1 2 3 4 5 G 7 8 9 10

Dimension of Approved
c As Required B Measurement 100% SR
excavated pit Drawings
Approved
d Final pit or bed level As Required B Measure 100% SR
Drawings
Side Slope During Approved
e As Required B Measurement Random SR
Excavation Drawings

2 Back Filling (R1)

a Compaction Test B Measurement Random I SR (R1)

C Materials
.
1 Cement

Ensure that cement

Covered
is stored in weather Covered Technical
a tight covered storage Storage Platform
B Visual Random
Specification
Storage,weather tight SR
on raised platforms
platforms

Initial & Final Setting IS:4031

b Vicat's Appratus C Physical Random SR
Time of Cement (Part-5)

Compressive Strength IS: 4031

c Moulds, CTM C Physical Random
(Part-B)
SR
of Cement

2 OF 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
FIELD QUAI_ITYPLAN - CIVIL WORKS PROJECT:
MUNDRA

~
THE INDURE PRIVATE LIMITED I-5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

QPNo. TCE.5146CV-570-032 CONTRACT NO: CGPL\UM08\VJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi - 110 048 MAIN
Rev 01 DATE: 24. 04.09 MIs THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK

1 2 3 4 5 6 7 8 9 10
2 Coarse Aggregate SR

Results to be as per
Sieve, balance,
Particle size and Once per 200 cum the requirement of
oven, thickness, As per techincal specs.,
shape (sieve Analysis, A or part thereof or IS: 2386 Part-l & design mix, subject to
a flakiness index,
gauge length, Physical
change of source, specifications
Canst. Dwgs. and SR
m1) variations within the
gauge Metal approved Methodology
elongation index) whichever is earlier limits specified in
Scoop
relevent IS Codes

These tests shall also

One for each
Specific gravity, Bulk IS: 2386(111), 456, As per techincal specs., Report from be carried out while
source and for
c density, Water As required B Physical 383 & Const. Dwgs. and Approved Lab I establishing design
every change of
absorption specifications approved Methodology SR mix. and the results to
source.
i
be intimated to CGPL

Mechanical
IS: 2386(IV), As per techincal specs., Report from To be tested at out
Properties- Crushing Once at the time of
d As required A Physical 15:383 and Const. Dwgs. and Approved Lab I side Laboratory at the
value, abrasion value Mix design
specifications approved Methodology SR time of mix design
and impact value

IS: 2386(V), As per techincal specs., Report from To be tested at out

A Once at the time of
e Soundness As required Physical 15:383 and Const. Dwgs. and Approved Lab I side Laboratory at the
(R1) Mix design
specifications approved Methodology SR time of mix design

IS: 2386(V1I), As per techincal specs., Report from To be tested at out

A Once at the time of
f Chemical Reaction As required Physical 15:383 and Const. Dwgs. and Approved Lab I side Laboratory at the
(R1) Mix design
specifications approved Methodology SR time of mix design

3 OF 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
FIELD QUALITY PLAN - CIVIL WORKS PROJECT:
MUNDRA

~
THE INDURE PRIVATE LIMITED 1-5012-C-FQ..Q2 PACKAGE: ASH HANDLING PLANT

QPNo. TCE.S146-CV-S70-032 CONTRACT NO: CGPL\UM08\vJ\55, DT. 09 OCT 2008

Greater Kallash - II,
New Delhi - 110 048 MAIN
Rev 01 DA TE: 24. 04.09 Mis THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK
1 2 3 4 5 6 7 8 9 10
..
IS: 2386 (II), IS: As per techincal specs., Report from To be tested at out
A Once at the time of
g Deletrious materials As required Physical 383 and Const. Dwgs. and Approved Lab I side Laboratory at the
(R1) Mix design
specifications approved Methodology SR time of mix design

AII-In-Aggregate IS: 2386 Part-I &

h As required A Physical Random AS per IS:383 SR Inhouse Laboratory
Grading specifications

3 Fine Aggregates/Sand

Once per 200 cum

IS: 2386 (I), As per techincal specs.,
Particle size and A or part thereof or Results Should be as
a As required Physical IS:383 & Const. Dwgs. and SR
shape (R1) change of source, per the requirement
specifications approved Methodology
whichever is earlier

Till The Setup

These tests shall be
Once for 12 weeks of Site Lab.
Specific Gravity, IS: 2386 (III), IS: As per techincal specs., carried out while
or change of Report from
b Density, absorption As required B Physical 383 and Const. Dwgs. and establishing design
source whichever Approved Lab
and bulking specifications approved Methodology mix and the results to
is earlier to be
be intimated to CGPL.
forwarded

Silt, Clay deleterious IS: 2386 (II), IS: As per techincal specs.,
Once per each Acceptance norms
d materials, organiC As required B Physical 383 and Const. Dwgs. and SR
source shall be as per IS:383
impurities specifications approved Methodology

4 OF 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
FIELD QUALITY PLAN - CIVIL WORKS PROJECT:
MUNDRA

~
THE INDURE PRIVATE LIMITED 1-5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

QPNo. TCE.5146-CV-570-032 CONTRACT NO: CGPL\UM08\VJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi - 110 048 MAIN
Rev 01 DA TE: 24. 04.09 PRIVATE LIMITED
SUPPLIE
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK
1 2 3 4 5 6 7 8 9 10

These tests shall be

carried out while
Report from
IS: 2386 (VII ). IS: As per techincal specs., establishing design
A Once at the time of Approved Lab
e Chemical Reaction As required Physical 383& Canst. Dwgs. and mix. and the results to
(R1) Mix design to be
specifications approved Methodology be intimated to CGPL.
forwarded
Acceptance as per IS
2386 (VII)
These tests shall be
carried out while
Report from
IS: 2386 (II), IS: As per techincal specs., establishing design
A Once at the time of Approved Lab
f Deletrious materials As required Physical 383 and Const. Dwgs. and mix. and the results to
(R1) Mix design to be
specifications approved Methodology be intimated to CGPL.
forwarded
Acceptance as per IS
2386 (VII)

Till The Setup

of Site Lab.
As per tech. specs.,
A Once before start IS: 3025 & Report from Acceptance norms
4 Water pH Value As required Physical Const. Drg and appvd
(R1) of work specifications Approved Lab shall be as per IS 456
methodology
to be
forwarded

5 OF 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
FIELD QUALITY PLAN - CIVIL WORKS PROJECT:
MUNDRA

~
THE INDURE PRIVATE LIMITED I-5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

Greater Kailash - II,

QPNo. TCE.S146-CV-S70-032 CONTRACT NO: CGPL\UM08\vJ\55, DT. 09 OCT 2008

New Delhi - 110 048 MAIN

Rev 01 . DA TE:24~ 04.09 MIs THE INDURE PRIVATE LIMITED
. SUPPLIER:
,
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE
ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT
NORMS RECORDS
CHECK
1 2 3 4 5 6 7 8 9 10

5 Concrete

Till The
Establishment
of Site Lab.
Report from For trial mix min. of 6
Approved Lab cubes for each mix., 3
Min. 2 Trial Mixes
to be specimen shall be
Trial Mix & Design for each grade of IS:516, IS:456 &

a As required A Physical
concrete to be
As per techincal specs forwarded, tested at 7 days,
Mix Specification

After The remaining 3 shall be

carried out
Establishment for 28 days compo
of Site Lab. It strength.
Shall Be

Carried Out At

Site.

Acceptance norms
Standard
As per techincal shall be as per IS 456.
Apparatus for IS: 456 &

b Workability test. B Physical As required specs.,Const. Drgs. And SR slump test for
measuring specifications

approved Methodology medium and High

Slump
workability.
One set of 6 cubes
3
per 100 m for
each grade of
As per techincal
concrete. Or, IS: 456, 516 &
Acceptance norms
c Crushing Strength As required A Physical specs.Const. Drgs. And SR I Log Book
minimum one set Specifications
shall be as per IS 456
approved Methodology
per day if qty is
3
less than 100 m
(R1)

6 OF 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
FIELD QUALITY PLAN CIVIL WORKS PROJECT:
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THE INDURE PRIVATE LIMITED 1-5012-C-FQ-02 KAGE: ASH HANDLING PLANT

QPNo. TCE.5146CV... TRACT NO: CGPL\UM08\vJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi -110048 MAIN
Rev 01 DATE: 24. 04.09 MIs THE INDURE PRIVATE LIMITED
.. SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK

1 2 3 4 5 6 7 8 9 10

Dimension and visual Construction As per techincal

Concrete Pour Acceptance as per
d examination for As required B Physical 100% Drawings and specs.,Const. Drgs. And
Card specifications
Finished Structure specifications approved Methodology

Concrete Convaying Placing and

h
Compaction.
To be Caliberated
once at time of
SR (For
Mixing of Concrete Starting and Review of
Cement,
shall be done in subsquently once Caliberation
(1) As required A Physical Aggregate &
Automised Batching in every 3 months Chart I Certificate
Admixture
Plant and shall conform , IS 457
Load Cells)
to IS :4925.
(R1)

Handling and Chutes, As per

As per construction
(2) Transportation of Concrete Pump B Physical 100% construction
methodology
Concrete etc methodology

As per
As per construction
(3) Palcing of Concrete Visual B Physical 100% construction
methodology
methodology

Chech for
Chech for Segregation
(4) Compaction As Required B Physical At random Segregation As
As per IS 456.
per IS 456.

Chech for Period

Chech for Period of
(5) Curing As Required B Physical At r~ndom of Curing as per
Curing as per IS 456
IS 456

7 OF 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
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THE INDURE PRIVATE LIMITED I-5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

QP No. TCE.5146-CV-570-032 CONTRACT NO: CGPL\UM08\VJ\55, DT. 09 OCT 2008

Greater Kadash - II,
New Delhi - 110 048 MAIN
Rev 01 DATE: 24. 04.09 MIs THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK
1 2 3 4 5 6 7 8 9 10

6 Form Work

Any staging intended

As per techincal specs., for use shall be
a Staging Material As required B Visual Once As per Standard Const. Drgs. And approved by the
approved Methodology engineer for its
durability and strength

Staging Work
Construction As per techincal
(Durability, strength Concrete Pour
b As required B Visual Once Drawings and specs.,Const. Drgs. And
and soundness of Card
specifications approved Methodology
staging, joints

c Shuttering
Form work material
shall be strictly as per
specifications and
approval of the
Engineer. Materials
for form work shall
As per techincal specs.,
As per unwarped, throughly
(1 ) Materials As required B Visual Random Const. Drgs. And
Specification clean and without
approved Methodology
broken or damaged
edges either due to
repetative use or
otherwise. Oiling of
form work before
concrete

8 OF 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
FIELD QUALITY PLAN - CIVIL WORKS PROJECT:
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THE INDlJRE PRIVATE LIMITED I-5012C-FQ-02 PACKAGE: ASH HANDLING PLANT

QPNo. TC E.5146-CV-570-032 CONTRACT NO: CGPL\UM08\vJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi - 110 048 MAIN
Rev 01 DATE: 24. 04.09 Mis THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK

1 2 3 4 5 6 7 8 9 10

Construction As per techincal Joints shall be leak

Concrete Pour
(2) Joints As required B Visual Random Drawings and specs.,Const. Drgs. And proff to avoid loss of
Card
specifications approved Methodology liquid

7 Reinforcement steel

Check for bar

bending schedule with B Visual & Approved Bar Bending
a As required 100%
necessary taps. (R1) Measurement drawings Schedule
Specers &Chairs

Check for cover, B Visual & Approved Concrete Pour

b As required 100%
spacing of bars (R1) Measurement drawings Card

Check for bending of B Visual & Approved Concrete Pour

c As required 100%
bars (R1) Measurement drawings Card

Embedded Parts(inlfluding laying of

8
rails & anchor fastners)
As per Drawingl
Position and level of As per Drawingl
a As required B Dimensional 100% Technical
embedded parts Technical Specifications
Specifications
As per Drawingl
Position depth and As per Drawing!
b As required B Dimensional At random Technical
size of bolt hole Technical Specifications
Specifications

90F 11
 4000 MW ULTRA MEGA POWER PLANT PROJECT AT
FIELD QUALITY PLAN - CIVIL WORKS PROJECT:
MUNDRA

~
THE INDURE PRIVATE LIMITED 1-5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

QPNo. TCE.5146-CV-570-032 CONTRACT NO: CGPL\UM08\VJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi - 110 048 MAIN
Rev 01 DATE: 24.04.09 MIs THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK
1 2 3 4 5 6 7 8 9 10

Location verticality of As per Drawing/

As per Drawing/
c pipe sleeve/opening As required B Dimensional At random Technical
Technical Specifications
of bolt hold Specifications

Welding /tieing of As per Drawing/

As per Drawing/
d embeddment to As required B Dimensional At random Technical
Technical Specifications
reinforcement Specifications

I Grouting

Procurement to be
Technical
Technical Specifications done from approved /
a Material As required B Physical Randomly Specifications &
& AFC drawings acceptable
AFC drawings
manufacturer / source

Approved
b Grouting pressure Test set up B Physical At random Approved drawings
drawings

As per
manufacture's As per manufacture's Random to be
c Composition of grout As required B Physical Each lot / Batch
Tech. Tech. specifications checked by QAP
specifications

Compressive As per Tech.

d Test set up B Test Each lot / Batch Tech. Specification
strength Specification

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 4000 MW ULTRA MEGA POWER PLANT PRO.IECT AT
FIELD QUALITY PLAN - CIVIL WORKS PROJECT:
MUNDRA

~
THE INDUREPRIVATE LIMITED 1-5012-C-FQ-02 PACKAGE: ASH HANDLING PLANT

QPNo. TC E.5146-CV-570-032 CONTRACT NO: CGPL\UM08\VJ\55, DT. 09 OCT 2008

Greater Kailash - II,
New Delhi - 110 048 MAIN
Rev 01 DA TE: 24. 04.09 MIs THE INDURE PRIVATE LIMITED
SUPPLIER:
CLASS
SL ACTIVITY AND TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF
CHARACTERISTICS INSTRUMENTS OF REMARKS
NO OPERATION CHECK CHECK DOCUMENT NORMS RECORDS
CHECK

r:-r
1 2

Bought out items

3
"
4 5 6 7 8 9 10

TC submitted should
bear proper
All bought out items to identification or
be procured from the Tech correlation with the
Verification of Tech Specification. 1
a approved vendor and B 100% Specification. I batch of material
TC or testing BOQ
on approval of Quality BOQ supplied and same
plans by CGPL shall be brought out in
the challan I
consignment note

Submission of list of
bought out itemsand
Tech
their vendors for Tech Specification.
b 8 Physical one time Specification.
eachof the bought out 180Q
IBOQ
item identified for
approval

11 OF 11