34

249304/2024/PS-PEM-MAX

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-508-501-A001

MANUFACTURER'S NAME & ADDRESS STANDARD MANUFACTURING QUALITY PLAN PROJECT: 2X800 MW LARA TPP
PACKAGE : DOUBLE GIRDER CRANES
ITEM: QP NO : CONTRACT NO :
REV : 0 CONTRACTOR :
DATE : VENDOR' S QAP No :

SL. COMPONENTS & CHARACTERISTCS CLASS TYPE PF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATION CHECK OF CHECK DOCUMENT NORMS RECORDS M C N
1 4 3 4 5 6 7 8 9 D* ** 10 11
1 Fabricated components
Box Girder, End Carriage, Crab Frame, Rope Drum
a Material Chemical & Physical Properties Major Corelation with 1/Heat/Batch E250 Grade BR IS: E250 Grade BR Mfr's T.C/ √ P V V Refer note: 1
T.C./ Check test 2062 IS: 2062 Check Test
in absence of T.C. Report

Ultransonic 100% T.C. / I.R. U.T. ON ABOVE 20MM THICK

U.T of plates. ASTM A435 ASTM A435 √ P V V PLATE
b weld setup dimensions Major Measurement 100% Components Components Vendor's P
drawings drawings inspection
report
1A Seamless pipe for rope drum Chemical & Physical Properties major Corelation with 100% ASTM A106Gr B ASTM A106Gr B Mfr's T.C/ √ P V V Refer note: 1
T.C./ Check test Check Test
in absence of T.C. Report

NDT Major Macro etching & 100% ASTM A106Gr B ASTM A106Gr B MTC/Lab TC √ P V V
flattening

NDT Major UT 100% ASTM E-213-2007 Notch depth UT Report √ P V V

shall not be
more than
12.5% of
thickness of pipe

2 Welding WPS (Welding procedure specification) in line with ASME sec. IX (QW - 482 ) - For Box Girder, End Carriage, Crab Frame, Trolley Gear Box Casing & Rope Drum
a Check for welding procedure Welding parameters Major Review of 100% ASME Sec-IX ASME Sec-IX QW-482,QW-483, √ P V V WPS/PQR/WPQ approved/
QW-484 as per reviewd by NTPC/ NPCIL/
qulification, welder's documents
ASME Sec-IX BVI/ LLOYES/TUV etc. shall
performance be accpetable

b Back chipping surface defect Major DPT 100% ASME Sec-VIII, Div- ASME Sec-VIII, DP Report √ P V V
I, Appen - 8 Div-I, Appen - 8
c Butt Welds NDT Critical RT 100% in ASME Sec-V ASME Sec-VIII, Cl RT Report √ P V V
tension, 25% UW-51 & 52
in
compression,
100% in rope
drum
Critical DPT 100% ASME Sec-V ASME Sec-VIII, DP Report √ P W V DP test of fillet weld for
rope drum to be
Div-I, Appen - 8
conducted. After final
machining random
witness by BHEL

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249304/2024/PS-PEM-MAX

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-508-501-A001

MANUFACTURER'S NAME & ADDRESS STANDARD MANUFACTURING QUALITY PLAN PROJECT: 2X800 MW LARA TPP
PACKAGE : DOUBLE GIRDER CRANES
ITEM: QP NO : CONTRACT NO :
REV : 0 CONTRACTOR :
DATE : VENDOR' S QAP No :

SL. COMPONENTS & CHARACTERISTCS CLASS TYPE PF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATION CHECK OF CHECK DOCUMENT NORMS RECORDS M C N
1 4 3 4 5 6 7 8 9 D* ** 10 11
d fillet welds Size and surface defects Major Visual 100% Manufacturing Manufacturing Vender √ P V V
drawing drawing inspection
Report
NDT Major DPT 10% RANDOM ASME Sec-V ASME Sec-VIII, Vender √ P W V
Div-I, Appen - 8 inspection
Report
e final insection of fabricated Dimensions for Girder, end Major Dimensional 100% Vendor Mfg. Drg. Vendor Mfg. Drg. vendor √ P V V
components listed in Sr.1 carriage rope drum etc. Measurement inspection
above Camber, Verticality, bend etc report

f Heat treatment of rope drum Stress relieving Major Review of SR chart 100% Approved Approved SR Chart √ P V V If fabricated from M.S
drawing/relevant drawing/ relevant Plate
standard standard

3 Gear box casing

a Material Surface condition Major Visual 100% Manufacturing Manufacturing Vendor √ P V V Refer note 1
drawing drawing inspection
Report
Chemical & mech Major Measurement 100% Manufacturing Manufacturing T.C. & I.R. √ P V V
Correlation with drawing/ IS: drawing/ IS:
T.C. Check test in 2062 2062
absesnce of T.C.
Correlation
b Dimension Dimensional conformity Major Measurement 100% Manufacturing Manufacturing Vendor P
drawing drawing inspection
Report
c Heat treatment stress relieving Major Review of SR chart 100% Approved Approved SR Chart √ P V V
drawing/relevant drawing/ relevant
standard standard

4 PLATFORMS Dimensional conformity Minor Measurement 100% Manufacturing Manufacturing Vendor √ P V V Refer note: 1
drawing drawing inspection
Report
5 L.T.FRAMES Dimensional conformity Minor Measurement 100% Manufacturing Manufacturing Vendor √ P V V
drawing drawing inspection
Report
6 HAND RAILINGS Dimensional conformity Minor Measurement 100% Manufacturing Manufacturing Vendor √ P V V
drawing drawing inspection
Report
7 CABIN (if applicable) Dimensional conformity Minor Measurement 100% Manufacturing Manufacturing Vendor √ P V V
drawing drawing inspection
Report
8 Current collector arms Dimensional conformity Minor Measurement 100% Mfr. Catalog Mfr. Catalog Vendor √ P V V
inspection
Report
9 DSL Guard Dimensional conformity Minor Measurement 100% Manufacturing Manufacturing Vendor √ P V V
drawing drawing inspection
Report

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 36
249304/2024/PS-PEM-MAX

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-508-501-A001

MANUFACTURER'S NAME & ADDRESS STANDARD MANUFACTURING QUALITY PLAN PROJECT: 2X800 MW LARA TPP
PACKAGE : DOUBLE GIRDER CRANES
ITEM: QP NO : CONTRACT NO :
REV : 0 CONTRACTOR :
DATE : VENDOR' S QAP No :

SL. COMPONENTS & CHARACTERISTCS CLASS TYPE PF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATION CHECK OF CHECK DOCUMENT NORMS RECORDS M C N
1 4 3 4 5 6 7 8 9 D* ** 10 11
10 Rails Dimensional conformity Minor Measurement 100% G.A.drg./IS : 3443 G.A.drg./IS : Vendor √ P V V
Vendore 3443 Vendor inspection
T.C./Appd.Data T.C./Appd.Data Report
Sheet Sheet
Chemical , tensile & hardness Major Chemical & 100% IS-3443 IS:3443 Manufacturer √ P V V
hardness TC
11 MECHANICAL COMPONENTS
A a) wheels
i) raw material Chemicals composition and Major Corelation with 100% Mfg.drg./IS:1570 / Mfg.drg./IS:1570 Test Certificate √ P V/ V Refer Note:1.
# UTS required for
Mechanical Proporties. Mfr's TC BS - 970 / BS - 970 W#
selection of PL value as
indicated in Table 6 of IS
3177 shall be witnessed by
BHEL.
ii) Machined a) Dimensions Major Measurement 100% Manufacturing Manufacturing Vendor P V V
drawing drawing inspection
Report
b) Hardness Mechanical 100% Approved Data Approved Data Vendor √ P V V
Sheet / Mfg. Drg. Sheet / Mfg. Drg. inspection
Report
c) UT NDT 100% ASTM A 388 ASTM A 388 Vendor √ P V V Refer UT procedure
inspection
Report
d) DPT NDT 100% ASME Sec-VIII- ASME Sec-VIII- Vendor √ P W V
App-8 App-8 inspection
Report
b) Raw material for Gears , i) Chemicals Composition & Major Correlation with 100% Manufacturing Manufacturing Mfr's T.C/ √ P V V
Pinions, Shafts,Axles etc heat treatment, Physical Mfr's TC/ Check drawing, BS : 970 drawing, BS : 970 Check Test
Properties. test in absence of / IS : 1570 / / IS : 1570 / Report
TC Approved Data Approved Data
Sheet Sheet
ii) UT (after machining) Major check for UT (above 50mm
100%dia) ASME Sec-V Refer UT Vendor √ P V V
procedure inspection
Report
iii) Hardness Major check for 100% drg. & Approved Mfg. drg. & Vendor √ P W V Hardness witnessing by
BHEL before teeth cutting.
Hardness Data Sheet Approved Data inspection
Sheet Report
iv) Dimensions Major Measurement 100% Mfg. Drawing Mfg. Drawing Vendor √ P V V
inspection
Report
V) D.P.Test on teeth Major NDT 100% ASTME-165 No linear Vendor √ P V V
indication inspection
Report
c) Casting for Gears and Chemical and Physical Major Chemical and 100% Approved drg/ Approved drg/ Mfr's T.C √ P V V
pinions, if applicable Physical data sheet data sheet
NDT Major U.T. 100% ASTM A 388 ASTM A 388 Vendor √ P V V Refer UT procedure
inspection
Report

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249304/2024/PS-PEM-MAX

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-508-501-A001

MANUFACTURER'S NAME & ADDRESS STANDARD MANUFACTURING QUALITY PLAN PROJECT: 2X800 MW LARA TPP
PACKAGE : DOUBLE GIRDER CRANES
ITEM: QP NO : CONTRACT NO :
REV : 0 CONTRACTOR :
DATE : VENDOR' S QAP No :

SL. COMPONENTS & CHARACTERISTCS CLASS TYPE PF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATION CHECK OF CHECK DOCUMENT NORMS RECORDS M C N
1 4 3 4 5 6 7 8 9 D* ** 10 11
B Pulleys, Brake drums, coupling & other major steel castings & forging
i) Materials Physical/Chemical/Hardness Major Corelation with 100% Mfg. Drawing Mfg. Drawing Mfr's T.C. √ P V V
mfr's TC
ii) Machined a) Dimensions Major Measurement 100% Components Components Vendor P V V
Drawing Drawing inspection
Report
b) DPT after machining. Major NDT 100% ASTM E-165 No linear Vendor √ P V V
indication inspection
Report
C Gear box assy & idle running Check for oil leakage,Noise Major Visual & 100% Vendor standard Smooth running Vendor √ P V V
level,vibration backlash, rise in Measurement no oil leakage, inspection
temp. after 2 Hrs. of running, Noise 85 db at 1 Report
reduction ratio, backlash and Mtr. Max. Temp.
contact pattern rise 30°C above
amb temp.
D a) Top block, bottom block dimensional conformity Major Masurement 100% Assembly drawing Assembly Vendor P V V
drawing inspection
Report
b) Hook i) Chemical composition, Heat Major Chemical, heat 100% IS:1875 Test Certifacte , √ P V V
treatment, Mechanical treatment & HT chart &
properties on integeral test bar Tensile , % Insp. Report
elongation
ii) UT on raw material of hook Major UT 100% ASME sec--v Annex-1 √ P V V
(Attached)
iii) Forging operation of hook Major Visual 100% IS:5749 /IS:15560 IS:5749 √ P V V
/IS:15560
iv) Proof load test Major Mechanical 100% IS:5749 /IS:15560 IS:5749 √ P W V
/IS:15560
v) UT & MPI after proof load Major UT & MPI 100% ASME sec - v & Annex-1 for UT √ P W V
test ASTM E709-2007 & No crack &
linear indication
(For MPI as per
ASME Sec VIII
Appen 6)

Identification Punch (By BHEL Major Visual 100% ----- ----- ----- - P CHP - Customer Hold Point
&/or customer, after proof load
& NDT witness)
E Rope drum assembly Diemnsion Major Measurement 100% Mfg. Drawing Tolerance as per Vendor insp P V V
drg Report

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249304/2024/PS-PEM-MAX

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-508-501-A001

MANUFACTURER'S NAME & ADDRESS STANDARD MANUFACTURING QUALITY PLAN PROJECT: 2X800 MW LARA TPP
PACKAGE : DOUBLE GIRDER CRANES
ITEM: QP NO : CONTRACT NO :
REV : 0 CONTRACTOR :
DATE : VENDOR' S QAP No :

SL. COMPONENTS & CHARACTERISTCS CLASS TYPE PF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATION CHECK OF CHECK DOCUMENT NORMS RECORDS M C N
1 4 3 4 5 6 7 8 9 D* ** 10 11
12 Electrical components
a) Motors ( =< 100 KW) make , type , rating, Routine Major Review mfr's TC 100% IS:325 IS 325/Mfr's T.C. Mfr's T.C. √ P V V Refer Note for motor upto
100 KW.For motor above
test
100KW separate QP shall
be applicable

b) Brakes Make , type , rating , dia , Major Review mfr's TC 100% Appd drgs Appd drgs Mfr's T.C. √ P V V
Functional test /Routine test

c) Control panel Interlocking fuctional, IR, HV, CR Test for HV, IR, 100% IS : 3177 / App. IS : 3177 / App. Vendor insp √ P W V Refer Note No. 4 VVVFD
Test Certificate to be
Sheet thikness, cable laying, functional check Panel Drg. & Panel Drg. & Report
submitted from app.
dressing , ferulling Overall BOM/ Data sheet BOM/ Data Vendor for verification.
diemsnions , painting shade, sheet
Panel surface finish, Paint
Thickness, adhesive test,
Component fixing, Degree of
protection by paper inserting
method Refer Note No. 4
d) Radio remote, Master controllers,
HV,Pendent , switches
IR,Functional Major Verfication 100% BOM/ Mfr. BOM/ Mfr. Mfr's T.C. √ P V V
Catalogue Catalogue
e) Limit switches Functional Major Verfication 100% Approved Approved Mfr's T.C. √ P V V
drawings drawings
f) Trailing cable, Power Control Make , type , rating ,Routine & Major Verfication 100% IS: 9968, IS 1554- IS: 9968, IS 1554- Mfr's T.C. √ P V V
Cable & DSL aceptance test insulation Part-1 Part-1
resistance values
g) Transformer make rating , routine test Major visual 100% Appd drg Appd drg Mfr's T.C. √ P V V
h) SFU, MCCB,MCB, Contactors, make, t ype , rating size, Major visual 100% Appd drg Appd drg Mfr's T.C. P V V
DSL, relays, fuses, resitance functional, continuity check
bank
i) VVVF drives make , type , rating, routine Major visual 100% Appd drg Appd drg Mfr's T.C. P V V
test

j) Anti collision devices , cable make , type Major visual 100% Appd drg Appd drg Mfr's T.C. P V V
gland , ,lugs ,r ectifier,
indicating lamps, terminal
blocks, load cell.
13 Bought out items
a) Wire rope Visual , tensile Major Type, grade, dia breaking
100%
strenth IS:2266 IS:2266 Mfr's T.C. √ P V V
b) Bearing Type & Size Major Verfication 100% Appd drg/Mfr's Appd drg/Mfr's Mfr's T.C. √ P V V
catalogue catalogue
14 Assembly of cranes
a) Bridge with LT Dimesions, wheel level Major Measurement 100% GA drg/IS:3177 GA drg/IS:3177 Insp. Report √ P W V
alignment
b) Crab assembly Dimesions, wheel level Major Measurement/ Visual 100% GA drg/IS:3177 GA drg/IS:3177 Insp. Report √ P W V
alignment

35
 39
249304/2024/PS-PEM-MAX

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-508-501-A001

MANUFACTURER'S NAME & ADDRESS STANDARD MANUFACTURING QUALITY PLAN PROJECT: 2X800 MW LARA TPP
PACKAGE : DOUBLE GIRDER CRANES
ITEM: QP NO : CONTRACT NO :
REV : 0 CONTRACTOR :
DATE : VENDOR' S QAP No :

SL. COMPONENTS & CHARACTERISTCS CLASS TYPE PF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATION CHECK OF CHECK DOCUMENT NORMS RECORDS M C N
1 4 3 4 5 6 7 8 9 D* ** 10 11
c) Final Inspection ( at works) Overall dimension: Span, Major Measurement 100% Approved drgs./IS Approved Insp. Report √ P W W
with actual panel and pendent Diagonal dimension check, :3177 drgs./IS: 3177
Wheel base & gauge, overhang,
LT Stopper, headroom, lift ,
Eqp. Layout on bridge platform,
, elevations /levels etc

No Load & Load Tests

a) No load: Hoists,CT & current Major Measurement 100% Approved drgs Approved drgs Insp. Report √ P W W
measurement, No Load running
of LT machinery for direction
and speed with VVVFD

b) SWL: Hoists, CT speed, Major Operational 100% GA drg/ IS:3177/ GA drg/ IS:3177/ Insp. Report √ P W W
current & Deflection Check & Approved Approved
measurement Measurement Drawing Drawing

c) Overload: Hoisting, CT Major Operational 100% GA drg/ IS:3177/ GA drg/ IS:3177/ Insp. Report √ P W W
movement & current Check & Approved Approved
measurment (at 125% SWL) Measurement Drawing Drawing

d) Operation check of brakes Major Operational 100% GA drg/ IS:3177/ GA drg/ IS:3177/ Insp. Report √ P W W
and limit switches . Check Approved Approved
Drawing Drawing

15 Painting Surface preparetion & Painting. Major Visual 100% Approved Approved Vendor's Report P V
DFT drgs/doc drgs/doc

Note 1 : Original TCs / Photocopies certified in original by mill shall be furnished for review. Test In absence of correlated TCs Check test to be witnessed by BHEL shall be
carried out from each plate/ bar for above 10 mm thk., certificates shall be offered for review at the time of stage inspection of components / assembly. Supplier
shall ensure that pitted material is not used.
Note 2 : X-Ray to be taken for thickness upto 19 mm and Gamma Ray for thickness above 19 mm. If Gamma Ray is used for lower thickness slow speed film like D2 or
equvalent which gives enough readable and interpretable film quality to be used for clarity. All NDT shall be carried out by Qualified Level II personnel.

36
 40
249304/2024/PS-PEM-MAX

THIS IS PART OF TECHNICAL SPECIFICATION PE-TS-508-501-A001

MANUFACTURER'S NAME & ADDRESS STANDARD MANUFACTURING QUALITY PLAN PROJECT: 2X800 MW LARA TPP
PACKAGE : DOUBLE GIRDER CRANES
ITEM: QP NO : CONTRACT NO :
REV : 0 CONTRACTOR :
DATE : VENDOR' S QAP No :

SL. COMPONENTS & CHARACTERISTCS CLASS TYPE PF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATION CHECK OF CHECK DOCUMENT NORMS RECORDS M C N
1 4 3 4 5 6 7 8 9 D* ** 10 11
Note 3 : LT motors shall be of type tested quality. For each type & rating of LT motors rated above 100 KW, the bidder shall submit for Owner's approval the reports of all
the type tests as per relevant standards and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the
equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or
should have been witnessed by a client.
In case the Bidder is not able to submit report of the type test(s) conducted within last ten yearsfrom the date of bid opening, or in case the type test report(s) are
not found to be meeting the specification requirements, the Bidder shall conduct all such tests under this contract free of cost to the Owner and submit the
reports for approval.
LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED
The following type test reports shall be submitted for each type and rating of LT motor of above 100 KW only
1. Measurement of resistance of windings of stator and wound rotor.
2. No load test at rated voltage to determine input current power and speed
3. Open circuit voltage ratio of wound rotor motors ( in case of Slip ring motors)
4. Full load test to determine efficiency power factor and slip .
5. Temperature rise test .
6. Momentary excess torque test.
7. High voltage test .
8. Test for vibration severity of motor.
9. Test for noise levels of motor
10. Test for degree of protection and
11. Over speed test.
LESS THAN 30KW: ACCEPTANCE OF MOTOR LESS THAN 30 KW IS BASED ON COC OF THE MANUFACTURER & THE CONTRACTOR CONFIRMING AS FOLLOWS: IT IS
HEREBY CONFIRMED THAT THE ABOVE MENTIONED MOTOR /MOTORS WAS/ WERE MANUFACTURED TAKING CARE OF CUSTOMER SPECIFIC REQUIREMENTS
REGARDING AMBIENT TEMP., VOLTAGE & FREQUENCY VARIATION, HOT STARTS, PULL OUT TORQUE, STARTING KVA/KW, TEMP. RISE, DISTANCE BETWEEN
CENTRE OF STUD & GLAND PLATE AND TESTED IN ACCORDANCE WITH APPROVED DRAWING /DATA SHEETS.
30 KW TO BELOW 100 KW:ACCEPTANCE OF MOTOR RATING BETWEEN 30 KW & 50 KW IS BASED ON NTPC REVIEW OF ROUTINE TEST INSPECTION REPORT AS PER
IS 325 ALONG WITH COC OF THE MANUFACTURER & THE CONTRACTOR CONFIRMING AS FOLLOWS:IT IS HEREBY CONFIRMED THAT THE ABOVE MENTIONED
MOTOR /MOTORS WAS/ WERE MANUFACTURED TAKING CARE OF NTPC SPECIFIC REQUIREMENTS REGARDING AMBIENT TEMP., VOLTAGE & FREQUENCY
VARIATION, HOT STARTS, PULL OUT TORQUE, STARTING KVA/KW, TEMP. RISE, DISTANCE BETWEEN CENTRE OF STUD & GLAND PLATE, SPACE HEATER AND
Note 4 : Performance of electrical & control devices along with the interlocks, protection & sequence to be checked during crane assembly and parked at works.
Note 5 : All material of construction shall be as per approved drg. / data sheet / specifications
LEGEND :
D: RECORDS INDETIFIED WITH 'TICK'( √ ) SHALL BE ESSENTIALLY INCLUDED BY CONTRACTOR IN QA DOCUMENTATION
M : MANUFACTURER/SUBCONTRACTOR
C: BHEL-CQS/THIRD PARTY
N : CUSTOMER
INDICATE "P" PERFORM "W" WITNESS AND "V" DOCUMENT REVIEW

MANAFACTURER/ CONTRACTOR
SUBCONTRACTOR
SIGNATURE REVIEWED BY NAME & SIGN OF APPROVING AUTHORITY & SEAL

37