ENGINEERING PROCUREMENT

CONSTRUCTION CONTRACT (EPCC)-MARMUL

ITP- Installation of Over Head Traveling Crane

Document No: GEN-00-102961-QA-5733-00023-0000-Rev.02

BEC Contract Number CME0001

PDO Contract Number C-311658

PDO Comments Incorporated

02 24-08-2015 VP AKS
-Reissued for review and approval
01 02-06-2015 Issued for review and approval VP AKS

Checked &
Rev. Date Description Originator PDO
Approved
ITP-Installation of Overhead Traveling Crane
Engineering, Procurement and Construction Contract (EPCC) - Marmul
C-311658 Doc : GEN-00-102961-QA-5733-00023-0000-Rev.02 CME0001

Document Preparation

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 Activity Name Designation Initials

Originator Venkatesh Padmanabhan QA/QC Engineer VP

Checked &
Anil Kumar Singh QA Manager AKS
Approved

Revision History

Revision
Date of Rev Revision Description
Number
01 02-06-2015 Issued for review and approval
02 24-08-2015 PDO Comments Incorporated -Reissued for review and approval

Check Civil foundation

Record review
release
1 AFC Drawing Check Shims at correct level, correct size 100%
Check steel structural
release (As Applicable)

Rail track installation

Distance between rail
centers & Diagonal
Vendor Drawing Span and Elevation as per Vendor's Manual
2 Top of rail elevation 100%
Vendor Manual
Track straightness
(Horizontal / Vertical )
Transverse inclination
of Tracks

Welding / Torqueing as per Vendor

Check anchor bolts
requirement
tightening or welding of
Vendor Drawing All Weld to be Inspected
3 rails (As applicable). 100%
Vendor Manual Welding as per Approved WPS and
Check bumper stops
Approved WPS Drawing
secured Correctly

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 Check name plate, data
Vendor Drawing Visual Inspection in according to Vendor
plate and transit
PR-1708 & Manual
4 damage 100%
EN13001,BS466,BSEN150 PR-1708 Clause 6.6
Check installation of
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crane and trolley

Installation as per Vendor Drawing

Welding / Torqueing as per Vendor
requirement
End Stoppers installations Vendor Drawing All Weld to be Inspected
5 (Anchor bolts Tightening Vendor Manual Welding as per Approved WPS and 100%
or Welding as applicable ) Approved WPS Drawing

All Welds to be free from defects

NDT & Acceptance to be done as per the 100%
6 NDT ( if applicable ) Approved NDT Procedure approved Procedure / Vendor Drawing /
AFC Drawing ( if applicable )

Access platforms and

7 Vendor Drawing As per AFC / Vendor Drawing
ladders installation 100%

Check lubrications and

Hydraulic system Vendor Drawing I
8 As per Vendor Data Sheet 100%
completed and filled with Recommendation
specified oil.

Installation of drives Vendor Drawing

Installation as per Vendor drawing and
9 ( motor, gears with Vendor Manual 100%
manual
frames )
SP-1099
Cable Installation & Cable Termination
10 Vendor Manual 100%
Cable Installation SP -1099 Clause 2.2.

Cable Testing as per DEP 63.10.08.11

Clause 4.6.1 / 3.1.1 and Appendix 11 ,12
SP-1099 SP-1099 Clause 2.3.3
Cable Testing Vendor Manual Insulation resistance and continuity Test
11 100%
DEP 63.10.08.11 for all UG Cables shall be carried out prior
to backfilling of trench
Test Value shall be as per Appendix .12 of
DEP 63.10.08.11

Resistance < 4 ohms when isolated from

main earth
SP-1099
12 Insulation tests Connection are proper and tight 100%
SP1100
SP-1099 Clause 2.3
BS466
SP-1109 Sec 2.5.2

13 OPERATION TEST
Functional Test without
PR-1708 / PR-1708 Clause 6.4.2
load
Vendor Manual / Lifting limit as per Vendor data sheet
Limit switch
13. Approved Testing Normal and slow speed as per Vendor
Speed switch 100%
1 Procedure Data sheet
Lifting units, traveling
SAT( Site Acceptance Main hoist, auxiliary hoist long travel and
and smooth running
Test) cross travel as per data sheet
Hoisting and Lowering

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 Functional Test with load
(100% SWL)
Brake Check PR-1708 Clause 6.4
Limit switch Vendor Manual / Visual Inspection criteria as per to Vendor
Speed switch PR-1708 / Manual
13.
Deflection as per Approved Testing Normal and slow speed (as per data 100%
2 Procedure
standard sheet)
Hoisting and Lowering Vendor Drawing (AFC) Requirements
Static and Dynamic
Load Test
Voltage drop

PR-1708 Clause 6.4

13. Functional Test with
3 overload (125% SWL)
Vendor Manual / Lifting unit (one revolution of the gear)
PR-1708 / as per vendor data sheet
Approved Testing Crab unit (one revolution of the wheel)
100%
Procedure as per vendor data sheet
Long travel test as per vendor data sheet
Deflection test As per vendor data sheet
(125% SWL)

As per Vendor Requirement / Manual /

Drawing
Touch up paint at damaged
Vendor
Spots and Marking ID
14 Drawing / Instruction 100%
Number ,SWL , Calibration
Due Date
(if applicable)

As per Vendor
Drawing/recommendation Visual Inspection in according to Vendor
Final Visual inspection and
15 /PR-1708 Manual / Vendor Drawing 100%
Conformant
SAT (Site acceptance PR-1708 Clause 6.4.2
test)

Inspection and test mark-up legend: M = Monitor, W = Witness, H = Hold Point, R = Document Review, A= Document Approval
The following definitions shall apply:

Hold Point (H): A critical step in fabrication and testing where it is mandatory that the Responsible Party inspect the component/e
as a Hold Point shall not proceed unless the Responsible Party/Representative is present or the Hold Point is formally waived. Th
specified in the contract in advance of the activity.

Witness Point (W): A critical step in fabrication and testing where it is desirable that the Responsible Party/Representative inspec
The Responsible Party shall be notified at a duration specified in the contract in advance of the activity. Once proper notification is
schedule regardless of the Responsible Partys attendance.

Monitor Point (M): A critical step in fabrication and testing where it is optional that the Responsible Party inspect the component/
Party shall be notified at a duration specified in the contract in advance of the first occurrence of the activity at each worksite. No
shall be required. The activity may proceed with or without the Responsible Partys attendance.

Approval Point (A): A critical step in design, procurement, and or fabrication and testing where it is mandatory that the Responsi
equipment/or activity. The Responsible Party shall be notified at a duration specified in the contract in advance of the first occurre
period of time specified by the contract. The activity may not proceed without the Responsible Partys approval.

Review Point (R): A critical step in design, procurement, and or fabrication and testing where it is desirable that the Responsible
activity. A separate notification is not needed unless otherwise specifically requested; the Responsible Party may perform this alo

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