QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
Type /

Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
1 BRIDGE
GIRDER, END
CARRIAGE,
CRAB, FRAME
ETC.

1.1 Materials - Chemical / Physical Major T.C. Correlation One per heat Component Component Material TC or For plate of
Plates if not available drawing/ drawing / Specs./ Supplier's Test thickness>=25mm,UT Red
then check test Specs./ IS 2062 Report 3 2 1
IS 2062
Reports / TC review.

Lamination /Internal Major UT 100% ASTM A-435 ASTM A-435 IR 2 - 1

1.2 Welding Welding procedure & Critical Test piece visual One for each ASME Sec.IX ASME Sec.IX PQR format
2 1 1
Welders qualification. & physical test. position
Load Bearing
1.2.1 a) Critical D.P.Test 100% IS:3658 IS:3658 Supplier's IR Use weld gauges
Butt welds
Welding quality & 2 - 1
Surface defects

b) Critical Radiography As per ASME ASME Sec.VIII Supplier's IR Review of radiography films by
Sub surface defects component Sec.VIII Div I Div I 2 1 - I.A.
drawing.
Other than load
1.2.2 Surface defects & Size Major Visual & DPT 100% Visual Use weld gauges
Bearing Butt welds
check DP test
& fillet welds 2 - 1
10% random

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
Type /

Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
Final Welding
1.2.3 Visual Inspection Major Inspection of 100% Visual Visual Supplier's IR Visual final stage.
Inspection 2 1 -
Welding quality
Bridge
1.2.4 Visual, Welding Major Visual & Visual 100% Component Component Supplier's IR
Girder(inside) &
Measurement welding quality DPT-random drawing drawing 2 1 -
End Carriage
of 10%
inspection
Final Inspection of
1.2.5 Dimensional Major Measurement 100% Component Component Supplier's IR Review of reports at final stage
fabricated 2 - 1
conformity drawing drawing
components

2 OTHER
FABRICATED
COMPONENTS

MH, LT & CT
2.1 Stress relieving Major Verification 100% Mfg's std. Stress relieving Supplier's IR SR chart will be reviewed by I.A.
Gear box, 2 - 1
chart
Housings
Surface defects & Major Visual/DP Test/ DPT 10% IS:3658/Comp IS:3658/Compon Supplier's IR
dimensional check Measurement random & onent drawing ent drawing 2 - 1
100% visual
Welding Joint quality
2.2 ROPE DRUM Critical Visual/DP 100% Component ASME Sec.VIII Supplier's IR 3/ Examination of RT films by I.A.
& Weldment defects
Test/RT/ drawing Div I 2` 1
Measurement 2

Stress relieving Major Verification 100% Mfg's std. Stress relieving Supplier's IR 3/
ROPE DRUM 2 1
chart 2

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
Type /

Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
RT of rope drum
2.2.1 Sub surface defect Critical Radiography As per ASME ASME Sec.VIII Supplier's Examination of RT films by I.A.
joints
component Sec.VIII Div I Div I IR/Vendor TC 2 - 1 For seamless pipes no RT.
drawing
a) Platform
2.3 Minor Measurement Critical Component Component Supplier's IR
b) LT Frame
Dimensional dimensions drawing drawing
c) Hand Rails
Conformity 100% others
2 1
at random

3 MECHANICAL
COMPONENTS

MH, CT & LT All the keys &keyways

3.1 Mfr's TC with chemical Major Correlation with 100% Component Component Mfr's TC/
Gear box Gears ,
composition & physical TC drawing/ drawing/ Supplier's IR shall be checked by TPIA
Pinions and axles
properties Dimensional Specification Specification before assembly. Reports
conformity Checks & IS:1570 / IS:1570 / BS 970
2 - 1
Inspection of Key way BS 970
shall be furnished with
milling tolerances & dimensions
LT & CT Shafts All the keys &keyways
3.1.1 Straightness & Major Correlation with 100% Component Component Mfr's TC/
Dimensional TC drawing/ drawing/ Supplier's IR shall be checked by TPIA
conformity Checks & Specification Specification 2 1 1 before assembly. Reports
Inspection of Key way IS:1570 / IS:1570 / BS 970
milling BS 970
shall be furnished with
tolerances & dimensions
Machined
3.2 Hardness Dimensional Major Measurement 100% Component Component Supplier's IR
components for
conformity. drawing drawing 2 1
MH, CT &LT Gear
box IS:2048

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
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Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
3.2.1 Gear box Dimensional Major Measurement 100% Component Component Supplier's IR
conformity/ Inspection drawing Drawing.
of machine surface of 2 1
gearbox base. IS:2048

Hardness of gear teeth

Major Measurement & 100% Component Component Supplier's IR Review of reports/
and grinding of Contact
no load running drawing / drawing / Load Test witnessed
surfaces Backlash,
Gear box assembly Specification Specification by I.A.
Number of bearings. Noise level of
3.3 (no load run test & 2 1 -
Oil seals, key way and gear box < 80db
load test)
keys.
Noise level & Bearing
temperature.
Pulleys,
3.4
Couplings, Buffers,
Plummer blocks &
other components

a) Chemical & Physical as Major Correlation with 100% Component Component Mfr's TC Review of Test certificates of all
Material (Cast applicable TC / Check test drawing / drawing / bought out components.
Steel and Steel) Specification Specification 3 - 1,2 by I.A. and issue Compliance
Noise level of certificate
gear box < 80db

b) Dimensional Visual Inspection / Major Visual 100% Component Component Supplier's IR

Inspection Dimensional Inspection Inspection / drawing drawing 3 - 1,2
Measurement

3.5 LT & CT Wheel

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
Type /

Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
Mfr's TC with chemical Major TC correlation if one per heat Component Component Mfr's TC /
composition & Tensile not available drawing / drawing / Spec. Supplier's Report 3/
1
a) strength then check test Spec. IS:1578 IS:1578 / BS 970 2
Matl. Forged for chemical /BS 970

UT Major UT checking 100% ASTM A-388 ASM A-388 Supplier's IR Reports/TC will review by I.A.
2 - 1

b) Dimensional Major Measurement 100% Component Component Supplier's IR

Machined Conformity drawing drawing 2 - 1

c) Hardness Major Measurement 100% Component Component Supplier's IR

drawing drawing 3 2 1
Material
Snatch block
3.6 Dimensional Major Measurement 100% Assembly Assembly Supplier's IR Review of reports by I.A.
assembly 2 - 1
Conformity Drawing Drawing

Physical & Chemical Major Witnessing / 100% Component Component Mfr's TC Proof load test from Govt.
Composition and UT Correlation with drawing / drawing / IS - 3 - 1 approved laboratory.
Test Certificate. IS – 1875 1875

3.7 Hook Proof Load Test Major Testing 100% Component Component Mfr's TC
3 - 1
drawing drawing

Stress relieving Major Verification 100% Component Component Vendor TC

3 - 2/1
drawing drawing

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
Type /

Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
Chemical & Physical as Major Correlation with 100% Component Component Mfr's TC All the keys &keyways
applicable and TC / Check test drawing / drawing / shall be checked by TPIA
3.8 Brake drums Dynamic balancing. Specification Specification 3 - 1,2 before assembly. Reports
Key way and key.
shall be furnished with
tolerances & dimensions
4 BOUGHT OUT
ITEMS

Dimensional, Major Mfr's TC 100% Component Component Mfr's TC Review of Mfr's TC by I.A.
drawing/ drawing / BOOM 3 - 1
Lay, core and stands. BOOM
4.1 Wire Rope
Breaking Load Major Mfr's TC 100% IS:1364 IS:1364 Mfr's TC 3 - 1

IS:1367 IS:1367
Specific brand
4.1.1 Bearings Mfr's TC
conformity. 3 1

Dimensional, visual,
4.1.2 Machined Bolts & Major Mfg TC Random Drawing Drawing Supplier IR, Use No black bolts and taper
chemical/ physical 3 1
Nuts MFG TC washers

5 ELECTRICAL
ITEMS

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
Type /

Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
5.1 Electrical Control Dimensional, Visual Major Electrical test 100% Electrical Approved Supplier's IR Review of test certificates of all
Panel Sequence / Functional Circuit drawing/ bought out items by IA
and high voltage Test diagram/ Specification.
3 1
Approved
drawing/
Specifications

5.2 Motor Visual Major Name Plate 100% IS 325 IS 325 Mfr's TC Review of TC by I.A.
3 - 1
details

Routine Major Elec. test 100% IS 325 IS 325 Mfr's TC

No load test, Insulation

resistance values, 3 - 1
winding resistance
values

5.3 Brakes and Visual Major Name plate 100% BOOM/Spec BOOM/Spec Mfr's TC Review of TC by I.A.
details
Brake coil Accessibility of parts. 3 - 1
verification of
TC

5.4 Resistance box Megger test, Resistance Major Electrical test 100% BOOM/ BOOM/ drawing Mfr's TC Review of I.A.
value drawing / / Specifications. 3 - 1
Specifications.

5.5 Master controller Sequence, Major Visual 100% BOM/ drawing BOM/ drawing / Mfr's TC Review of TC by I.A.
Limit Number of cams, / Specifications.
3 - 1
switch/Circuit Idle operational test Specifications.
breakers

5.6 Cables Routine test Major Test One per size BOM/spec. BOM/spec. Mfr's TC 3 - 1 Review of TC by I.A.

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
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Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
6 ASSEMBLY OF
CRANE
Bridge Girder &
6.1 Overall Dimension s Major Measurement 100% Approved Approved Supplier's IR
End carriage
Structural Alignment General General
assembly.
& LT Wheel Arrangement Arrangement
alignment. Span drawing / drawing / 2 1 -
measurement Specifications Specifications

Diagonal Checks
Crab assembly
6.2 Dimensional & CT Major Measurement 100% Approved Approved Supplier's IR
with Main Hoist &
Wheel alignment drawing / drawing / 2 1 -
CT machinery
Specifications Specifications

7 NO LOAD TEST
Main Hoist and
7.1 No Load test Major No Load test 100% Approved IS 3177 Supplier's IR Measure Gear Box Noise. (Noise
drawing / Level should be <80db) Follow
2 1 -
Specifications format annexed for parameters to
& IPSS be measured etc.,
CT Mechanism
7.1 No Load test Major No Load test 100% Approved IS 3177 Supplier's IR Measure Gear Box Noise.
drawing /
2 1 - (Noise Level should be <80db)
Specifications
& IPSS
LT Mechanism
7.2 No Load test Major No Load test 100% Approved IS 3177 Supplier's IR 2 1 - Measure Gear Box Noise.
drawing /
Specifications (Noise Level should be <80db)

8 TESTING

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
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Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
DEFLECTION
8.1 Load test Major Measurement 100% Approved Approved Supplier's IR & Record Test procedure followed.
TEST
drawing / drawing / ISRO Format
With Safe Working Specification / Specification / IS 2 1 -
Load IS 3177 as 3177 as
applicable. applicable.
FULL LOAD
8.2 Load test Major Measurement of 100% Approved Approved Supplier's IR &
TEST
speed, voltage drawing / drawing / ISRO Format
SAFE WORKING & Current Specification / Specification / IS 2 1 -
LOAD (MH & Measurement IS 3177 as 3177 as
CT) applicable. applicable.

8.3 Load test Major Observation and 100% Approved Approved Supplier's IR &
OVER LOAD manoeuvre drawing / drawing / ISRO Format
TEST ability of CT & Specification / Specification / IS 2 1 -
(MH & CT) Hoist motion IS 3177 as 3177 as
applicable. applicable.
Span, Level, Joints and Major Measurement 100% Approved Approved
9 GANTRY
Anchoring of girders drawing / drawing /
GIRDER AND
Specification / Specification / IS 2 1
RAIL
IS 3177 as 3177 as
ALIGNMENT
applicable applicable

10 LOAD TESTING
AFTER
ERECTION AT
SITE.

10.1 Functional checks of all Major

No Load Test motions, limit switches 3/2 1
and Safety Inter locks

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

Agency
Type /

Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
10.2 Load test Major Measurement 100% Approved Approved Supplier's IR &
Deflection test with drawing / drawing / ISRO Format
full load Specification / Specification / IS 3/2 1 -
IS 3177 as 3177 as
applicable. applicable.

10.3 Full load test (MH, Load test Major Measurement of 100% Approved Approved Supplier's IR &
CT & LT) & speed, voltage drawing / drawing / ISRO Format
Safety & current Specification / Specification / IS 3/2 1 -
Mechanisms. measurement IS 3177 as 3177 as
applicable. applicable.

Brake holding Test

Brake path test, Brake

current, winding
10.4 Brake Test resistance values, 3 1
electrical test (IR with
respect to body)

Hoist operation
10.5 In SLVC mode
without encoder
capability to be 1
checked

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 QAP INSPECTION PLAN FOR EOT CRANES ANNEXUXE-IX

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Performed

Witnessed
Components Characteristic Extent Ref. Acceptance Format of
# Category Method of Remarks

Verified
/ Operations to be checked of check Document Norm record
check

A B C D E F G H I J K
VVVF Drives
10.6 output voltage, current,
Torque curves
(Graphs), Brake
resistance during load
test,
3 1
Braking resistor
resistance value & IR,
Braking resistor max
temperature during load
test

10.7 Major Observation and 100% Approved Approved Supplier's IR & Examine for weld cracks etc.,
Over Load test manoeuvre drawing / drawing / ISRO Format
125% of Full Load Load test ability of CT & Specification / Specification / IS 3/2 1 -
(MH, CT & LT) Hoist motion IS 3177 as 3177 as
applicable. applicable.
Painting
11 3/2 1
Safety features
12 3/2 1
Special
13
requirements

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 ANNEXURE – X
THE PARTY SHALL SUBMIT THE FOLLOWING
TEST CERTIFICATES, INSPECTION REPORTS&MAINTANACE CATALOGUES
1. Raw Material Test Reports
2. Welding Procedure Specifications(WPS)
3. Welding Procedure qualification/Procedure qualification Records(PQR)
4. Girder and End Carriage Inspection Reports
5. DP Test Reports of fillet weld joints of girders
6. NDT Level II Certificates
7. Rope Drum SR Charts
8. Rope Drum fillet joint DP Test report
9. Gear Box Reports & lubrication charts.
10. Dimensional Reports including tolerances of Key & Key ways of Gear Box,
MH, LT, CT & Wheels and shafts.
11. Key material Test certificates
12. CT/LT Wheel Physical /Chemical Reports
13. Wheel Hardness Test Reports
14. Wheel UT Report
15. Wheel Dimensional Report
16. Hook Test Report with twice its SWL at govt approval test house/dock labour board.
17. Coupling Test Certificates
18. Dimensional Reports of Couplings
19. Brake Drum Dynamic Balancing Reports
20. Material & Dimensional Report for Sheaves
21. Inspection Report for lower block assembly
22. Wire rope Test Certificates
23. Flame Proof Certificates of EHT Brakes, Thruster, Motors & Under bridge Light fittings.
24. VFD panel test report for HV & Dielectric strength test.
25. Motor Routine Test Certificate & Inverter suitability.
26. Test certificate for IGUS cable.
27. Brake Test Certificate
28. ATEX compliance certificate for FLP Imported Brakes.
29. Inspection Reports as Per ISRO Crane Test Procedure
30. Electrical wiring diagrams, control drawings.
31. Cable routing diagrams showing cross sectional details of clamping/fixing arrangement of
cable etc.,
32. Maintenance Catalogues of motors, Brakes, Gear Boxes and VVVF Drive systems.
33. Painting Inspection Report.
34. Inspection Release Note & Inspection Report
35. Load test report
36. Drive back up data in CD/DVD.
 ANNEXURE – XII
List of Spare Parts:
Sl. No Item Description Capacity Quantity

1 Main Hoist EHT Brake Thruster 60t 1

2 (Imported Thruster) 10t 1

3 LT EHT Brake Thruster 60t 1

4 CT EHT Brake Thruster 60t 1

5 Rotary Limit Switch 60t 1

6 Over Load Relay for Main Hoist 60t 1

7 Over Load Relay for LT 60t 1

8 Over Load Relay for CT 60t 1

Note: The above mentioned spares shall be suitable for 60/10t FLP EOT crane.