Attachments QAM 129

8/8/2019 Attachments QAM 129

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BHARATIYA NABHIKIYA VIDYUT NIGAM LIMITED

(A Government of India Enterprise)

KALPAKKAM 603 102

BHAVINI

PFBR

QUALITY ASSURANCE MANUAL

FOR

PROCUREMENT, MANUFACTURING

&

SITE CONSTRUCTION ACTIVITIES

REVISION NO.1

September 2004


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KALPAKKAM 603 102

SYSTEM: CONSTRUCTION

DOCUMENT No. : PFBR-QMS-QA-1 Rev. 1. USI No. 81300

QUALITY ASSURANCE MANUAL FOR PROCUREMENT,

MANUFACTURING & SITE CONSTRUCTION ACTIVITIES

Names Date Signature

Shri. K. Gopal, SO/F, QAPreparedby

Shri. G.V.V.S.R.Kishore SO/C, QA

Shri. S.S. Dhere, ACE (Civil)Shri. V.K. Sethi, SO/H,Procurement (Mechanical).Shri. K. Ganeshan, SO/F(Electrical)Shri. A. Ananth, SO/E.(Instrumentation)Shri. H.R. Sridhara, SO/E, (FE)Shri. M. Krishna Rao. PE (SP)Shri. M. Palaniappan, SO/H (QA)

Reviewedby

Shri. S. Gurunathan, CE (QA)Shri. Prabhat Kumar,Project Director, BHAVINI

Approvedby

Shri. R. Prabhakar,Director (Technical), BHAVINI


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REVISION CONTROL SHEET

REV. NO. REVISION DETAILS DATE OF REVISION

REV.0 FIRST

ISSUE

MARCH

2004

REV.1

REVISED AND

REDRAFTED

INCORPORATING

COMMENTS OF

AERB ( PDSC & CESC )

SEPTEMBER

2004


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KALPAKKAM 603 102

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1.1.1. SCOPE

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1.2.1. DEFINITIONS

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1.2.2. ABBREVIATIONS

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1.3.1. PROGRAMME RESPONSIBILITY

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STATEMENT

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1.3.3. ORGANISATION

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ORGANISATION STRUCTURE, FUNCTIONS AND RESPONSIBILITIES

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ORGANISATION CHART OF BHAVINI

DIRECTOR

(FINANCE)

DIRECTOR (CONSTRUCTION)

/ PROJECT DIRECTOR

HEAD

(MECHANICAL)HEAD

(CIVIL)

CHAIRMAN &

MANAGING

DIRECTOR

HEAD

(FIELD

ENGINEERI

NG)

HEAD

QA

(PROCUREMENT)

HEAD

(PROCURE

MENT)

HEAD

(ELECTRICAL

AND C & I)

HEAD

QA

(CONSTRUCTION)

(IND

&SA

DIRECTOR

(TECHNICAL)


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0>12&(6'(38'%('.156&21113,1&7(21166(2*

*0 1''.3'&'(3'.3.3'@12..('.3''9-(')


36/129

- 36 -

20 &3(4'(32%&'8&'%2'(7('(12&)1%=(3'%&3(4'(31'&-2'-&5

8-32'(3 &1631(*((')5 (3 3, 71 8 -'%&(') ' 1% *31-&, '%'

6&133 6&8&.(3 2'(7('(1 1% 3' %7 ,(&2' &1631(*(('(1 8&

6%)1(26&&118'%=&+

,0 ,3'(8(2'(38.


37/129

- 37 -

1.3.6. QA PROGRAMME REVIEWS

%(1-(')11-&323-1%*&7(=,6&(,(2)'1'32(3'%&)&1

3,&7(1,13211&)'&82'6&&..'(23,&3(4'(32%313218

3&7(1(35L%3L61('(31%*&2&,,3,(11-,7(1(31''%(1.3-

1%*66&7,(3'%1..'%,3,1'11'%66&78'%&((3(11-


38/129

- 38 -

1.4.1. DOCUMENT CONTROL

>&=(313,62(8(2'(31

'%231'&-2'(32'(7('(1 1% *2&&(,-' 8=(3 66&7,,2-.3'1 %

,&=(313,162(8(2'(318&'%.(363'('.11%*6&6&,52%2+,3,

66&7,*)2'&3(3&(3&-68&'%(&-'%&(4,231-'3'13,

1%*.,7(*''%;(,3(3&(3&-6'6&


39/129

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3.3'&2,-&1

1' 8.3.3'6&2,-&15 1%* 6&6&,3, 66&7,(3 ,,('(3 ''%

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(.(',''%8=(3F

&2,-&8&&6&'(38&2,-&

>&=(388(26&2,-&

3,&7-'(3&2,-&

&2,-&8&3.3'7(=8&&..

'&(&2(6'5(3162'(351'&3,(11-

-,('1

3'&83A38&.32

:&+&2,-&1

2&,3,>2-.3''(3

!3,7&B&318&81)1'.15231'&-2'(3,2-.3'1

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,&=(315*)(3,(7(,-231'&-2'(3&-61B23'&2'&1

%6&2,-&13&)23'(3'%8=(3F

('5 ,12&(6'(3 8 2'(7('(15 (,3'(8(2'(3 3-.*&5 &7(1(3 3-.*&5

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268=&+ 8&3211-2%12,15162(8(2'(35,&=(31

&A&9-(1('1

&A9-(8(2'(38'%6&1336&8&.(3'%=&+59-(6.3'3,

6&211

&2-'(31'*'+38&'%18')86&1333,9-(6.3',-&(3

(31''(35(3162'(33,'1'(3

>'(,(31'&-2'(352%2+(1'&638&'%(31''(33,

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40/129

- 40 -

'% 6&2,-&1 8 (7( B 2%3(2 B 2'& 11.*) B (6(3 B 2'&(2 B

31'&-.3''(3=&+11%*66&7,*)'%&162'(7!,18&-61

315 > 3, 6&2,-&1 1% * &7(=, B 66&7, *) '% &162'(7

!,18&-61

&2,-&15 31 3, (31'&-2'(31 B 12%.1 & &7(=, *) ; &-6 *8&

66&7

1.4.2. DESIGN CONTROL

%&1631(*((')8&>1(3(1=('%55%7&&..(3

>1(3 =%(2% (1 &7(=, *) $ 5 .) 11(3 >1(3 :&+1 '

231-'3'1=%(3'-&3%7&&..226'*'53,$!

;(,3(3&(3&-68$!(3'&821=('%5=('%&&,'>1(3

>1(3 36-'1 &2(7,8&.5 & (11-,*) ;'%&-%7&(-1&-61 (3

$!8&(.6.3''(3

9-1'1B6&6118&>1(3.,(8(2'(31(32-,(3'%18&.23'&2'&1=(*

6-'-6';(,3(3&(3%1=(*6&211,1>1(3%39-1'1B;(,

%39-1'1;B31-'3'1%(11->3,;&-61%(11-;%1

,2-.3'1 1% * 8&=&,, ' 231'&-2'(3 &-6 8& (.6.3''(3 -2%

,2-.3'11%*(32&6&',(31-*19-3'&7(1(38'%,&=(38'&'%,1(3

B,&=(31& 8&435=%37& 3211&)5 ; &-6 1% (11- =%(2% 1%*

8&=&,,'231'&-2'(3&-68&(.6.3''(3

%7(1(3(3>1(3>2-.3'1(16&211,*);3'%1.(311'%&((3

,1(3,2-.3''(1'%&1631(*((')8'%-1&&-6'31-&'%''1'&7(1(31

8>1(3>2-.3'1&-1,(3'%(&&162'(7&1

1.4.3. PROCUREMENT CONTROL

&2-&.3'3'&3,3,&-(8(2'(3

&2-&.3'8.'&(B9-(6.3'8&$!1%*-3,&'+318=1F

3,3'(35 3,&(35 3-82'-&& B 3,& 7-'(35 3-82'-&(35 3162'(35

1'(33,-66)

'%2'(7('(1&',''%6&2-&.3'8.(&2'&'!=7&56&211(38

'3,&18&.


41/129

- 41 -

&2-&.3'2'(7('(1

;=(32'(7('(1&6&8&.,(36&2-&.3'82.633'1B9-(6.3'B1&7(21

/&8&&,'1G&,-2'H0

0&6&'(35&7(=566&75,(1'&(*-'(33,2%323'&8

2%3(2162(8(2'(3

3,&,2-.3'*0 3,&B1%67-'(33,9-(8(2'(3512&-'(3)8.3-82'-&&@13-51

3211&)

202%3(27-'(35(,3'(8(2'(38'2%3(2,7('(318&.'%3,&

,2-.3'3,'%(&226'32B&3,'1'(36&2,-&1562+(36&2,-&1'2

0-(')3'&3,-&7(32/(32-,(3162(8(2G!,H5:('3113,7(=

1'10

80.6('(383-82'-&(32&,1B>2-.3'181*-('6&,-2'

/.633'B9-(6.3'0

07-'(386&8&.328'%6&,-2'/.633'B9-(6.3'0=('%(361'

=&&3')6&(,

%03'&833A238&.3213,8=A-632&&2'(72'(31

(03&'(33,23'&8&2&,18&(3162'(35>3,'%&'1'1


42/129

- 42 -

% 23'&2'&B .3-82'-&& B 73,& B 1-*A73,& 6&6& 3, 1-*.(' '%(&

.3-1(3(3=('%'%(13-8$!

&2-&.3'&2,-&1

8'& (,3'(8)(3 '% 3, 8& 6&2-&.3' 8 '% 6&,-2' 8& '% &2-.3'8&8-&'%&'3,&(32'(31

%26*((')3,9-(')1)1'.873,&B1-*A73,&(11111,*)&-63

=('%&2-&.3'3,;(,3(3&(3&-61(32%3(2>(&2'&'5$!3

'% *1(1 8 18') 2'&)5 &(*((')5 6&8&.32 &9-(&.3'5 .3-82'-&(3

(3'&(22(13,6&A9-(8(2'(35 '% (3,3'&.) (,3'(8) '%., 8 6-&2%13,

&2..3,611(*1-&2181-66)3,1-1'66&6&('6&2-&.3'2'(31

3&2(6'8*(,15'% (3,3'&6&6&1'2%3(27-'(33,(,3'(8(1'2%3(2)

226'* 3, .3-82'-&(3A=(1 26* *(,,&/10 >7('(31 8&. '% 162(8(,

&9-(&.3'1&(1',*) '%(3,3'&3,&7(=,=('%'%;(,3(3&(3&-6

8 2%3(2 >(&2'&' B ,1(3', 3(3& B 2..('' *8& '% =&, 823'&2'$(,1&7-','+(37&(-182'&1(3'22-3''31-&'%'9-(')

3, 12%,- & .' *) '% 6&162'(7 *(,,&1 ;& &-& 1-66(&1 8 (,3'(2

('.15=%1 9-(')1)1'.13,26*(('(1%7 &,)*31'*(1%, 3,6-'

-3,&66&7,73,&(1'8&6&'(2-&('.15162(8(273,&7-'(3.)3'*

,38&&6'('(7&9-(&.3'1B6&2-&.3'1


43/129

- 43 -

8'& 12'(3 '2%3(2) 226'* 3, 26* 6&2-&.3' 1-&25 '% 6-&2%1

&2..3,'(3 (1 '%3 6&211, 8& 66&7 8&. 2.6'3' -'%&(') %

66&7,6-&2%1&2..3,'(3 3=('% '2%3(26&'(3513211&)5 '*

(32-,,(3'%6-&2%1&,&5(113''B8&62.3'86-&2%1&,&

26) 8 =('% '2%3(2 162(8(2'(31 (1 8&=&,, ' >(&2'& /2%3(20 8&

&&3(32'(7('(1

8'& =&, 8 23'&2'5 '% 1-66(& 1-*.('1 '% .3-82'-&(3 6&2,-&15 >

6&2,-&15 (3162'(3 3, '1'(3 6&2,-&1 3, 31 238&.(3 ' '%

162(8(2'(31 3-82'-&(3 ,2-.3'1 & 66&7, *) &2-&.3' &-6 8

2%3(2>(&2'&'3162'(33,'1'(36&2,-&15313,,2-.3'1

&66&7,*)/&2-&.3'0&-666&7,,2-.3'1&13'''%1-66(&

*)'%2%3(2>(&2'&'5$! -(')-&7(32(12&&(,-'16&'%

66&7,63566&7,.3-82'-&(36&2,-&1566&7, (3162'(3D '1'(3

6&2,-&1

1631(*(('(18&&6&'(357(=3,66&783,&>2-.3'1(3

2%3(2>(&2'&'5$!

03,3'

3,3'(1&(1,*)(3,3'&3,66&7,*)2.6'3'-'%&(')

*02%3(262(8(2'(3

2%3(2 162(8(2'(3 (32-,1 '2%3(2 &9-(&.3'15 126 8 =&+ 3, 1-66)5

66(2* ,&=(315 162(8(2'(315 1'3,&,1 3, ,2-.3'15 &9-(&.3'15

(3162'(33,'1'(351-&82'&'.3'51'&5%3,(3562+(35'&316&''(33,

,(7&) 23,('(31 2%3(2 162(8(2'(3 (1 6&6&, 3, 66&7, *) 2'&

3(3&(3&-65

203,&>2-.3'

3,& ,2-.3' (1 2.6(, *) (3,3'& 3, 2%2+, 3, 66&7, *) !,5&2-&.3'&-6(32%3(2>(&2'&'8$!

,03,&7-'(33,-&2%12..3,'(3

$(,1&7-',3,6-&2%1&2..3,'(3(16&6&,*)(3,3'&3,66&7,

*)2.6'3'-'%&(')

09-1'8&-(')-&7(32(113'*)!,5&2-&.3'&-6'!,5

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44/129

- 44 -

8032)(1,2(,,*)>(&2'&/2%3(205$!

0%315(83)5''%6&2-&.3',2-.3'1-3,&1.718&7(=

3,66&718=,8&'%&((3,2-.3'

&2-&.3'8'3,&,$-%'-''.1B&6&('&)'.

%,1(33(3&(71,-231(,&'(3'7(*((')81'3,&,6&,-2'1B.116&,-2, ('.1 3, .+1 -1 8 1-2% 6&,-2'1 ' '% I'3' 611(* (.(&)5

6&6&('&)('.18&.6&733,&6-',1-66(&1&231(,&,3,162(8(,3'%

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&2-&.3'8..&2(&,&,-2'1

..&2(&,B88'%1%86&,-2'1=('%6&739-(').)*&9-(1('(3,*)

'%,1(3&=('%,,('(3'1'1BI.(3'(31'238(&.('19-(')3,226',8&

-16&7(,,('.'1'%9-(')&9-(&.3'18&'%(3'3,,-1%,,('(3'1'1

BI.(3'(31&,3(3A%-1&'%&-%366&7,*8'&6&2-&.3'8'%

('.*-'*8&('(16-''-1

&2-&.3'86&1

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3'&8&133

>-)9-(8(,=,&116&66&7,:3,&3)6&.('','2&&)-'

=,(3 3 '% (1162(8(,5'%1.(12&&(,

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45/129

- 45 -

>(161('(383A38&.321

%1-66(&1'*(1%16&2,-&'23'&.'&(156&'152.633'151)1'.1&

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8& 6&.6' &2&,(3 3, &6&'(3 8 33A238&.(3 6&,-2'1 ' 2%3(2 B

31'&-2'(3 >(&2'&' % 33A238&.(3 6&,-2'1 & 6&.6') 1&',

/6%)1(2 16&'(33, '(30 ' 6&73' '%(& (3,7&'3' -1 1-*19-3')%33A238&.321=%(2%'%1-66(&6&6118&231(,&'(33,,(161('(3(3'%

8&. 8 3A38&.32 6&' /0 & &7(=, *) 3(3&1 8 &2-&.3'

&-63,/&2-&.3'0 &-63, 8&=&,, 3=('%'%(& 2..3'1 ''%

;(,3(3&(3&-6 8&1-('*,(161('(3 (3231-''(3=('%5 %

(1 G66&7,H & G66&7, 1 ',H /( 66&7 =('% 162(8(2 3'(30 &

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46/129

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6*(('(1 8 '% 1-66(& B 1-*A23'&2'& 1% * 7-', 8(&1' *) '% 62+

23'&2'&3,66&7,*)2%3(2>(&2'&'%(17-'(3(32-,18(&1'%3,

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9-(6.3' B 82(('(15 '%(& 9-(') 23'& 1)1'. 3, 6&2'(215 12&-'(3) 3,

232-&&32823'&2'&B1-66(&M1.3-3,'%(&61'6&8&.3231(.(&

=&+12&&(,-'8&3-2&6=&63'13,'%&1-2%&6-',&3(4'(31

1.4.4. CONTROL OF ITEMS

2(7(33,3162'(3

.'&(1 B 9-(6.3' 6&2-&, 1% * ,(7&, ' 1(' 3 ,- (3162'(3 3,

2&32 *) &162'(7 &-6 & ('1 -'%&(4, &6&13''(7 1 13 1 '%

.'&(1B('.1B9-(6.3'&&2(7,'1('5'%)1%*7(1-)(3162',*)

232&3,1('231'&-2'(3&-656&(&'226'32'1('.'&(1B9-(6.3'

6&2-&, *) 62+ 23'&2'&1 1% * (3162', 3, &1, 8& 1(' 1 6&

66&7, 3 3 &2(6' ' 23'&2'&@1 6&.(11 ' 1('5 3 -,(' 8 '%

6&2-&.3'3,.3-82'-&(36&8&.,*)/&2-&.3'06&1331%*

2&&(, -' *) /31'&-2'(30 ' 31-& '%' '% ('.1 .' '% 162(8(2'(3

&9-(&.3'1 ;-&'%&5 7(1- (3162'(3 1% * 2&&(, -' *) 23'&2'&@1

6&1333,232&3,1('231'&-2'(3&-68&3)'&31(',.3,2&&'(3

=('% ,16'2% ,2-.3'1 377.3' 8 /31'&-2'(30 1% * 2, 8&

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&-6

3162'(3 B 7&(8(2'(3 &6&'1 1% * 6&6&, 3, (11-, =('% 2&) ,8(3,

1'&(31'&-2'(3132152&'(3'1'B2%2+13'2&&(,-'3('.1(3'%1%63,'*2&&(,-''1('13',(31%(66(3&15'%1.1%*2&&(,-'

' 1(' *) '% 232&3, 1(' 231'&-2'(3 &-6 3, =('311, B 226', *)

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47/129

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B & (3 '% 162(8(, & 6&(& ' '%(& (31''(3 3, -1 '& 8 .'&( B

9-(6.3' 1% *-3,&'+3 ' 31-& ,- (,3'(8(2'(35 1&'(3 3, 2'(3

3,'6&73','&(&'(389-('),-'1-2%882'112&&1(3523'.(3'(35

2(.'(223,('(313,6%)1(2,.33&5'%8=(3162'11%*'+3

(3'231(,&'(38&1'&Fa) Access to storage area.

*03(3113,%-1+6(36&2'(21

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1%*2&&(,-'22&,(3''%16&2,-&1

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48/129

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&'2'(7'(313'&

&'2'(7 2'(3 1% * 66(, =%&7& 162(8(, ' '% ('.1 3, 1-&821 '

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49/129

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1.4.5. & 1.4.6. PROCESS CONTROL (MANUFACTURING, SITE CONSTRUCTION

& COMMISSIONING)

2'(7('(1 882'(3 9-(') (3 '% &1 8 .3-82'-&(35 (' 231'&-2'(35

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*),6)(39-(8(, B 2&'(8(,B -'%&(4,6&133 2'(7('(1 &2&&(,-'

-1(366&7,5'1',2-.3'1

31=('% 3'& (3'1 ? &7(=5=('311 3, %, 6(3'1 & 6&6&, 8&

2'(7('(1882'(39-(')

HOUSE KEEPING

!-1N6(33,23(311&31-&,'%&-%-''%63'=('%7(='.(3'(3

9-(') 8 ('.1 ,-&(3 1'& B 8*&(2'(3 B 1(' 231'&-2'(3 B (31''(3 B

2..(11(3(3 3'& 8 37(&3.3' 23,('(31 3, 2211 ' 7&(-1 &1 (1

31-&,-2&23&1B23431B,-1'8&&1&2&)(,3'(8(,3,

2211'1-2%&1(1&-',

211&) %-1 +6(3 3, 23(311 6&2,-&1 & (11-, (7(3 ,'(1 8 '%

1'61'*'+33,'%32(1&1631(*8&7&(-11'61


50/129

- 50 -

"

1.5.1. VERIFICATION PROGRAMME

2'(7('(1882'(39-(')&7&(8(,8&2.6(32=('%'%162(8(,&9-(&.3'1

' (1 31-&, '%' &133 (377, (3 '1+ 7&(8(2'(3 1% 3' %7 3) ,(&2'

&1631(*((')8&'1+6&8&.323'&33,I'&37&(8(2'(31&2&&(,-'

1.5.2. INTERNAL VERIFICATION

3'&3&(8(2'(3(1,38&2'(7('(12&&(,-'*)$!6&133

1.5.3. EXTERNAL VERIFICATION

I'&37&(8(2'(3(1,383'&2'&1@2'(7('(1%I'3'81-2%7&(8(2'(3

1%**1,3'%(.6&'328'%('.&1&7(25&','18')

1.5.4. VERIFICATION PLANS AND PROCEDURES

7&(8(2'(32'(7('(1&6&8&.,16&66&7,7&(8(2'(3631(3'%8&.8

-(')11-&3231%1-(')11-&32311%F

,3'(8)&8&32,2-.3'1(32-,(3=&+6&2,-&1

,3'(8)2%7&(8(2'(36(3'3,(3,(2'('1&'(719-32(3'%=&+

2)2B6&2111'1

,3'(8)'%2%&2'&(1'(21'*7&(8(,'2%6(3'3,(3+(''(3,(7(,-

6&2,-&

3,(2'(3'&821=('%'%&7&(8(2'(36313,162(8)%='%)1%*

23'&,

,3'(8)23'&6(3'1517(=(3'15:('311(3'13,!,(3'1

,3'(8)%=5=%35=%&3,*)=%.'%7&(8(2'(31%*23,-2',

3,(2'226'322&('&(

3,(2'(11-8&6&'1


51/129

- 51 -

1.5.5. CALIBRATION AND CONTROL OF MEASURING AND TEST EQUIPMENT

&2,-&1 1% * 6&6&, 6&12&(*(3 '% 12'(35 (,3'(8(2'(35 -15 2(*&'(3

&9-(&.3'13,2(*&'(38&9-32)8.1-&(33,'1'9-(6.3'B'1%

6&2,-&1 1% * 6&6&, *1, 3 66(2*((')5 &2..3,, 1'3,&,15

&2..3,'(38.3-82'-&&18.1-&(33,'1'9-(6.3'3,I6&(328

-1&1

'1%*31-&,'%''%.1-&(33,'1'9-(6.3'8&-11%*86&6&

&35')6522-&2)3,6&2(1(33)2(*&',3,2&'(8(,(31'&-.3'11%*

-1,'%.1-&(33,'1'9-(6.3'1%*3-.*&,3,(1',12&(*(3'%

1.1%*7(*=('%'%-1&5(3,(2'(3'%,-,'8&A2(*&'(3

% &2&, 82(*&'(31% *.(3'(3,3 '%.1-&(3 3, '1'9-(6.3'5

6&8&*) (3 '% 8&. 8 ,%1(7 *1 & 3 &2&,1 '&2* ' '%

9-(6.3'%*11%%7'1'8=(3,'(1FA

/0>'82(*&'(3

/*0>'87(,(')82(*&'(3

/20(3'-&3,3.8-'%&(4,6&136&8&.(3'%2(*&'(3=&+

/,0(3'-&3,3.8-'%&(4,6&137&(8)(3'%2(*&'(3=&+

%.1-&(33,'1'9-(6.3'8-3,-'A8A2(*&'(3&8-3,,.,1%*

,61(',*2+(3 '% 12'(31'&15=('% ('1 23,('(3 =&(''333''2%,'

'.1&,)226',*)-1(3 '%1 -'A8A2(*&'(39-(6.3' 1%*1111,

8& '%(& 226'*((')3,1-('* (38&.'(31% *2..-3(2',' '%882',

&-61B23'&2'&18'&&6(&5'%1.1-&(3D'1'9-(6.3'1%*2%2+,

8&2(*&'(353,(88-3,1'(182'&)5'%)1%*.,7(*8&-1&2&,

8 &A2(*&'(3 1% * ., 1 ,8(3, *7


52/129

- 52 -

>-&(3 3) '1'(3 B 2(*&'(3 2%2+5 =%3,7('(31 *)3, 6&12&(*, (.('1 &

,'2',5 3 7-'(3 1%*.,8 '% 7(,(')86&7(-1.1-&.3'1 3,

'1'153,226'328'1',('.11%*&1111,

1.5.6. VERIFICATION STATUS

% 2-&&3'1''-1 (1 (3,(2', *) '% -1 8.&+(315 1'.615 '15 *15 &-'(3

2&,15(3162'(3&2&,156%)1(22'(33,'%&1-('*.315=%(2%23(3,(2'

226'*((')&33A238&.328('.1=('%&&,'7&(8(2'(316&8&.,

1.5.7. PRE SERVICE INSPECTION (PSI)

8 2.633'1 3, 1)1'.1 (1 2&&(, -' -1(3 66&7,6&2,-&1 ' 1'1

(,3'(8(,*),2-.3'(11-,*)5%2(*&'(3*2+1-1,,-&(3

&(,3'(8(, 8& '%(& '&2*((')3,6&1&7,8& 8-'-&-1,-&(3 3&7(2

3162'(3/0,-&(3'%6&'(36%1

1.5.8. AUDIT AND ASSESSMENT

AUDIT

.6&%31(71)1'.83'&3DI'&3-(')-,('(11'*(1%,(3&,&'

1111'%882'(73118'%&&..1.3'(3,(3'%(13-

66&6&(') '&(3, 6&1335 =% & 3' ,(&2') &1631(* 8& &1 *(3

-,(',51%6&8&.3,,2-.3''%-,('1%)1%%71-88(2(3'-'%&(')3,

&3(4'(38&,.'.+'%-,('.3(38-3,882'(7-,('6&1331%

*12',3'%*1(18F

N3=,3,I6&(328-,('(3'2%3(9-1J

N3=,866(2*2,156&2,-&13,(3,-1'&(6&2111

62((4,+3=,3,I6&(32(3'%&'*-,(',J


53/129

- 53 -

3-,('.=('%.,&(1231'('-',(&2'&/0

B>

3-,('3(7(3,'(181268-,('5-,(''...*&153,2'(7('(1'*

-,(',5 >6&'.3' B &3(4'(31 ' * 3'(8(,5 66(2* ,2-.3'1 1-2% 1

6&2,-&13,2%2+(1'13,333-12%,-(1(11-,''%*(33(387&)23,&)&

3'&3-,('1&6&8&.,(31-2%.33&'%''%>6&'.3'18$!&

27&,'1'32(3)&

I'&3-,('1&6&8&.,(31-2%.33&'%''%3'&2'&18$!&

27&,'1'32(3)&

3,,('(35-,('1&2&&(,-'-3,&'%8=(323,('(31J

:%3 (' (1 3211&) ' 7&(8) (.6.3''(3 8 &9-(&, 2&&2'(7

2'(3J

:%3 1(3(8(23' 2%31 & ., (3 '% 8-32'(3 &1 8

6&&..51-2%11(3(8(23'&A&3(4'(3&1(3(8(23'&7(1(318

'%6&2,-&J

:%3 (' (1 1-162', '%' '% 9-(') 8 '% ('. & 1&7(21 (1 (3

'&.(3'%2-1/10

31'('-'2&&2'(72'(31

2'(8),8(2(32(1

7(= (.6.3''(3 6(2(1 &9-(&, ' (.(3' &2-&&32 8

,8(2(32(1

.6&''&(3(3'6&13313211&)

>2-.3'-,('&6&'13,2&&2'(72'(31'+3


54/129

- 54 -

% -,(' 6&'1 =( * ,(1'&(*-', ' ;-32'(3 >(&2'&1 8 $!5 !,1 8

&-61(3$!51(,3'!,183'&2'&1'1('/3)3-,('16&'(3(3'

'%162(8(2 23'&2'&05 8& 31-&(3 (.6.3''(3 8 &2..3,'(31 (3 '(.)

.33&

.6.3''(3 8 2&&2'(7 .1-&1 B &2..3,'(3 =( * 31-&, ,-&(31-*19-3'-,('1

% &1631(*((') 8& 2.6(323, (.6.3''(38 '% &2..3,'(3 (1=('%

&162'(7>(&2'&1

ASSESSMENT

8 1111.3' 3, (3,63,3' 1111.3' & 633, (3 &,& ' 6&7(,

238(,323,''+'(.)2&&2'(72'(31&11-2%1(3'&82.3.3'5

18')5%-1+6(35'&(3(33,9-(8(2'(386&13356&1&7'(38 (31',

9-(6.3'3,&2&,182((')&1111,8&'%(&,9-2)3,(.6&7.3'1(83)

1111.3'(12&&(,-''1'32)&*)63.3'.231'('-',*)

>%&1-'181111.3'&2..-3(2','>5>(&2'&1D&-6!,1


55/129

- 55 -

#

1.6.1. NON- CONFORMANCE CONTROL

0 %9-(6.3'B.'&(B ('.13'238&.(3' '%162(8(,&9-(&.3'1

1%*23'&,16&66&7,33A238&.3223'&6&2,-&'6&73''%(&

(3,7&'3' -1 32(1 (377, (3 6&2-&.3'5 .3-82'-&5 8*&(2'(35

(3162'(3B'1'(33,&2'(3B(31''(32'(7('(11%*&9-(&,'%7'%(&

=333A238&.3223'&6&2,-&1232-&&,*);3,&162'(7

*033A238&.321*1&7,1%*&2&,,(3'%(3162'(3&6&'3,'%

33A238&.(3 .'&( B ('.1 1% * (,3'(8(, 3, +6' 1(, -3'( '% 33

238&.32& &17,% &131 8& 33A238&.321 1% * (,3'(8(, 3,

2&&2'(72'(31%*'+3'7(,'%(&&2-&&32;=2%&'8&,(161('(38

33A238&.32(1(73(36A"%8&.'8338&.326&'(1(73

(36A#D

2033A238&.3211%*&7(=,3,,7('(311%*6&211,;&

,(161('(3 8 33A238&.3215 &2..3,'(33 '%11% * 6&61, *)

231'&-2'(332(15'%1.1%*232-&&,*)3,8(366&7B66&7

13',B &


56/129

- 56 -

3)1(3(8(23',1(323211(33('.1(.6&'3''8')=(**&-%'''%

3'(28$

1.6.2. CORRECTIVE ACTION

%338&.326&'1&6&(,(2)3)4,8&'%(&2-113,3211&)

2&&2'(72'(31&(3('(','&.7'%,8(2(32(111'6&73'&6'('(3


57/129

- 57 -

FLOW CHART FOR DISPOSITION OF NON-

CONFORMANCE

Acceptance Non-conforman

RejectAcceptable, Submit NCR

Approved Modify

Approved as noted conditional *acceptance

Reject

Acceptance

NCR: Non-conformance Report* After conditional acceptance of the design concession, no work isenvisaged on the non-conforming item.

REVIEW BY QA

COMPLETION OFACTIVITY

REPAIR ORREWORK

NCR REGISTATIONAND

DISTRIBUTION

CLEARANCEFOR NEXT STAGE

RECORD COMMITMENT AND/OR

CONDITIONAL IMPLEMENTATION TOMEET CONDITION

SCR

INSPECTION

NCRREGISTRATION/DISTRIBUTION

INSPECTION

NCR REVIEW

DISPOSITION BY

FE GROUP


58/129

- 58 -

Page-1 of 2


(A Government of India Enterprise)PFBR Project, Kalpakkam

NON-CONFORMANCE REPORT

Application for disposition of non-conformancesP.O. No.(See Note-1 on back side) .NCR No. Project/USI No.

Contractor / Sub- Contractor .Component/System/Structure/ItemManf / Contractors Ref. No. . Spec.No./Drg. No. .Equipment / Tag No.. P.O. Item No. ------------------------------------------------------------------------------------------Details of Proposed Concession: (See Note-2 on back side)This request does not involve a change in contract price

Estimated cost ..(Name, Designation, Date and seal ) Requested by.

------------------------------------------------------------------------------------------Quality Surveyors comments (See Note-3 on back side)Name Original signed . Date..

APPROVAL OF INDENTOR / DESIGNER / CONSULTANT / FE (See Note-4 on back side)

APPROVEDAPPROVED AS NOTEDREJECTED / REPAIR / RE-WORK.

NOTES:(Name, Designation & Date) Indentor / Designer / Consultant / FEImmediate Superior/ACE / CE/ Head, FE

CLOSING DCR IN CASE APPROVED AS NOTED VERIFICATION BY QUALITY SURVEYOR OFMANUFACTURER/ CONTRACTOR / SUB-CONTRACTOR/ QA, IGCAR or its nominee

All stipulations in conditional approval met? Yes / NoIf No, defective item repaired / rejected? .. If repaired, new NCR No..

(Name, Designation & Date) Contractor/Sub-Contractor QA, BHAVINI

Distribution: CONSTRUCTIONIndenting group. Head of Concerned Construction group REG/IGCAR... Head (QA)..Consultant.. Head (FE) ..Quality Surveyor Head, Site Planning GroupContractor .. History Docket ..


59/129

- 59 -

Page-2 of 2

NON-CONFORMANCE REPORT

(BACK SIDE OF NCR)

Note-1: For Package contract, please indicate Package P.O.No.

and Main P.O./Sub.P.O. as applicable.

Note-2: This should include reasons for deviations and corrective

actions to prevent repetition enclose sketch, attach

additional sheet, if necessary. If deviation is on

quantified parameters, report the obtained

parameters as follows.

Sl.No. Design Value Obtained Value Remarks/Reason fordeviation

'AF %6-&2%1&@19-(')1-&7)&B-'%&(4,&6&13''(71%

7&(8)'%,7('(313,31-&'%''%23'&2'&%1(32-,,'%,7('(31

'AF3218;(,3(3&(3&-65&7(=6&211*)(..,('1-6&(&(16'(3


60/129

- 60 -

$

1.7.1. TYPES OF RECORDS

2&,11%*6&6&,3,.(3'(3,'6&7(,*


61/129

- 61 -

&'(3&2&,11-2%1&A&7(23162'(3*1(3,'1%*3&',3,

.(3'(3,*)1('&-6

% &162'(7 231'&-2'(3 &-61 1% 8&.-' '%(& &2&, 3, ,2-.3''(3

23'&6&2,-&1

1.7.3. GENERATION OF RECORDS

%>1(3162(8(2'(35&2-&.3',2-.3'15..(11(3(3,2-.3'1531

(3,(2''%&2&,1'*3&',%&2&,1&1'.6,3,,',*)-'%&(4,

6&131 *8& 1'& % &2&,1 23 * ('%& &((31 & &6&,-2, 26(1

!=7&5 &2&,1 1% * (*5 (,3'(8(* =('% &162' ' ('. B &73'

,2-.3'1

31'&-2'(3.6'(3>2-.3'1

31'&-2'(3 .6'(3 &'(8(2'1 /10 3, )1'. &318& >2-.3'1 />101% * 6&6&, *) '% 231'&-2'(3 &-6 3, 8'& 232-&&32 *) 3, ;

1-*.('','2%3(2&7(21%,8D&-6%1,2-.3'11%*6&6&,

16&66&7,6&2,-&1

1.7.4. INDEX

3(7&1 -*


62/129

- 62 -

0,.31'&'26*((')8&186&'(3

*03*.(3'3325&=&+5&6(&5&62.3'&.,(8(2'(383('.

20,'&.(3'%2-18322(,3'&.8-32'(383('.

,06&7(,&8&32,'3,,2-.3'8&(3A1&7(2(3162'(3

082(('',2..(11(3(3

3&.33'2&,1F

2&,15 =%(2% 1% * 3211&) ' ,.31'&' 22.6(1%.3' 8 '% 2'(7(') (3

22&,32 =('% '% 162(8(2'(3 &9-(&.3'1 1% * &'(3, '( '% 1)1'.1 &

'&318&&,8&.231'&-2'(3'2..(11(3(3&-6

% (1' 8 6&.33' B 33A6&.33' &2&,1 3, '%(& &'3'(3 6&(, 1% *

23'&,(322&,32=('%'%66&7,6&2,-&

.6&&)2&,1F

%1& '% &2&,1 3' 8(3 (3 '% *7 '= 2'&(15*-' 3&', ,-&(3

231'&-2'(36&(,'1&717(,328&1'(182'&)2.6'(38'%2'(7('(1

1.7.7. DISPOSAL

&(,(2&7(=18'%&2&,1&2&&(,-'(3&,&'=,-'-33211&)&2&,1

3,&,(161,8*)1%&,,(3B(32(3&'(38'&2&'(8(2'(3*)-'%&(4,6&131

1.7.8. STORAGE AND PRESERVATION

'& 8 ,2-.3' 3, &2&,1 1% * '% &1631(*((') 8 '% &162'(7

231'&-2'(3&-65'(('(1%3,,7&8&1'&(323'&(4,82((')

3'&(4,>2-.3'3,2&,'&;2((')1%*2',3,231'&-2',1

1'6&'2''%&2&,18&.611(*,.&,1'&-2'(3*)1-2%2-1118(&5

8,(35 (312'15 &,3'1 3, 8&. 611(* ,'&(&'(3 *) ,7&1 37(&3.3'

23,('(311-2%1'.6&'-&3,%-.(,(')%(182((')=(%723'&6&2,-&1

'3*'%8=(3F

0 221123'&8&6&131

*0 ,)&'&(783),1(&,&2&,1

20 3162'(33,.(3'3328&2&,1


63/129

- 63 -

3162'(38 '% 1'& 82((')1%*-3,&'+3' 1' '=(2 )& '31-&

'%'5

/(0 %82((')1%*,9-'3,'%3211&)37(&3.3'3,'%&

&'2'(7.1-&1&(3882'

/((0 %&2&,1&-6,',&-&)

/(((0 .6(3 (3162'(3 8 &2&,1 (1 ,3 ' 2%2+ 162'1 1-2% 1 &2(6'5

23'&5&'&(7*((')3,1'31-&'%'&2&,1&3','&(&'(3,-

'(.6&6&%3,(3&1'&6&2'(21

;& '% 6-&618 1'&8>2-.3'1 3, 2&,1.3' 8& '% (8'(.8 '%

3'5 6&.33' 1'& 82((') 1% * 1'*(1%, 6&(& ' 2..32.3' 8

2..(11(3(32'(7('(1

1.7.9. RECORDS INSPECTION

3162'(38'%2&,1(12&&(,-'323'(3-*1(1*)6&131&1631(*8&

1'& 8&2&,1 %1& 1 (3162', *)'%&-6 ' 1'32 (3'%&

.3'%12&,18(3162'(3&.(3'(3,

%&2&,1'&82((')(1(3162',' 1'32(3)&'31-&,9-2)3,

8&-6','.(3'3328'%&2&,1.6(33162'(38'%&2&,1(12&&(,

-''7&(8)'%&2&,1)1'.


64/129

- 64 -

QUALITY ASSURANCE IN CIVIL CONSTRUCTION

INDEX

>

>>

;

;;>

A; "

>> "

#

"

# ;!>

;

;>


65/129

- 65 -

QUALITY ASSURANCE IN CIVIL CONSTRUCTION

-(')11-&328(7(231'&-2'(3(127&,-3,&'%(12%6'& 3,(1'*&,

3=('% &73'(7( '2%3(2 162(8(2'(31 1 1' -' (3 '% '3,& ,2-.3'15

162(8(2'(316&7(,,(3'%,1(3,&=(315$'3,&,13,66(2*,&=(315

'2 8&32 ' (3162'(35 '1'1 3, 162( 6&21115 6&2,-&15

1'3,&,15226'322&('&(3,1.6(3631&1(3,(2',%&(3%%,

6(3'1*)3,=%(2%'%2'(7(')(13''6&2,-3'('%&9-(&,(3162'(31&'1'1

%71%=31'(182'&)&1-'1&=(3,(2',(3'%-(')11-&3231

3&162'18-(')11-&32,-&(3'%6&


66/129

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FA2..3,'(318&6&11-&&-'(38&2+8-3,'(31(3&(7&7)

&


67/129

- 67 -

%=*-%,)(3 >='&(3 1%*2&&(,-' '31-& '%' '% I27'(33, 1'&-2'-& & 8&

8&.='&'1'18231'&-2'(33,.1-&1'I2-,&-3,='&3,

='& 8&. '%& 1-&21 1-2% 1 -3,&&-3, 1'&.15 9-(8(&15 16&(315

&'1(3156&2(6(''(3&(38('&'(38&.'%1-&828&'2>='&(31%*

2&&(,-''%&-%)'.(3'(3I27',6&'(31&13*),&)*)-181-('*

6-.61&*((3-'='&3,1-1%.3-)&*)'%&66&7,.31

.(0.+)5*-).(,.1-)(3 %3-.*&3,6''&38&-'%11%*16&162(8(2'(313,

,&=(31%9-(6.3'56&11-&13,6&6&'(38&-'.(I1'*-1,1%

1238&.''%162(8(2'(313,,&=(31

% 8=(3 &6&'1 1% * 6&6&, ' &-& (3'&71 ' 1-..&(4 (.6&'3'

*1&7'(313,,'

0%A=(1,'8&,&((35='&'1'13,(3'&A2332'(31

*0631%=(3&-'%1'13,&-'(3'+

20 MM 12'(3 1%=(3 ,&((3 1'1 3, &-' (3'+5 (3 21 8

2-&'(3&-'(3

"(09%&-).(>%0-)(3.2.)+>.&?1(5%,.1(5*-).( I27',&11%*23,5,*&(1&.7,53,'%6('1'&(..,'I2'

1%6 3, 1(41 *8& 3) 8-&'%& =&+ 1-2% 1 62.3' 8 .-, .' 3,

&(38&2.3'(12..32,.8'%(.6&'3''1'1'*2&&(,-'*8&

2&3281'&'8&231'&-2'(38-3,'(3&F

''(2',1'

'3,&,3'&'(31'

(1.(2&11!1' 3(7&1C2+(31'

&11-&'&1'

*&'&)1'

('%&6%

$2+%&1'1

2+>8&.'(31'1


68/129

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)2(2',1'1

$2+(*&'(31'1

:'&111'1

%*7'1'11%* 23,-2', 16& 1'3,&,1=%&7&1 162(8(, (3'%

,&=(31*),1(3&1

&231'&-2'(37&(8(2'(31%(32-,'%8=(3F

0'&(1B3&,(3'1-1,(36&,-2'(38232&'5

*0'&(1-1,(3231'&-2'(33,

2031'&-2'(36&2111

"

&(45'%-3(8&.9-(')8232&'8&9-(&,1'&3'%3,,-&*((')'11-&

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- 81 -

FLOW CHART SHOWING PRODUCTION OF

GOOD UNIFORM CONCRETE

DURABILITY

ECONOMY

GOODUNIFORM

CONCRETESTRENGTH

GOOD QUALITY OF PASTE,

WELL SELECTED

INGREDIENTS,

APPROPRIATE CEMENT,

DENSE CONCRETE

EFFECTIVE USE OF

INGREDIENTS, EFFECTIVE

OPERATION,

EASE OF HANDLING,

MINIMUM WASTE

RESISTANCE TO

ADVERSECHEMICAL

REACTIONS

WATER TIGHTNESS,

LOW VOLUME CHANGE,

STABLE AGGREGATE,

SUITABLE CEMENT,

HOMOGENEOUS

CONCRETE,

PLACEMENT

TEMPERATURE,

LOW WATER CEMENT

RATIO,

RESISTANCE TOWEATHERING

LOW WATER

CEMENT RATIO,

HIGH STRENGTH,DENSE CONCRETE,

ADEQUATE CURING,

SPECIAL FINISH

RESISTANCE TOWEAR


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SCHEMATIC DIAGRAM FOR DESIGN OF CONCRETE MIX

DESIGNED CONCRETE MIXPROPORTIONS

QUANTITIES OF CONCRETE

INGRADIENTS IN M3

ACCEPTED

FAILURE

PROBABILITY

FACTORS

EXPOSURE

DURABILITY

CONDITIONS

DEGREE OFQUALITY

CONTROL

QUALITY OF

CHEMICAL

ATTACK,SIZE OF POUR

STRUCTURALREQUIREMENTS

TARGET MEANSTRENGTH

CHARACTERISTIC

STRENGTH

AGE AT WHICHSTRENGTH IS

REQUIRED

SIZE, SHAPE ANDTYPE OF COARSE

AGGREGATE

WATER CEMENT

RATIO

CONSISTENCY

REQUIREMENTS

WATER CONTENT PER M3

% OF FINE TO TOTAL

VOLUME OF AGGREGATE

% OF AIR

CAPACITY OF CONCRETE MIX PLANT

Is trial mix performance adequate? yes/no. IfYes,Design Concrete Mix is finalized. If No, Re

evaluate and conduct fresh trials.

WEIGHT OF INGREDIENTS PER BATCH


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QUALITY ASSURANCE IN MECHANICAL CONSTRUCTION

INDEX

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Attachments QAM 129

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