FIELD QUALITY PLAN

FOR

BOWL MILL
(Type: HP 1103)
With Planetary Gear Box
(Erection & Commissioning)

FOR

NTPC PROJECTS – BARH II (2X660 MW)

(M/s NTPC Ltd.)

NTPC FQP. No.:- 9560-102-ER-QVM-G-007

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR - EASTERN REGION

DOC. NO.: QPX:BAR:660:BR:29

REV. NO. : R00

WI:QLY:03-F02/R0
 FIELD QUALITY PLAN

FOR

BOWL MILL
(Type: HP 1103)
With Planetary Gear Box
(Erection & Commissioning)

FOR

NTPC PROJECTS – BARH II (2X660 MW)

(M/s NTPC Ltd.)

PREPARED BY APPROVED BY
DGM/ QLY NTPC
FQP NO. QPX:BAR:660:BR:29

NTPC DRG. NO. 9560-102-ER-QVM-G-007

ORIGINAL DATE OF ISSUE 22.10.2010

REVISION NO. & DATE R00 DT 22.10.2010

COPY NO.
ISSUED TO
DATE OF ISSUE
CONTROLLED / INFORMATION
COPY
ISSUED BY
( SIGNATURE &
DESIGNATION )

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR – EASTERN REGION
WI:QLY:03-F03/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
BOWL MILL REV NO. R-00
( ERECTIONPSER (ERECTION & COMMISSIONING)
SHEET 1 / 1 SHEET

CONTENTS

Sl.No. Description No. of Sheets

1.0 Status of Revisions 01

2.0 Authorisation for different categories of checks 01

3.0 Statement of checks 12

4.0 Documents referred in Field Quality Plan 01

5.0 Log Sheets : L-00 to L-07 09

6.0 Protocol 01

7.0 Feedback on Field Quality Plan 01

******

WI:QLY:03-F04/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
BOWL MILL REV NO. R-00

PSER (ERECTION & COMMISSIONING) SHEET 1 / 1 SHEET

STATUS OF REVISIONS

S l. Reference of Sheet(s) Revision No. Remarks

No. Revised & Date

NIL

WI:QLY:03-F05/R0
 AUTHORISATION FOR DIFFERENT CATEGORY OF
CONSTRUCTION/ERECTION CHECKS AND
NONCONFORMITY DISPOSITION
POWER SECTOR
NTPC Doc. No. : 9560-102-ER-QVM-G-007 Rev. 00
Category of Agency Inspection Accepting Nonconformity
Check Authority Authority Disposition Authority
‘A’ Customer BHEL Erection Engineer Head of Erection ENGG Center/
Hold Point & QAE Head (Quality), PS-
Region.
‘B’ Customer BHEL Erection Engineer Head of Erection ENGG Center/
Hold Point Head (Quality), PS-
Region.
‘C’ BHEL Task performer Head of Erection ENGG Center/
Head (Quality): PS-
Region.
Category of Agency Witness & Accepting Authority Surveillance by NTPC
Check
‘A’ NTPC FQA in association with Executing Head (FQA)
Engineer
‘B’ NTPC Executing Engineer FQA Engineer
‘C’ NTPC Executing Engineer Another Engineer
authorized by Head
(executing Department)

LEGEND for TYPE OF CHECK:

R – Record Verification, V – Visual Check, P – Physical Check, M – Measurement, T – Test.
Note:
1. Disposition authority for all categories of checks shall be as under:
Product nonconformities: BHEL Engineering Center.
Process/System nonconformities: BHEL, Head (Quality)-PS Region.

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

3. In case of nonconformity, accepting authority shall ensure the disposition of the nonconformity
before acceptance, and disposition shall be reflected in the log sheets/protocols.

4. QAE shall witness ‘A’ category checks. He is also authorized to carry out surveillance in any of
B & C category of checks at his discretion.

5. Concerned agencies shall ensure that instruments having valid calibration are only used for
measurements.

6. Quantum of check shall be 100% for all characteristics unless otherwise mentioned specifically
in Field Quality Plan/ reference documents.
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV NO. R-00
BOWL MILL
PSER (ERECTION & COMMISSIONING) SHEET 1 / 12 SHEETS

STATEMENT OF CHECKS

Unit Capacity : 660 MW

System : BOILER
Sub System : BOWL MILL (Type : HP 1103)
Area : ERECTION & COMMISSIONING

 For checks where log sheets are not called for, suitable records should be
maintained in the form of log book / protocols.

 As an evidence of having carried out the work satisfactorily, a general purpose log
sheet L-00 shall be maintained for all the checks.

 Abbreviations used in the column “Type of check” are :

R : Record Verification

M : Measurement

V : Visual check

M / R : Measurement & Record

V / R : Visual check & Record.

T/ R : Test & Record

WI:QLY:03-F07/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 2 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD
1.0 VERIFICATION OF MATERIALS & DOCUMENTS

1.1 Ensure availability of following documents: V B 100%

- Erection drawings,
- Shipping List,
- Erection Manual,
- List of BHEL approved welding consumables,
- O & M Manual,
- Procedure for Grouting of foundation bolts/ frame,
1.2 Ensure availability of materials as per drawing/ shipping V B 100%
list.

2.0 WELDING & NDT:

2.1 Ensure availability of applicable WPS V A 100% Drawing / Welding WPS
Schedule

2.2 Check for Welder performance qualification and T/R A 100% WPS, Welding WQR
maintain record. Manual, NDE
Manual
2.3 Adoption of correct procedure, approved electrodes and P A 100% Drawing/Welding
methods. Manual/ WPS,
Welding Schedule
2.4 NDE of weld joints and interpret as per applicable code. T/R NDE kit A As Drawing / Welding
applicable Schedule / NDE
Manual
WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 3 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD
3.0 FOUNDATION (MILL, MOTOR, LUBE Oil UNIT &
GEARBOX):
3.1 Disposition with respect to Boiler axes. M/R Tape / A 100% Drawing / Erection L - 01
Tolerance: ± 5 mm. Piano wire Guidelines
3.2 Elevation of top surface. M/R Water level / B 100% - do -
Tolerance: ± 10 mm. Tape

3.3 Center line of foundation bolt hole with respect to foundation M/R Tape/Piano wire B 100% - do -
center line.
Tolerance: ± 2 mm.
3.4 Diagonals of bolt hole centers. M/R Tape B 100% - do -
Tolerance: 5 mm Maximum.

3.5 Depth of foundation hole. M/R Tape B 100% - do -

Tolerance: ± 10 mm.
3.6 Spacing between the pockets. M/R Tape C 100% - do -
Tolerance: ± 2 mm.

4.0 BASE/ SOLE PLATES (GEARBOX, AIRINLET HOUSING &

MOTOR):

4.1 Orientate sole plate correctly to have holes on edge at

correct location so that it suits with erection & removal of rail V/R B 100% Drawing /erection
frame holes. Guidelines.

4.2 Leveling of base plates for Gearbox M Precision level / B 100% Drawing / Erection
Tolerance: 0.1 mm / M. Micro water Guidelines
level

4.3 Leveling of mill Side Air inlet housing sole plates, individually M Precision level / B 100% Drawing / Erection
(Tolerance:0.2 mm/ M) and combined Micro water Guidelines
Tolerance: ± 0.2 mm. level
WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 4 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD
4.4 Ensure grouting gap between base plates and foundation. M/R Tape/ level C 100% - do -
Tolerance: 40 + / - 10 mm.

5.0 BOWL MILL:

5.1 During assembly of mill parts, ensure correct orientation, Mill V B 100% Drawing / Erection
serial number and match marks of corresponding mill-parts. Guidelines

5.2 MILL DRIVE ASSEMBLY (PLANETARY GEARBOX):

5.2.1 Leveling of gearbox base plate within ± 0.1 mm / M after M/R Precision level B 100% - do -
fastening the anchor bolts. (0.004”).

5.2.2 Ensure that the dowel pin is installed after gear box is installed V/R B 100% Drawing / Erection
and aligned. The pin would be installed in the gear box base Guidelines
to sole plates at the gear box output adopter.

5.2.3 Ensure tightening of foundation bolts. V/R B 100% - do -

5.3 DRIVE MOTOR & COUPLING:

5.3.1 Leveling of motor base within ± 0.05 mm / M. M/R Precision level B 100% Drawing / Erection
Guidelines
5.3.2 Dimensions of shaft ends and coupling. M/R Tape B 100% - do - L – 02

5.3.3. Verify mill box sole plates to gear box base plates alignment . M/R Tape B 100% Drawing /erction
guidelines.
5.3.4 Alignment of coupling with motor & gearbox input shaft. M/R Dial gauge A 100% - do - L – 03

5.3.5 Ensure servicing of coupling before installation V B 100% Drawing / Erection

Guidelines
5.3.6 Set motor location so have proper distance from motor shaft M/R Tape B 100% Drawings/Erection
to gear box shaft. Guidelines
5.3.7. Install motor half coupling and spacer shaft. V C 100% DO
WI:QLY:03-F08
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 5 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD
5.3.8 Grouting of gearbox base plate and Mill side air inlet V/R B 100% Grouting
housing sole plate. procedure

5.3.9 Grouting of mill motor after successful trial run V B 100% Grouting
completion. procedure

5.3.10 Ensure proper curing of grouting and check for its V/R Comp. B 100% Grouting
compressive strength (cube testing) after curing. Strength procedure
testing M/c
5.3.11 Ensure that the foundation studs are tensioned. V/R Stud tensioner B 100% Drawing / Erection
Guidelines
5.4 BOWL & BOWL HUB ASSEMBLY:

5.4.1 Ensure lube oil filled in gearbox thrust bearing V/R B 100% Drawing / Erection
housing prior to starting bowl hub and bowl assembly. Guidelines

5.4.2 Ensure superbolts are torque tight between the bowl M/R Torque wrench B 100% Drawing / Erection
hub flange and gearbox rotary table (flange). Guidelines

5.5 MILL SIDE & LINER ASSEMBLY:

5.5.1 Ensure installation of dowel pins in the sole plates of M/R Tensioning B 100% Drawing /
Mill side air inlet housing and its anchor bolts are device Erection
tensioned with device. Tape Guidelines

5.5.2 Completion of mill side assembly placement with V B 100% Drawing /

correct orientation of air inlet duct opening and tramp Erection
iron spout opening. Guidelines
WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 6 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD
5.5.3 Ensure alignment between air inlet housing, its sole plate w.r.t the M/R Precisionr level B 100% Drawing / Erection
gearbox base plate before and after tightening all the fasteners. Guidelines
T.I.R 0.38 mm for the upper surfaces of the air inlet housing.

5.5.4 Ensure the mill side is concentric with the gearbox before M/R Torque wrench B 100% Drawing / Erection
tightening of foundation bolts. T.I.R 0.25 mm. Feeler Gauge Guidelines
Vernier caliper

5.5.5 Ensure the components of bowl hub liner, scraper assembly & V C 100% Drawing / Erection
Seal ring assembly are placed in the air inlet housing prior to Guidelines
installing bowl bowl- hub assembly.

5.6 BOWL, BOWL HUB AND VANE WHEEL (AIR PORT RING)
ASSEMBLY:

5.6.1 Ensure completion of bull ring segments, bowl extension ring and M/R Torque wrench B 100% Drawing / Erection
vane wheel assembly before torque tightening the fasteners. Guidelines

5.6.2 Ensure the required gap between seal-ring assembly and bowl M/R Feeler Gauge B 100% Drawing / Erection
hub is achieved within limits during the final adjustment. Vernier caliper Guidelines
Note: Clearance to be set to a value of 0.5 MM within +/- 0.25
MM.. Also ensure installation of bowl hub insulation.

5.6.3 Ensure tightness of fasteners, upon installation of bowl hub, liner M/R Torque wrench B 100% Drawing / Erection
scrapper and guard assembly. Guidelines

5.6.4 Ensure the clearance of bowl hub liner & scrapper. Ensure M/R Tape B 100% Drawing / Erection
installation of packing and gland on underside of mill side bottom Guidelines
liner.
WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 7 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD
5.7 SEPARATOR BODY ASSEMBLY:

5.7.1 Completion of separator body assembly with correct M Torque wrench C 100% Drawing / Erection
orientation and torque tightening of connecting bolts. Guidelines

5.7.2 Set gap between air restriction ring to vane wheel outer V A 100% Drawing / Erection
shroud at 6mm + 3.3 / -0.0. Guidelines

5.8 ROLLER JOURNAL ASSEMBLY:

5.8.1 Install grinding roll on journal shaft V B 100% Drawing / Erection

Guidelines
5.8.2 Ensure timing mark on housing lines up with position 0- V C 100% Drawing / Erection
12 'o' clock. Guidelines

5.8.3 Ensure that all the bolts connecting separator body V C 100% Drawing / Erection
and journal opening cover are snug tight. Guidelines

WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 8 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD

5.9 INNER CONE ASSEMBLY & CERAMIC LINERS

INCLUDING CENTER FEED PIPE:

5.9.1 Completion of inner cone & ceramic liner assembly. V C 100% Drawing / Erection
Ensure gap between feed pipe on pulverizer and feed Guidelines
pipe to mill and installation of coupling.

5.9.2 Clearance between inverted cone with inner cone M/R Tape B 100% Drawing / Erection L – 05
before fixing it on center feed pipe. Guidelines
Tolerance: +5 mm/ - 5 mm.

5.9.3 Ensure that one of the separator body manhole and V C 100% Drawing / Erection
inner cone manholes are in line. Guidelines

5.9.4 Ensure concentricity of enter feed pipe with inner cone V/R B 100% Drawing / Erection L – 05
section. : ± 5 Tolerance mm. Guidelines

5.10 SEPARATOR TOP & CLASSIFIER ASSEMBLY

5.10.1 Align separator top and body using timing mark. V B 100% Drawing / Erection
Ensure completion of separator top and setting of Guidelines
classifier vane assembly
5.10.2 Ensure torque tightening of connecting bolts between M/R Torque wrench B 100% Drawing / Erection
separator body and separator top.. Guidelines
WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
REV. NO.: R00
BOWL MILL
PSER (STATEMENT OF CHECKS) PAGE 9 OF 12
SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : ERECTION
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD

5.11 MILL DISCHARGE VALVE ASSEMBLY

5.11.1 Completion of mill discharge valve assembly. Ensure V C 100% Drawing / Erection
proper orientation of valves and valve adapter as per Guidelines
respective drgs using timing marks.

5.11.2 Adjustment of duct supports of the PF pipes to avoid

loading at coupling joints(MDV to PF piping –check for M/R Tape C 100% Drawing / Erection
expansion clearance of 6mm) Guidelines
5.11.3 Ensure completion of seal air piping of coal pipes, verify V B 100% Drawing / Erection
operation of butterfly valve-it is to be open when discharge Guidelines
valve closes.

5.12 LUBRICATION SYSTEM

5.12.1 Completion of lube oil system & connected piping as per V B 100% Drawing / Erection
drawing. Guidelines

5.12.2 Ensure lube oil lines are clean as per supplier’s procedure. V C 100% Suppliers Procedure

5.13 OTHER ACCESSORIES

5.13.1 Completion of seal air system,DP connections & sampling V C 100% Drawing
points
5.13.2 Completion of pipe connections for inert system & V C 100% Drawing / Erection
emergency water quenching at centre feed pipe Guidelines
5.13.3 Ensure all installed instruments are calibrated V/R B 100% Drawing / Erection
Guidelines
WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR REV. NO.: R00
BOWL MILL
(STATEMENT OF CHECKS) PAGE 10 OF 12
PSER

SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : COMMISSIONING

TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD

1 Ensure completion of alignment of coupling with motor M/R B 100% Erection Log
and mill and internal clearances. Sheets

2 Ensure setting of journal spring compression. M/R B 100% O&M Manual

3 Ensure trial run of lube oil pumps & completion of oil V/R B 100% - do -
flushing of pipe lines,filling of fresh oil, and correct
level of lube oil in journal assembly. Ensure flushing of
gear box preservatives,

4 Ensure correct level & grade of lubricant, before filling V/R B 100% - do -
in mill gear box, lube oil tank, roller journal.

5 Ensure free rotation of journal assembly. V B 100% - do -

6 Ensure no foreign material is inside the mill. V B 100% - do -

7 Ensure availability of service air, instrument air and V C 100% - do -

cooling water.

8 Ensure proper functioning of local / remote indications, V B 100% - do -

interlocks and protections.

9 Ensure completion of setting of classifier vanes. V B 100% - do -

WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
BOWL MILL REV. NO.: R00

PSER (STATEMENT OF CHECKS) PAGE 11 OF 12

SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : COMMISSIONING
TYPE QUANTUM/ FORMAT
REFERENCE DOCUMENT/
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD

10 Ensure completion of commissioning of seal air V B 100% - do -

damper and mill discharge valve assembly.

11 Ensure availability of water and steam for fire fighting V C 100% - do -

devices.

12 By charging seal air, ensure proper pressure & flow. V C 100% O & M Manual /
Commissioning
Procedure

13 Ensure readiness of mill for trial run. V A 100% - do - L – 06

14 Check drive motor for the following :

14.1 IR value / winding resistance of drive motor and M 1 KV / 2.5 KV B 100% - do -

cables. MEGGER

14.2 Earth connection of drive motor, proper direction of M 500 V B 100% - do -

rotation of shaft. MEGGER

15 Ensure successful trial run of drive unit. V B 100% - do -

16 Trial run of bowl mill, setting of ring roller clearance & V A 100% - do - L – 07
gap between journal head to spring.

WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
BOWL MILL REV. NO.: R00

PSER (STATEMENT OF CHECKS) PAGE 12 OF 12

SYSTEM : BOILER SUB-SYSTEM : BOWL MILL AREA : COMMISSIONING
TYPE QUANTUM/ SHEETDOCUMENT/
REFERENCE / SHEETS
FORMAT
SL NO. CHARACTERISTICS / ITEM OF INSTRUMENT CLASS FREQUENCY OF REMARKS
ACCEPTANCE STANDARD
CHECK OF CHECK RECORD

17 After completion of trial run, check the following:

17.1 Tension of foundation bolts. M Stud tensioner B 100% O & M Manual /

Commissioning
Procedure

17.2 Alignment of motor with mill. M Dial gauge B 100% - do -

18 Completion of clean air flow test (in cold condition). V B 100% - do -

19 Ensure tightness of fasteners and arrest air leakages. V B 100% - do -

20 Ensure readiness of Mill Reject handling system. V B 100% - do -

21 Completion of pulverized fuel fineness test for the mill V B 100% - do -

and setting classifier opening.

WI:QLY:03-F08/R0
 FIELD QUALITY PLAN FQP NO. QPX:BAR:660:BR:29
FOR
BOWL MILL REV NO. R-00
( ERECTION ( ERECTION & COMMISSIONING )
PSER SHEET 1 / 1 SHEET

DOCUMENTS REFERRED IN FIELD QUALITY PLAN

SL.NO. Reference Document Issuing Authority

1 GUIDELINES FOR ERECTION OF BOWL MILLS BHEL, HYDERABAD

2 ERECTION MANUAL OF BOWL MILLS ALSTOM

3 O&M MANUAL ALSTOM

WI:QLY:03-F09/R0
 RECORD OF QUALITY CHECKS
PSER

RESULTS DRAWING /
SHEET
CHECK ACHIEVED DOCUMENT FORMAT OF INSPECTED BY CLEARED BY
NO. OF REMARKS
NO. OK / NOT REFERENCE RECORD SIGN. & DATE SIGN. & DATE
FQP
OK

Note: Any protocol made is to be numbered & mentioned in “Format of Record” column.

FQP NO. QPX:BAR:660:BR:29

SYSTEM SUB-SYSTEM AREA
PROJECT REV. NO.: R00

UNIT NO. LOG SHEET NO. : L- 00

RATING PAGE 1 OF 1
WI:QLY:03-F10/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT NO.

MILL FOUNDATION DIMENSIONS

ALL DIMENSIONS ARE IN mm.
NOTE: LAYOUT OF EQUIPMENTS/ ASSEMBLIES AS PER
DRAWING
MILL Axial Axial Radial Radial Distance Between C/L of Mill & Foundation Bolt Holes Diagonal Distance Distance Distance
Distance Distance Distance Distance Distance Between C/L Between Between Mill
NO. Between Between Between Between between of Mill & Mill Base Base Plate &
C/L of Mill C/L of Mill C/L of Mill C/L of Mill Foundation Gear Box Plate & Drive motor
& Boiler & Boiler & Boiler & Boiler Bolt Holes Lube Oil
Column Column Column Column Unit
DRG ACT DRG ACT DRG ACT DRG ACT DRG ACT DRG ACT DRG ACT DRG ACT DRG ACT DRG ACT DRG ACT

Remarks (If any):

NAME SIGNATURE / DATE FQP NO. QPX:BAR:660:BR:29
PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET No.: L-01
RATING CUSTOMER PAGE 1 OF 1
WI:QLY:03-F11/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT
REF.

MEASUREMENTS OF SHAFT ENDS & COUPLING

Work order No.: Location:

Mill size: XRP 1103 Mill Serial No.:
All dimensions are in mm.

Motor Shaft Input Shaft

 BM HM KM  BW HW KW

+ 0.04 + 0.2 - 0.026 + 0.035 + 0.2 - 0.026

As per
140 148 36 120 127.4 32.0
Drawing
- 0.00 - 0.0 - 0.088 - 0.00 - 0.0 - 0.088

Actual

NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29

PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-02 0202
RATING CUSTOMER PAGE 1 OF 1
WI:QLY:03-F11/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT REF.

COUPLING ALIGNMENT
Work order No.: Location:
Mill size: XRP 1103 Mill Serial No.:
All dimensions are in mm.

Rotate together both shafts of motor and input shaft (Dial indicators are attached on any one of
the shafts as shown above). The difference of the two dial reading values shall be less than 0.05
mm. Dial indicator pointer shall be equal distance from shaft center and about 25 mm inside from
the edge.

Allowable out of axial alignment 0.05 mm

NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29

PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET No.: L-03
RATING CUSTOMER PAGE 1 OF 2
WI:QLY:03-F11/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT REF.

COUPLING ALIGNMENT
Work order No.: Location:
Mill size: XRP 1103 Mill Serial No.:
All dimensions are in mm.

Rotate together both shafts of motor and input shaft (Dial indicator is attached on any one of the
shafts as shown above). The radial alignment shall be within 0.05 mm.

Top

Left Right

Bottom
Figure - 2

Allowable radial alignment out: 0.05 mm

NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29

PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET NO.: L-03
RATING CUSTOMER PAGE 2 OF 2
WI:QLY:03-F11/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT REF.

AIRPORT ASSEMBLY AND VANE WHEEL CLEARANCES

Work order No.: Location:
Mill size: XRP 1103 Mill Serial No.:
All dimensions are in mm.

Sl.
Dimension As per drawing Actual
No.
1 A 8±2
2 B* 20±3
3 C 30±5
Note:
1. Refer applicable drawing.
2. * Value to be recorded if installed
3. Items namely, Journal block off liner (assy.) OR air restriction rings OR air restriction blocks shall be
installed later on based on the mill performance, if required.
NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29
PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET No.: L- 04
RATING CUSTOMER PAGE 1 OF 1
WI:QLY:03-F11/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT REF.

CENTRE FEED PIPE WITH INNER CONE CLEARANCE

Work order No.: Location:

Mill size: XRP 1103 Mill Serial No.:
All dimensions are in mm.

Dimensions measured
Dimensions as per
Sl.No.
Drawing
0 90 180 270

X 100±5

Y 114±5

Note: Dimensions to be measured at four places at 90 intervals.

NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29

PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET No.: L-05
RATING CUSTOMER PAGE 1 OF 1
WI:QLY:03-F11/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT REF.

JOINT PROTOCOL PRIOR TO TRIAL RUN

Work order No.: Location:
Mill size: XRP 1103 Mill Serial No.:
All dimensions are in mm.
Sl. No. Description Observation
1 Bowl mill and motor aligned with reference axes.
2 Completion of alignment of base plates (Mill & Motor).
3 Completion of drive unit & bowl mill assembly.
4 Completion of mill motor coupling alignment.
5 Completion of mill side & liner assembly.
6 Completion of airport assembly and vane wheel clearances.
7 Completion of roller journal assembly.
Completion of inner cone assembly and inverted cone
8
assembly.
9 Completion of centre feed pipe assembly.
Completion of separator top and setting of classifier vane
10
assembly.
11 Completion of mill discharge valve assembly.
12 Completion of lube oil units and pipe lines.
Completion of fire fighting system, instrument air, service air
13
and cooling water systems.
14 Completion of seal air system for the bowl mill.
Completion of lubrication of bowl mill, gear box, roller journal,
15
journal stop bolt and coupling.
Removal of foreign materials and closure of Sep. Body
16
inspection door with gaskets.
Closure of mill side & liner assembly inspection door with
17
gaskets.
18 Completion of log sheets.
Completion of Electrical and C&I terminations and simulation
19
checks for all permissive, interlocks and protections.
20 Is the erection complete? If No, give details. Yes / No
21 Remarks.

The bowl mill Serial No. ------------------- has been cleared for trial run.
NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29
PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET No.: L-06
RATING CUSTOMER PAGE 1 OF 1
WI:QLY:03-F11/R0
 INSTRUMENT REGN.NO.

DATE OF INSPECTION
PSER
DRAWING / DOCUMENT REF.

COLD TRIAL RUN DATA

Work order No.: Location:
Mill size: XRP 1103 Mill Serial No.:
All dimensions are in mm.
S. No. Description Observation

1 Clearance for trial run.

2 Completion of permanent cabling of drive unit,

correct direction of rotation and trial run.

3 Observation during cold trial run of bowl mill.

4 Remarks.

The bowl mill cold trial run was taken for ----
hours on -------------------- and found satisfactory.
Note: Enclose Trial run log data, mill
gearbox and motor vibration values etc. for
future reference, as records.

The bowl mill is cleared for further operation.

NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29

PROJECT INSPECTED BY REV. NO.: R00
UNIT NO. CLEARED BY LOG SHEET No.: L-07
RATING CUSTOMER PAGE 1 OF 1
WI:QLY:03-F11/R0
 INSTRUMENT REG. NO./TAG

DATE OF INSPECTION

PSER
DRAWING / DOCUMENT REF.

PROTOCOL

NAME SIGNATURE & DATE FQP NO. QPX:BAR:660:BR:29

PROJECT INSPECTED BY REV.NO.: R00
UNIT NO. CLEARED BY PROTOCOL NO.
RATING CUSTOMER PAGE:
WI:QLY:03-F12/R0
 FEEDBACK ON
FIELD QUALITY PLAN
PSER

In the Field Quality Plan, following Checks / Log sheets may be added / rewritten / deleted (cannot be
carried out / not required) due to reasons as mentioned below :

Sheet Check No. /

No. Log Sheet Proposed Change / Reasons / Remarks
of FQP No.

From : To
PROJECT FQP NO. QPX:BAR:660:BR:29
1. Head (Quality)
UNIT NO. PS-ER REV NO. R-00
Kolkata-91

RATING SHEET 1 / 1 SHEET

WI:QLY:03-F13/R0