Sample SMQP Final-1

MANUFACTURING QUALITY PLAN
Manufacturers Details Customer : POWERGRID Vendors Code : Item : Galvanized Tower Structures / Parts Q.P.No. : Rev. No. : Date : Valid From : Valid Upto :
INSTRUCTIONS FOR CODE ALLOCATION
Code 1 A B C D E F Code 3 P Q R S T U V Code 5 E N
Indicates place where testing is planned to be performed i.e. Inspection location At Equipment Manufacturer's works (Fabricator)
Code 2 J K
Indicates who has to perform the tests i.e. Testing Agency The Equipment Manufacturer The Component Manufacturer The Third Party The Turnkey Contractor
At Component Manufacturer's works (Re-roller) At Authorized Distributor's place At Independent Lab At Turn Key Contractor's location Not specified Indicates who shall witness the tests i.e. Witnessing Agency Component Manufacturer itself Component Manufacturer and Equipment Manufacturer Component Manufacturer, Equipment Manufacturer and Contractor Equipment Manufacturer itself Equipment Manufacturer and Contractor Equipment Manufacturer, Contractor and POWERGRID Third Party itself Whether specific approval of sub-vendor / Component make is envisaged? Envisaged Not Envisaged
L M
Code 4 W X Y Z
Review of Test Reports/Certificates

By Equipment manufacturer during raw material / bought out component inspection
By Contractor during product/process inspection By POWERGRID during product/process inspection By Contractor and/or POWERGRID during product/process inspection
Code 6 Y N
Whether test records required to be submitted after final inspection for issuance of CIP/MICC Yes No
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NOTES/GENERAL REQUIREMENTS TO BE CHECKED/ENSURED

I. IMPORTING OF RAW MATERIAL ,STELL ANGLE SECTIONS AND BILLETS (1) The manufacturer may approach Power Grid for giving clearances of Imported Billets or imported angle sections, based on review of an un-priced copy of purchase order AND DULY SINGNED CONTRACT AGREMENT and manufacturers test certificate AS PER BSEN- 10024 DOCUMENT TYPE- 3.2 , ALONG WITH THIRD PATY INSPECTION REPORT (BVQI.LLOYDS,ETC), before shipment, to avoid discrepancy detection at later stage. Filled in information as per format at Annexure-I, shall be submitted to concerned Inspection office of POWERGRID. THE DOCUMENT LIKE BILL OF LANDING, PACKING LIST. Country of origin certificate, ETC AFTER RECIEPT OF MATERIAL shall be submitted. For imported angle sections THIRD PARTY INSPECTION IS MANDATORY(not required for billets). IT SHOULD BE RECORDED IN PURCHASE ORDER.
23
4. The suitability of hot dip galvanization as per BSEN-10025- 1-2004 clause-7.4.3 ,class -3, shall be intimated to producer of steel. If the POWERGRID technical specification specifies the grade of steel as Fe-490/490B or equivalent, then the equivalsnt grade of steel( keeping chemical and impact properties same) applicable is S-355 JO. Hence order may please be placed for this grade for high tensile steel and S-275 JO for mild steel 5 For IMPORTED ANGLE sections EMBLUM OF MANUFACTURER IS MANDATORY .Othervise, THE REFUSAL OF THE PARTY IN WRITING SHOULD BE PRODUCED and FOOL PROOF SYSTEM OF IDENTIFICATION OF MATERIAL LIKE SOURCE, MILD STEEL AND HIGH TENSILE STEEL, GRADE, etc SHOULD BE INFORMED
6. IF THE SPECIFICATION OF THE MATERIAL IS OTHER THAN BSEN SPECIFICATION, THEN THE EQUIVALENT NATIONAL STANDARDS OF ORIGIN COUNTRY SHALL BE SUBMITTED FOR APPROVAL PRIOR TO PLACEMENT of THE ORDER. 7IF THE ORDER IS NOT PLACED DIRECTLY ON THE MANUFACTURERER ,Then THE COPY OF THE DULY SINGNED UNPRICED COPY of Purchase ORDER AND the CONTRACT PLACED BY INTERMEDIATORY, SHALL BE SUBMITTED TO ENSURE THAT ALL THE REQUIRMENT OF POWERGRID CONTRACT/ TLT MANUFACTURER PURSHASE ORDER Have BEEN INTIMATED TO PRODUCER OF THE STEEL In every specification there is provision of finalization of lower limit on mutual agreement. So while placing the order other than BSEN-10025 -2004 relevant specifications may please be examined and deviation in physical, chemical and any specific
8.
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requirement in technical specification may be intimated to producer of steel and may be agreed mutually. In this case, no material shall be produced prior to the mutual agreement date. 9. 10TLT manufacturer shall ensure that no non - moving stock, second grade material shall be purchased or imported and also the it shall be non alloy prime grade material as defined in BSEN- 10020 It is observed that various international steel makers are having the on line system of viewing the test certificate, traceability , raw material used , heat no, etc. If possible the access to this system may please be given to POWERGRID so that the same can be viewed In various test certificate the various comments and details are given in the language of origin country.Hence it shall be ensured that the English translation of the same shall be provided for reviewing the test certificate In test certificate the heat-vise chemical composition of ladle analysis is to be recorded not product chemical composition . If inspection is done by third party then the heat wise chemical composition of product shall be recorded .
1112-
Material procurement from Indian Re rollers . In case Steel sections are purchased from the main producers or directly from the re-rollers, the following conditions shall be fulfilled:(A) The Rerollers have to be approved by POWERGRID .Tower manufacturers shall ensure that the Materials bear the identification marks of the re-rollers ie. PG00 embossing for MS ,PHT00 embossing for HT(E350 GRADE) and SHPHT embossing FOR SS-540 GRADE re-rolled section. . PG 00 MEANS YEAR OF MANUFACTURE (B) Copy of MQP shall be available at re-rollers works.
II.
THE GRADED RAW MATERIAL FOR ROLLIG MILD STEELas per IS 2830, shall be procured FROM APROVED PRIMARY STEEL PRODUCERS AND FOR HIGH TENSILE STEEL,it shall be JSP-355 OF JINDAL, TISTEN -50 OF TISCO, SAIL TOWER GRADE VI OF SAIL and JSP-540 FOR ROLLING JIS-SS-540 OR E-400 . UNDER IS-2062 billets/ SEMIS to be procured from the Billet producer like SAIL, RINL, TISCO, IISCO, SISCON and Jindal .For other parties POWERGRIDs approvals will have to be obtained. For any new grade of high tensile steel other than mentioned above,specific approval of grade from POWERGRID is required. (D) TLT contractor Shall offer the Steel sections rolled out of indigenous / imported billets at re-rollers works for Inspection to POWERGRID and inform at least one week before proposed inspection date. The rolled angle section shall be duly corelated with corresponding billets.
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(E) REROLLER shall ENSURE THE CHEMICAL TESTING of INCOMING RAW MATERIAL,SEMIES AND IF ANY LOT IS NOT AS PER TDC( FOR HIGH TENSILE) OR IS-2830 (FOR MILD STEEL) , THEN THE SAME SHALL BE REPORTED TO PRIME PRODUCERS with COPY marked TO POWERGRID . COPY OF THE QUALITY COMPLAINTS SHALL BE KEPT IN RECORDS FOR REVIEW
(F) ANY LOT OF PRIME PRODUCERS WHICH IS UNDER QUALITY COMPLAINT SHALL NOT BE USED. IF it is used the same shall have the permission of POWERGRID . Permission will be granted by POWERGRID based on the merit of the case if requested by prime producer of steel.
III.
Inspection of angle sections at Black stage of Tower structures irrespective of specific contract, can be followed as Detailed hereunder. A) TLT manufacturer will inspect the material as per P.O, P.O length, and P.O requirement and issue the MICC to the re roller as per enclosed format.Accordingly inspection call will be raised on IMS and the unique MICC NO shall be mentioned in the inspection call .The MICC shall become the part of POWERGRID CIP at re rollers works. And inspection of material will be done as per relevant specification as applicable in the contract . B) The material test certificate and invoice of raw material semies shall be in the name of concern re-rollers C) In the case of conversion route, all the test certificate shall be issued in the name of TLT manufacturer and the concerned reroller shall be consignee of the material D) The hot rolled angles shall be dispatched to the works of the TLT manufacturer directly .If any change in the place of fabrication is planned the same shall be with the approval of POWERGRID. The re -roller shall mention TLT manufacturers MICC NO/POWERGRID CIP NO in the invoice E) If any material is rejected during inwards testing at TLT manufacturer works,then the same shall be intimated to POWERGRID and relevant CIP may please be amended .
F) The presence of micro- alloying elements is a must for high tensile steel . Material produced under IS - 2830 with minimum 0.5 % Mn shall be used for rolling MS sections. G) Inspection call for angle sections at black stage at re-rollers work, shall be raised against any one of the ongoing Contracts.
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(H) TLT contractor shall maintain a separate register indicating splitting and swapping of material between different Projects awarded to same contractor, which can be reviewed by Powergrid inspection engineer. Separate register for each Contractor is to be maintained if the fabricator is executing jobs for different contractors (I) All section shall be offered for inspection as per relevant standard at the re-rollers works. The grade of The billets should be suitably selected to meet the raw material requirements. Colour code for black section shall be as below; IS 2062 E250 : Green IS 2062 E350 : White BSEN10025 355JO : Yellow BSEN10025 355JR : Pink( not required) BSEN10025 275JO : Grey BSEN10025 -275 JR : Blue IV. FABRICATION OF TOWER PARTS AND FINAL INSPECTION: (1) TLT contractor shall maintain operator card for each work (operation) station per shift and maintain it till the materials offered, inspected and cleared which can be verified at the time of inspection. (2) IF during the process of manufacturing of the lot any re-work due to fabrication defects / any lot are rejected during fabrication process,quality check/ issue of wrong grade raw material for fabrication, then the same shall be informed at the time of inspection to POWERGRID inspectors and the lot which has been rejected by TLT manufacturer will be disposed off only after inspection of replacement lot. ( 3)- Process inspection shall be started with the venders having ERP system in place and proper correlation from raw material to the finished gavanised tower parts may please be shown . The raw material correlation statement from material inward ,issue, completion of fabrication , & galvanizing and handing over to yard has to be given on soft copies and original route sheets has to be preserved if it is required the same can also be varifed w.r.t soft copies data till completion of inspection. (4) Welding procedure and Welders performance qualification approval by POWERGRID is required in case welding is involved at any stage of fabrication/erection. (5) All bent pieces shall be checked at the process of bending by a bend gauge made as per bend ratio/degree shown in the sketch of the item/mark no. On the stand one piece is thoroughly checked with bend gauge and all other pieces are checked by comparison method and pieces are cleared for further process. If the holes are to be made near the bend line the same shall be done after bending.
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( 6) All the concerned calibration certificates for testing machines/measuring equipments shall be made available for review at the time of final inspection. (7) ALL Grades of steel used and the standards to which they conform shall be as approved by Power Grid Engineering for the specific contract and shall be indicated in approved Drawings/ BOM/offer list at the time of inspection. ( 8) Steel plates below 6 mm used for packing plates/Packing washers shall be as per POWERGRID specification/ approved drawings by Engineering Department.Steel produced as per IS 1079 1994 (Grade-O) are also acceptable.However if below 6 mm thickness plates are used as load bearing plates, gusset, splices etc. same shall confirm to IS 2062 or equivalent standard . If possible grade _O plates should be recorded in BOM (9) In approved BOM along with grade of steel used and section summary the operation involved in manufacturing should also be mentioned. (10) TLT contractor shall maintain proper co-relation of test certificate with respect to the material from raw material stage to Finished material stage. (11) At the time of offering of galvanized tower parts for final inspection ,a stament showing details of rawmaterial CIPs from which raw materials are consumed ,sectionvise consumption quantity,previous quantity available in each CIP,and balace quantity available for next fabrication,etc shall be submitted for verification. (12) Inspection will be based on actual quantity of galvanized bunduled production. For ensuring this readiness of material print out of the bundled production/galvanized production of the lot under offer has to be taken from ERP / mother system in presence of POWERGRID inspector prior to commencement of inspection . And the same shall be treated as offer list of material for inspection. In this offer list various operation of manufacturing such as cutting notching ,punching, heel grinding shall be there such as C/P/HG/S ETC (13) Stripping off galvanizing of rejected material shall be done before re-galvanizing in case of rejection is due to galvanizing Testing / defects. POWERGRID INSPECTOR MAY witness the striping process and galvanization process
14 ) TLT contractor shall dispose off entire section rejected in physical testing by gas cutting or by machine cutting from any end of rejected mark number IN PRESENCE OF POWERGRID INSPECTORS AND SHALL SUBMIT THE PHOTOCOPY OF EXCISE INVOICE AND RELEVANT PAPERS FOR RECORD. And a duplicate record of the same shall be maintained at the works of TLT manufacturer 15 ) In case of any contradiction between Technical Specification / Approved Drawing and MQP, the details mentioned in The Technical Specification / Approved Drawing shall be final
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16 ) TLT contractor should progressively align their Quality System and sub-vendors Quality System to the requirements of ISO 9000 series Quality Standards and in due course of time should get their quality system certified to ISO 9001. The quality Manual should also be submitted to POWERGRID. 17) - TLT MANUFACTURER WILL TAKE SUFFICIENT PRECAUTION THAT ANY OF THE TOWER PARTS OF TESTed TOWER SHALL NOT BE USED IN FABRICATED LOT. - And all test tower mark no will have prefix- T- easy identification 18- During proto assembly if any mild steel angles have been used in place of high tensile steel or angles of non approved source or raw material then the same shall be destroyed after completion of proto inspection. And the same shall be recorded in proto inspection report And proto assembly towers shall be offered separately not in combination with production lot/ batches 19 ) The Universal-testing machine shall have valid calibration certificate Issued by NABL accredited testing agency only
(20) After completion of the a project supplies, a combined statement of raw material cip qty, actual quantity lifted ,actual quantity consumed , qty diverted to other projects and balance if any shall be intimated to POWERGRID. before final MICC of the relevant contract (21) Before starting the supplies under any new contract, use of major quantity from old stock without verification and consent of POWERGRID is not permitted but this condition is not applicable to stock of plates, randomly used section in small quantity During the testing of the material if any mild steel section is giving the high tensile steel mechanical properties, then chemical composition of the sample has to be checked to verify the grade of steel . If high tensile steel is used in place of mild steel then it shall be reported before commencement of inspection so that it can be verified Before commencement of inspection it shall be informed that that in which mark no rework or rectification (EXCLUDING Galvanization) has been done. If any lot has been rejected during in house quality check then the rejected lot shall be kept till the completion of inspection and if required the same can verified during the inspection. During final galvanizing test (mass of zinc coating) , test samples has to be tested for dimension also.in case of doubt the unit weight test shall be done. If test samples are found not confirming the lot will be checked and if it is found to be intentional negative rolling , then lot will be rejected.
(22) (23) (24)
(25)
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(26)
The chemical composition of the material for which raw material inspection has not been done by POWERGRID (including imported) has to be done at the time of final inspection of finished galvanized tower parts to establish the correlation with raw material statement . For HT steel, requirement of micro-alloys elements shall be as follows:
(27)
Ladle Analysis: Vanadium 0.025% min, Niobium 0.015% min. or Vanadium + Niobium + Titanium = 0.025% min. However, the sum or individual shall not exceed 0.25% as per IS2062. Product Analysis: A tolerance of 0.005% from Laddle analysis ( 28) Pieces of light sections to be wire bundled & of heavy sections to be supplied loose. Stacking to have proper ventilation and kept inclined. Damage to galvanization coating to be avoided while handling. TLT MANUFACTUTER to ensure sequential supplies and other details as per POWERGRID Technical Specification (29) Prior approval of POWERGRID is required to be taken for any activity or process that is out-sourced. (30) Any addition/ change in Vendor/ Design/ Process shall call for review by POWERGRID and change in MQP, if necessary. (31) POWERGRID may review the effective implementation of the Process during Product/ Process inspection. In case any violations in process or process parameters are observed, then the reasons along with corrective and preventive measures shall be conveyed to POWERGRID within 2 weeks. (32) After galvanized tower parts inspection, it may also be ensured that all the material inspected and cleared for dispatch shall be dispatched within 15 days and same shall be intimated to Power grid In the format provided in the CIP . (33) At the time of claiming the MICC, original copy CIP received for bolts and nuts and accessories may be submitted with all enclosure V. INSPECTION OF BOLTS AND NUTS: (1) Bolts & nuts, Step Bolts & Nuts and other bought out items are to be procured from Power Grid approved sources and CIP at subvendors works. If material is tested in third party lab. sample identification no and its correlation with the lot shall be there and in chemical analysis all the element present during spectro test should be reported in the test certificate. Graded raw material IS 1875: 1991
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as per requirement of product shall be procured. THE chemical testing samples has to be preserved by third party lab incase of level II items. If required POWERGRID may verify the same prior to issuance if CIP. (2) IN THE RAW MATERIAL OF BOLTS AND NUTS,Elements not specified in Table 1 OF IS 2004 shall not be added to the steel, except when agreed to, and shall not exceed the following limits: AS PER CLUASE NO-7.3 OF IS-2004 (3) Constitutent Percent- Nickel 0.30, Chromium 0.30,Copper 0.25 , Molybdenum 0.05,Vanadium 0.05,Tin 0.05,Boron 0.000 3 Trace elements (Cr + Ni + MO) when added together shall not exceed 0.050 percent. Percent copper + 1O x (Percent tin) shall not exceed0.050 percent (4) If any new party is approved for level _II items, at least ten initial inspection visits by POWERGRID is a must .After that vender can be allowed to dispatch the material for level II items based on no rejection during initial six month period . (5) All forging items used for transmission line towers to be procured as per IS -2004 and condition of chemical composition as per clause no- may also be complied with .and in chemical anylsis all the elements present may be reported (6) Any change IN PRODUCTION CAPACITY may be intimated to POWERGRID .
(Can attach more than one page)

A. Raw Material Inspection (Indigenous) At Re-Rollers Work Component Referenc s/ Operation e Sr. Type of Quantum of Check / & documen No. Check Sampling with basis Description t for of Test Testing 1. RAW MATERIALS 1.1 Structural Steel (Angle Sections, Plates and sheets) 1.1. Mechanical 1 Properties Acceptance Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
E Steel to be procured from Power Grid approved Sources. For re-rollers specific approval of Power Grid is to be ensured/ CIP for every lot at re-rollers works.
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(a)
Test For Ultimate Tensile Strengt h
2 - Samples per Cast/Heat *
IS - 1608
As per IS 2062 Table-2
CIP
Y CIP at Rerollers works *In case proper heat/cast number is not established,then 2 samples per section per 100 mt
a. Raw Material Inspection (Indigenous) Component s/ Operation Sr. Type of Quantum of Check / & No. Check Sampling with basis Description of Test (b) Test For 2 - Samples per Yield Cast/Heat. *
Stress
Reference document for Testing IS - 1608
Acceptance Norms As per IS 2062 Table-2
Format of Record
CIP
Applicable Codes
1 2 3 4 5 6
Remarks
Y
CIP at Rerollers works
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10

(c)
Percentage Elongation Test
2 - Samples per Cast/Heat. *
IS - 1608
As per IS 2062 Table -2
CIP
a. Raw Material Inspection (Indigenous) Component s/ Operation Sr. Type of Quantum of Check / & No. Check Sampling with basis Description of Test (d) Bend 2 - Samples per Test Cast/Heat. *
Referenc e documen t for Testing

IS 1599
Format of Record
CIP
Applicable Codes
1 2 3 4 5 6
Remarks
B K
Y CIP at Rerollers works
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11

A. Raw Material Inspection (Indigenous) Component s/ Operation Type of Sr. Quantum of Check / & No. Check Sampling with basis Description of Test (e) V notch One sample per Impact cast/heat for HT
Reference document for Testing IS 1757 for Impact
Format of Record
CIP
Applicable Codes
1 2 3 4 5 6
Remarks Y CIP at Rerollers works
B K
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12

test
1.1. 2
Chemical Composition
Chemic al Analysis
material. Applicable only for Grade E350 and E410 as per IS 2062 2 - Samples per Cast/Heat
Chemical analysis for each lot / heat . *
Testing IS 2062/ Power Grid Specn./ As per IS 2062 Table-1

Elements C, Mn, P, S, Si, Ni, Cr, Mo, Cu, AI, N and micro alloying elements as V / Nb / Ti and any other element specified by applicable product specifications for the applicable grade, class and type. For permitted variations in product analysis relevant standard to be referred.
CIP
B K / / D L
U / V
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13

Manufacturers Details Customer : POWERGRID Vendors Code : Item : Galvanized Tower Structures / Parts CIP Q.P.No. : Rev. No. : Date : Valid From : Valid Upto :
1.1. 3
Visual Inspection
Visual
5 samples/section
.
IS 2062/ Power Grid specn.
(Removal of minor defects as per IS 2062 Clause 7.2
B K
acceptable)
Rolled shapes and plates shall be free from defects like Scaling, scabbing, pipy, fish ends, cracks, prominent rolling marks, deep scratches, deep grooves, waviness, twists ,lamination, and any other harmful defects hampering safety and ease of fitments during tower assembly
A. Raw Material Inspection (Indigenous) Component s/ Operation Quantum of Sr. Type of & Check / Sampling No. Check Description with basis of Test 1.1. Dimensional Measureme 5 samples/section 4 Inspection nt
Reference document for Testing IS 808/ IS 1730 / IS 1852 & PowerGrid Specn. IS 1852/ IS 808
Acceptance Norms
Format of Record
CIP
Applicable Codes
1 2 3 4 5 6
Remarks
1.1. 5
Tolerances For Leg Length Of
- do -
(i) Up to 45 mm Leg Length 1.5 mm
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14

Angles Equal / Un Equal (ii) > 45 to 100 mm Leg Length 2.0 mm (iii) >100 mm Leg Length 2.0 % of leg length Difference between Leg Length of Equal Angles shall be limited to 75 % of Total Tolerance (Plus & Minus)
1.1. 6
Out of Square ness
Measureme nt
- do -
IS 1852 Power Grid Specn.
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15

A. Raw Material Inspection (Indigenous) Sr. No.

1.1. 7
Components/ Operation & Description of Test Camber
Type of Check Measurement
Quantum of Check / Sampling with basis 5 samples/section
Referenc e documen t for Testing IS 1852
Acceptance Norms (i) For Flange Less than 100 mm Reasonably Straight (ii) For Flange 100 mm & above Max 0.2% of length Up to 3 mm thick 5% > 3 mm thick + 5%, - 3 % over weights specified in IS 808 THIS TOLERENCE IS FOR TEST SAPMLE NOT FOR THE LOT UNDER OFFER +5%, -2.5% over weights specified in IS 1730 < 8 mm thick + 12.5 %, - 5 % 8 mm - 12 mm + 7.5 %, - 5 % over 12 mm 5 %
Format of Record
Applicable Codes
1 2 3 4 5 6
Remarks CIP at Rerollers works
B K
1.1. 8
Weight Tolerance For Angle Sections
Unit Weight Test
One Sample for 20 MT / section or part thereof.
IS 1852 / IS 808
1.1. 9
Weight Tolerances For Plates Thickness Tolerance For Plates
Unit Weight Test
One Sample for 20 MT / section or part thereof. 5 samples/section
IS 1852 / IS 1730
1.1.10
Measurement
IS 2062/ IS 1730 / IS 1852
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16

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A. Raw Material Inspection (Indigenous) Sr. No. 1.2 1.2.1 Components/ Operation & Description of Test Zinc Zinc Receipt Chemical Composition Chemic al Analysis One sample for 50 MT or Part thereof IS 209 (Grade 99.95%) % of zinc 99.95 min in the spectro test results all the elements as specified in specification shall be measured and reminder will be the purity of zinc A J/ / L D S / V Z Type of Check Quantum of Check / Sampling with basis Reference document for Testing Acceptance Norms Forma t of Recor d Applicable Codes
1 2 3 4 5 6
Remarks
E N THIS IS APPLICABLE FOR ZINC PROCURED FROM INDIAN ORIGIN NOT FOR IMPORTED ZINC. IMPORTED ZINC HAS TO CLEARED BASED ON DOCUMENTS & TEST CERTIFICATE HEATNO.WISE T/C AND IT VARIFICATION ON THE LOT AND RANDOM CHEMICAL COMPOSITION CHECK
a. Raw Material Inspection (Imported) Sr. No. 1A. Components/ Operation & Description of Test RAW MATERIALS Type of Check Quantum of Check / Sampling with basis Referenc e documen t for Testing Acceptance Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
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18

1A.1 1A.1. 1 (a)
Structural Steel (Imported) Mechanical Properties
E Test For Ultimate Tensile Strength One sample for every 20MT / Section /lot or part thereof One sample for 40 MT/Sec/Cast Or part thereof as per BSEN 10025-2: 2004 One sample for every 20MT / Section /lot or part thereof One sample for 40 MT/Sec/Cast or part thereof as per BSEN 10025-2: 2004 BSEN 10025-2: 2004/ Power Grid Specn. BSEN 100252: 2004/ 04.2209. 82.04-1 / Steel Inspectio n Report A / D J/ L S & V Z N
(b)
Test For Yield Stress
BSEN 10025-2: 2004/ Power Grid Specn.
BSEN 100252: 2004/
04.2209. 82.04-1 / Steel Inspectio n Report
A / D
J/ L
S & V
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19

A. Raw Material Inspection (Imported) Componen ts/ Sr. Type of Quantum of Check / Operation No Check Sampling with basis & . Descriptio n of Test (c) Percenta One sample for every ge 20MT / Section /lot or Elongatio part thereof n Test One sample for 40 MT/Sec/Cast Or part thereof as per BSEN 10025-2: 2004 (d ) Bend Test BSEN 10025-2:2004
Reference document for Testing BSEN 100252:2004 / Power Grid Specn.
Acceptance Norms BSEN 10025-2: 2004/
Format of Record
Applicable Codes
1 2 3 4 5 6
Remarks N
A / D
J/ L
S & V
BSEN 10025-2: 2004// Power Grid Specn. BSEN 10025-2: 2004 / Power Grid Specn
BSEN 10025-2: 2004/16
A /
(e)
'V' notch impact test
One sample for every 20MT / Section /lot or part thereof One sample for 40 MT/Sec/Cast Or part thereof as per BSEN 10025-2: 2004
BSEN 10025-2: 2004/
A / D
J/ L
S & V
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20

A. Raw Material Inspection (Imported) Component Quantum of s/ Sr. Type of Check / Operation No. Check Sampling with & basis Description of Test 1 Chemic One sample for Chemical A.1. al every 40 MT per Compositio 2 Analysis section per heat n or part thereof 1A. 1.3 Visual Inspection Visual 8 samples/section
Reference document for Testing BSEN 100252:2004/ Power Grid Specn. BSEN 100252: 2004/ Power Grid Specn. BSEN 100561/ BSEN 10056 2
Acceptance Norms BSEN 100252: 2004/ BSEN 100252: 2004/
Format of Record
Applicable Codes
1 2 3 4 5 6
Remarks N
A / D A / D
J/ L
S / V S & V
J/ L
1A. 1.4 1A. 1.5
Dimensional Inspection Tolerance For Leg Length Of Angles
Measure ment
- do - do -
BSEN 100252: 2004/ BSEN 100252: 2004/
04.2209. A 82.04-1 / / Steel D Inspectio n Report
J/ L
S & V
A. Raw Material Inspection (Imported) Sr . N o. Components/ Operation & Description of Test Type of Check Quantum of Check / Sampling with basis Reference document for Testing Acceptance Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
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21

1 A .1 .6 1 A 1. 7
Out of Squareness
Measuremen t
8 samples/section
BSEN 10056 2/
BSEN 100562
A / D A / D
J/ L
S & V S & V
Camber
Visual/ Measuremen t
- do -
BSEN 100562/
BSEN 100562 Leg Length
J/ L
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22

A. Raw Material Inspection (Imported) Sr. No. 1A.1. 8

1.A.1. 9
Components/ Operation & Description of Test Weight Tolerance for Angle Sections Thickness Tolerance For Angle Sections
Type of Check Unit weight test Measure -ment
Quantum of Check / Sampling with basis 2 - Samples per Cast/Heat 8 samples/section
Reference document for Testing BSEN 10056 2/ BSEN 10056 2
Acceptance Norms BSEN 100562 BSEN 100252: 2004/
Format of Record
Applicable Codes
1 2 3 4 5 6
Remarks N Unit weight test has to be done during final inspection as per remark no -as above
A / D A / D
J/ L J/ L
S & V S & V
A. Raw Material Inspection (INWARD PLACE) Componen ts/ Sr. Operation Type of Check No. & Descriptio n of Test
/ RECEIPT)(NOT APPLICABLE IF FABRICATOR & REROLLER ARE SAME PARTY LOCATED AT SAME Quantum of Check / Sampling with basis Reference document for Testing Format of Record Applicable Codes
1 2 3 4 5 6
Acceptance Norms
Remarks
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23

RAW MATERIAL 1B.1 S Structural Steel (Angle Sections, Plates and sheets) 1B.1.1 Mechanica l Properties (i) UTS Test (ii) Yield Stress Test (iii) Percentage Elongation Test (iv) Bend Test (v) Min. Charpy Vnotch Impact Test 1B.1.2
Chemical Analysis Chemical Compositio n
1B.
A J
One sample for40MT/se ction or part thereof
One sample for 40MT/sect ion or part thereof
A J
1B.1.2
A. Raw Material Inspection (INWARD)
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Component s/ Operation Sr. & No. Description of Test 1B.1.3 Visual Inspection 1B.1.4 Dimensional Inspection
Type of Check
Visual
Quantum of Check / Sampling with basis 8 samples/se ction - do -
Reference document for Testing
Acceptance Norms
Format of Record
Applicable Codes
1 2 3 4 5 6
Remarks
Measurement Measurement - do -
1B.1.5 Tolerances For Leg Length Of Angles Equal / Un 1B.1.6 Equal Out of Square ness 1B.1.7 Camber
Measurement - do Measurement - do -
1B.1.8
Weight Tolerance For Angle Sections Weight Tolerances For Plates Thickness Tolerance For Plates
Unit Weight Test
One sample for 40MT/sectio n or part thereof One sample for 40MT/sectio n or part thereof 8 samples/se ction
1B.1.9
Unit Weight Test
1B.1.1 0
Measurement
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25

B. In Process Inspection Sr. No. 2.0 Components/ Operation & Description of Test INPROCESS INSPECTION Fabrication of Tower Parts Type of Check Quantum of Check / Sampling with basis Reference document for Testing Acceptance Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
IS 802 Part II/ IS 7215/ Power Grid approved Drwg., Shop Sketches Visual Dimension al Visual 100 % Ist 3 Pieces and random sample Ist 3 Pieces and random sample
Free hand torch cutting is not permitted. Guided torch cutting is permitted. All burned edges shall be ground smooth and neatly finished with lumps and imperfections removed.
(a) (b)
Straightening Cropping (Cutting)
(c)
Stamping
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26

(d)
Punching / Drilling
Dimension al
Ist 3 Pieces and random sample
Holes may be punched or drilled for material up to I3 mm thickness. For more than 13 mm thickness holes to be drilled. Holes near bends to be punched / drilled after bending. Hole size not to exceed more than I.5 mm larger than nominal bolt diameter after galvanizing. (Tolerance - +0.4 mm) Hole ovality shall be permitted up to 0.4 mm Hole should be perpendicular to surface & difference in diameter on both sides of flange should not be more than 0.8 mm All burrs left by drilling or punching operation to be removed completely.
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27

B. In Process Inspection Sr. No. (e) Components/ Operation & Description of Test Edge Security Type of Check Dimension al Quantum of Check / Sampling with basis Ist 3 Pieces and random Reference document for Testing IS 802 Part II/ IS 7215/ Power Grid approved Drwg., Shop Sketches Acceptance Norms sampleDistance of the
hole to the rolled edge or sheared edge of the member to be maintained as specified in the drawing. Tolerance - +/- 2 mm
Format of Record
Applicable Codes
1 2 3 4 5 6
Remarks N
(i) (ii) (iii) (iv)
For 13.5 mm dia Hole For 17.5 mm dia Hole For 21.5 mm dia Hole For 25 mm & 25.5 mm dia Hole Drilling & Punching Hole To Hole Distance Ist 3 Pieces and random sample
Sheared 20mm Min. Rolled 16mm Min. Sheared 23mm Min. Rolled 20mm Min. Sheared 28mm Min. Rolled 25mm Min. As per approved Drawing Tolerance cumulative and between consecutive hole shall be within 2 mm and 1mm respectively A J S Z N
(f)
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28

(g)
Notching Flange Cut Corner Cut Bevel Cut
Ist 3 Pieces and random sampleS

C
Cutting to be done by shearing up to 8 mm thickness Above 8 mm thickness cutting is to be done by flame Cutting Tolerance on flange cutting Up to 100 mm cut - +/2 mm Above 100 mm cut - +/- 3 mm
04.2202. A 75.01-7 / Route card
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29

B. In Process Inspection Sr. No. Components/ Operation & Description of Test Heel Cutting Type of Check Quantum of Check / Sampling with basis Ist 3 Pieces and random sample Reference document for Testing Power Grid Approved Drwgs./ Shop Sketches Acceptance Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
h)
Dimensi Onal
Length and width of heel cutting as specified on approved drawing or sketch. Heel cutting up to 10 mm heel width, heel to be cut on heel cutting machine More than 10 mm heel width, heel to be cut with flame cutting. Heel to be cut with guided flamecutting. Heel cutting Tolerance Length - + 5 mm Width - up to 6 mm - +/- 1 mm 7 mm and above - +/- 2 mm All burned edges shall be ground smooth and neatly finished with lumps and imperfections removed.
04.2202. A 75.01-7 / Route card
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30

(i)
Bending
Ist 3 Pieces and random sample
IS 802(Part II)/ IS 7215/ Power Grid Approved Drawing / Shop Sketches
(1) HT Sections / Plates All Sections & all plates to be hot bent.
The bending shall be done either in hot condition or cold condition with the help of bending dies. Sections below MS 75 x 75 x 6 mm size Cold Bending- up to 10 degree angle Hot bending - Above 10 degree angle Section above MS 75 x 75 x 6 mm Hot bending only Plates up to MS 6 mm thickness Cold Bending - up to 15 degree angle Hot bending - Above 15 degree angle Plates above MS 6 mm thickness Hot bending only All sections and plates of any thickness-Hot Bending only
04.2202. A 75.01-7 / Route card
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31

Hot bending is done at specified temperatures Temperature range -700 to 850 degree Celsius. Bend angle is verified by approved bend gauges Tolerances: I) Shifting of bend line on either side - max. 2 mm (2) Maximum permissible deviation in bending slope is 3.0 mm per 300 mm on either side (3) Maximum permissible deviation in angle for opening and closing operation is +/- 1 degree(4) Reduction in thickness due to bending is acceptable up to 5 % of actual thickness of the material prior to bending All hot bend material shall be air cooled only. Bend shall be free from prominent die marks, hammer marks, waviness, scaling, folds etc
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32

B. In Process Inspection Sr. No. (j) Components/ Operation & Description of Test Welding Type of Check (a) WPS Approval (b) PQR Approval Quantum of Check / Sampling with basis Random samples Reference document for Testing As per Power Grid Technical specn. /approved Drg./Power Grid approved Welding procedure & Welder`s qualification Acceptanc e Norms Format of Record Weld Card Applicable Codes
1 2 3 4 5 6
Remarks N CIP
(k)
Final Inspection of Fabricated Parts
Random samples
All parameters from (a) to (j) Above are checked and record maintained before releasing the Materials for galvanizing.
04.2202.75 A .01-7 / Route card
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33

B. In Process Inspection Sr. No. 3.0

3.1
Components/ Operation & Description of Test GALVANIZING

Zinc Bath Chemical Composition
Type of Check
Quantum of Check / Sampling with basis
Referenc e documen t for Testing
Acceptance Norms
Format of Record
Applicable Codes
1 2 3 4 5 6
Remarks
Chemical Analysis
Two samples in a Month
The molten metal in galvanizing bath shall contain l 98.5% zinc by mass or more IS 2629 TLT MANUFAC TUTER Norms Strength of solution . 5% to 15%
TLT A MANUFACTUT / ER Chemical D Report/ TPL Reports A
J/ L
S / V
3.2 (a)
Degreasing Degreasing in Acid base degreasing solution at room temperature which does not require water rinsing Pickling Pickling is done in Hydrochloric acid at room temperature.
Chemical
One sample Daily
(b)
Chemica l
One sample daily
IS 2629 TLT MANUFAC TUTER Norms
Acid concentration 1%-15% Iron contents 120 gm/ltr Max pH Value 5 to 6
04.2209. 82.04-17 Daily Analysis Report/ 04.2207. 75.01-1 Beam card
(c)
Rinsing Only in absence of Auto neutralization Pre Flux Solution.
Chemica l
One sample daily
IS 2629 TLT MANUFAC TUTER Norms
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34

B. In Process Inspection Sr. No. (d) Components/ Operation & Description of Test Pre Fluxing In Zinc Chloride and Amonium Chloride solution patent fluxing reagent. Type of Check Chemic al Quantum of Check / Sampling with basis One sample daily Referenc e documen t for Testing IS 2629 TLT MANUFA CTUTER Norms Acceptance Norms The Specification of solution are kept as mentioned below: 3Specific Gravity 1.16 1.32 (15 35 Be) 3pH Value 4-5 3Iron Content 0.3%max The Temp is kept between 500C to 1200C Format of Record 04.2209. 82.04-17 Daily Analysis Report/ 04.2207. 75.01-1 Beam card Applicable Codes
1 2 3 4 5 6
Remarks N
(e)
Pre-heating On hot plate / dry air oven
Measur ement
One check per day
IS 2629 TLT MANUFA CTUTER Norms
04.2207. 75.01-6 Furnace Register/ 04.2207. 75.01-1 Beam card
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35

B. In Process Inspection Sr. No. 3.2 Components/ Operation & Description of Test Dipping After drying is over the material is dipped in molten zinc. Following parameters are controlled Zinc bath temperature Recording is done by graphical manner or actual verification by thermometer. Immersion & Withdrawal time. Type of Check Quantum of Check / Samplin g with Referenc e documen t for Testing Acceptance Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
A A
J J
S S
Z Z
N N
(a)
Hourly check
IS 2629 TLT MANUFA CTUTER IS 2629
440 to 460 C.
(b)
(c)
Quenching:
Articles to be immersed till reaction takes place which is indicated by stoppage of bubbling, withdrawal to be controlled so that Zinc drains freely After dipping the material is quenched in water Strength of the solution to be maintained between 0.2 to 1% Sodium Dichromate to 0.5% H2SO4. Temperature of solution should be less than 65C
04.2207. 75.01-6 Furnace Register/ 04.2207. 75.01-1 Beam card
(d)
Dichromating:
One Sample daily
IS 2629 TLT MANUFA CTUTER Norms
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36

B. In Process Inspection Sr. No. 3.3 (a) Components/ Operation & Description of Test Galvanizing Checking Visual Checking Type of Check Quantum of Check / Samplin g with 100 % Referenc e documen t for Testing IS 2629 Acceptance Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
Visual
Surface to be free from defects like bare / black spots, (except when small and suitable for patching) heavy ash & flux inclusions, lumps, pimples, runs etc Minimum value or Average Coating thickness 5 mm thick and over 86microns Under 5 mm, 65microns Minimum value or Average Mass of Coating (g/m2)] 5 mm thick and over - 610 Under 5 mm, but not less than 2 mm - 460 Material to withstand 4 dips of one minute each without showing signs of copper deposits in CuSO4 Solution of 1.186 Sp.Gr at 18o 2oC temperature.
04.2207. 75.01-1 Beam card
(b)
Thickness of Zinc coating
Measureme nt
6 samples / shift
IS 4759
(c)
Weight of Zinc coating
Measureme nt
4 samples / shift
IS 4759 / IS 6745
(d)
Uniformity of Zinc coating
Measureme nt
4 samples / shift
IS 2633
04.2209. 82.04-12 Galvanizin g Inspection Report 04.2209. 82.04-12 Galvanizin g Inspection Report 04.2209. 82.04-12 Galvanizin g Inspection Report
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37

(e)
Adhesion Tests of Zinc coating
Pivoted Hammer Test
4 samples / shift
IS 2629
No removal or lifting of coating in areas between hammer impressions
04.2209. 82.04-12 Galvanizin g Inspection Report
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C. Final Inspection & Testing Components/ Operation & Description of Test FINAL INSPECTION & TESTING (Inspection Engineer to Check/ensure compliance to notes/General Requirements given on Page (30, 31 & 32) of MQP. MECHANICAL PROPERTIES (i) UTS Test (ii) Yield Stress Test (iii) Percentage Elongation Test (iv) Bend Test (v) Min. Charpy V notch Impact test Any3 Coupons (representati ve sample ) from the offer lot. Please refer Sl No 5 under Notes in Page No 2 Quantum of Check / Sampling with basis Fo rm at of Re co rd Applicable Codes
Sr. No.
Type of Check
Reference document for Testing
Acceptance Norms
Remark s
6
4.0
W / Z
(a)
CIP Please Refer Cl. No. 1.1.1(a), 1.1.1(b) & 1.1.1(c), 1A.1.1(a), 1A. 1.1(b), Please refer Cl. No. 1.1.1(d), 1A.1.1(d) Please Refer Cl. No. 1.1.1(e) & 1A.1.1 (e) Please Refer Cl. No. 1.1.1(a), 1.1.1(b) & 1.1.1(c), 1A.1.1(a), 1A. 1.1(b), 1A.1.1(c) Please refer Cl. No. 1.1.1(d), 1A.1.1(d) Please Refer Cl. No. 1.1.1(e) & 1A.1.1 (e) CIP
CIP
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39

C. Final Inspection & Testing Sr. No. Components/ Operation & Description of Test GALVANIZING TESTS (i) (ii) (iii) Thickness of Zinc Coating Weight of Zinc Coating Adhension Test of Zinc Coating Any3 Coupons (represen tative sample ) from the offer lot. Please refer Sl No 5 under Notes in Page No 2 Please refer Cl. 3.3 (b) to 3.3 (e) CIP Type of Check Quantum of Check / Samplin g with Reference document for Testing Acceptanc e Norms Format of Record Applicable Codes
1 2 3 4 5 6
Remarks
(b)
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40

(c)
VISUAL & DIMENSIONAL INSPECTION For Fabrication (as per approved dwg.) & Galvanizing
1 sample per mark no per offered lot
Please refer Cl. No 2(a) to 2(j) & Cl. No. 3.3 (a)
Surface to be free from defects like bare/ black spots, (except when small and suitable for patching) heavy ash & flux inclusions, lumps, pimples, runs, sharp edges, spikes, dross etc. Surface shall be smooth so that interconnecti ng partswill fit properly and parts may be readily assembled.
CIP for 10 random samples per lot
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Power Grid Specification --means Power Grid Technical Specification, Approved Drawing, Approved Technical data sheet and LOA provisions applicable for the specific contract
Shall ---Shall is an absolute requirement which shall be followed strictly in order to conform with the standard. Should ----Should is a recommendation. Alternative solutions having the same functionality and quality are acceptable. May --- May indicates a course of action that is permissible within the limits of the standard (permission). Can -- Can-requirements are conditional and indicate a possibility open to the user of the standard. NDT -Non Destructive Testing
Page of 42
42

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MANUFACTURING QUALITY PLAN

INSTRUCTIONS FOR CODE ALLOCATION

Code 1 A B C D E F Code 3 P Q R S T U V Code 5 E N

Review of Test Reports/Certificates

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NOTES/GENERAL REQUIREMENTS TO BE CHECKED/ENSURED

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(22) (23) (24)

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Test For Ultimate Tensile Strengt h

2 - Samples per Cast/Heat *

As per IS 2062 Table-2

Reference document for Testing IS - 1608

Acceptance Norms As per IS 2062 Table-2

CIP at Rerollers works

MANUFACTURING QUALITY PLAN

Percentage Elongation Test

2 - Samples per Cast/Heat. *

As per IS 2062 Table -2

CIP at Rerollers works

Referenc e documen t for Testing

Acceptance Norms As per IS 2062 Table-2

Y CIP at Rerollers works

MANUFACTURING QUALITY PLAN

Reference document for Testing IS 1757 for Impact

Acceptance Norms As per IS 2062 Table-2

Remarks Y CIP at Rerollers works

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Testing IS 2062/ Power Grid Specn./ As per IS 2062 Table-1

CIP at Rerollers works

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IS 2062/ Power Grid specn.

(Removal of minor defects as per IS 2062 Clause 7.2

CIP at Rerollers works

CIP at Rerollers works

Tolerances For Leg Length Of

(i) Up to 45 mm Leg Length 1.5 mm

CIP at Rerollers works

MANUFACTURING QUALITY PLAN

Out of Square ness

IS 1852 Power Grid Specn.

CIP at Rerollers works

MANUFACTURING QUALITY PLAN

A. Raw Material Inspection (Indigenous) Sr. No.

Components/ Operation & Description of Test Camber

Type of Check Measurement

Quantum of Check / Sampling with basis 5 samples/section

Referenc e documen t for Testing IS 1852

Remarks CIP at Rerollers works

Weight Tolerance For Angle Sections

Unit Weight Test

One Sample for 20 MT / section or part thereof.

CIP at Rerollers works

Weight Tolerances For Plates Thickness Tolerance For Plates

Unit Weight Test

One Sample for 20 MT / section or part thereof. 5 samples/section