QAP-for-ACSR-Conductor.pdf

8/14/2019 QAP-for-ACSR-Conductor.pdf

1/10

Vendor's Code

1 2 3 4 5 6

A.1.0 E

A J S W/Y - N

D L V W/Y - N

2.0 E

A J S W/Y - N

D L V W/Y - N

2.2 Dimensional 1 sample from each coil IS 5484 Format No

QCI/F/02/01

A J S W/Y - N

2.3 Mechanical 1 sample from each coil IS 5484 Format No

QCI/F/02/01

A J S W/Y - N

2.4 Mechanical 1 sample from each coil IS 5484 Format No

QCI/F/02/01

A J S W/Y - N

2.5 Electrical 1 sample from each coil IS 5484 Format No

QCI/F/02/01

A J S W/Y - N

2.6 Visual 100% on each coil IS 5484 Format No

QCI/F/02/01

A J S W/Y - N

Applicable Codes Remarks

Spectro Test

Report

DIAMOND POWER INFRASTRUCTURE

LIMITED. PH-II, VILL-

VADADALA,TALUKA-SAVLI,DIST-

VADODARA.

Rev. No. Valid upto : 3 YEARS.

Date : Page

No

Type of Check Quantum of Check/ Sampling

with basis

Reference document for

Testing

Acceptance Norms

MANUFACTURING QUALITY PLAN

Manufacturers Details

(Name, Works, Address etc.)

Customer Item : Aluminium Conductors Steel

Reinforced(Multistrand ACSR)

Q.P.No. Valid From :

Format of Record

Section: RAW MATERIAL INSPECTIONAluminium Ingot

1.1 Chemical Composition Spectro

Analysis

1 sample per heat of 8 MT or

part thereof

IS : 5484/1997 & IS 4026

- 1987 (GR-II)

Sr. No. Components/ Operations

& Description of Test

Si 0.13 % (max)

In absence of Manufacturers

T.C's and/or proper

co-relation, one sample per lot

of 100 MT or part thereof shall

be tested at third party

recognized laboratory.

Fe 0.30 % (Max)

Cu 0.04 % (max)

Ti+Va 0.02 % (max)

Mn 0.01 % (Max)

Zr 0.01 % (Max)

Cr 0.01 % (Max)

AL 99.5 % (min)

Spectro Test

ReportSi 0.13 % (max)


T.C's and/or proper

co-relation, one sample per lot

of 100 MT or part thereof shall

be tested at third party

recognized laboratory.

Fe 0.30 % (Max)

Cu 0.04 % (max)

Ti+Va 0.02 % (max)

Mn 0.01 % (Max)

Zr 0.01 % (Max)

IS 4026 - 1987 (GR-II)

Min. 8 % at 250 mm gauge length

Aluminium Wire Rod

(Continuously Castled)

2.1 Chemical Composition Spectro

Analysis

1 sample per heat of 8 MT or

part thereof

AL 99.5 % (min)

Resistivity and

ConductivityMaximum resistivity 0.028264 ohm mm

2/ metre at

200 C. Min. Coductivity 61.0 % of IACS.

Cleanliness and surface

smoothness

The wire rod shall be free from

pipes,laps,cracks,twists,seams & other injurious

defects within the limits of good comercial practices.

Cr 0.01 % (Max)Diameter Min. 9.00 mm, Nom. 9.50mm

Max. 10.00 mm

Tensile Strength Min. 103 to 138 N/mm2

Elongation at break

51FO40

51FO40

71FO40

FO

FO


2/10

Vendor's Code

1 2 3 4 5 6

3.0 E

3 sample per heat. Suppliers TC B K P W/Y - N


T.C's and/or proper

co-relation . One sample per

lot of 50 MT or part thereof

shall be tested at TPL.

Third party Lab

report

D L V W/Y - N

3.2 Physical Each Drumh IEC 888 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

3.2 Dimensional 20 % Coils per lot IEC 888 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

3.3 Mechanical 20 % Coils per lot IEC 888/1987 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

3.4 Mechanical 20 % Coils per lot IS 398 (Part V): 1992 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N


QCI/F/02/02

A/B J/K S/P W/Y - N


QCI/F/02/02

A/B J/K S/P W/Y - N


QCI/F/02/02

A/B J/K S/P W/Y - N

3.8 Chemical 20 % Coils per lot As per Tender Specs Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

3.9 Chemical 20 % Coils per lot IEC 888/1987 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

3.10 Visual 100 % Coils per lot IEC 888/1987 Suppliers TC A/B J/K S/P W/Y - N

3.11 Visual 100 % Coils per lot IEC 888/1987 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

3.12 Chemical 1 sample for every lot of 50 MT

or part thereof

IEC 888/1987 Suppliers TC D K V W/Y - N Record of

supplier Tc

also to be

maintained

Check for Purity of Zinc As per approved GTP

Adhesion Test The Zinc coating shall remain adherent to the steel

wire when wound 8 turns on a mandrel having

diameter equal to 4 x The diameter of wire

Preece Test (Dip Test) Shall pass 1 Mtx3 dips and 1/2 Mt x 1 dip without

any red deposit of copper upon base metal

Mass of Zinc coating As per approved GTP

Elongation at break Min. 4.0 % at 250 mm gauge length, Note: The

sample has to pass either the torsion test or

elongation test, that is, if the conductor is passing

any of the two tests, the sample should be

considered as passing.

Surface finish of GS Wire

coils

The Wires shall be smooth, uniform and free from

imperfections such as spills, splits, scale inclusion,

die marks, scratches, abrasion, blow holes etc.

Check for Joints There shall be NO JOINT

Torsion Test Min. 18 Twist on a gauge length of 100 x diameter of

wire

Wrapping Test Wrap-8,Unwrap-6,Wrap-6 On a mendrel having

diameter equal to 4 x diameter of wire.

The wire shall not break.

Lay Ratio As per approved GTP

Diameter As per approved GTP

Tensile Strength/

Breaking Load

As per approved GTP

Format of Record Applicable Codes Remarks

High Tensile

Galvanized Steel Core




with basis


Testing

3.1 Chemical Analysis Chemical

IEC 888

As per approved GTP

Acceptance Norms




VADODARA.


Date : Page

No







51FO50

51FO50

71FO50

FO

FO

51FO40

51FO40

71FO40

FO

FO


3/10

Vendor's Code

1 2 3 4 5 6

4.0 E

3 sample per heat. Suppliers TC B K P W/Y - NIn absence of Manufacturers

T.C's and/or proper

co-relation . One sample per

lot of 50 MT or part thereof

shall be tested at TPL.

Third party Lab

report

D L V W/Y - N

4.2 Dimensional 20 % Coils per lot IEC 888 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N


QCI/F/02/02

A/B J/K S/P W/Y - N

4.4 Mechanical 20 % Coils per lot IS 398 (Part V): 1992 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

4.5 Mechanical 20 % Coils per lot IEC 888/1987

Clause 10.3.b

Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N


QCI/F/02/02

A/B J/K S/P W/Y - N


QCI/F/02/02

A/B J/K S/P W/Y - N

4.8 Chemical 20 % Coils per lot As per Spec. Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

4.9 Chemical 20 % Coils per lot IEC 888/1987 Suppliers TC and

QCI/F/02/02

A/B J/K S/P W/Y - N

4.10 Visual 100 % Coils per lot IEC 888/1987 Suppliers TC A/B J/K S/P W/Y - N

Preece Test (Dip Test) Shall pass 1 Mtx3 dips and 1/2 Mt x 1 dip without

any red deposit of copper upon base metal


Surface finish of GS Wire

coils

The Wires shall be smooth, uniform and free from

imperfections such as spills, splits, scale inclusion,

die marks, scratches, abrasion, blow holes etc.

Adhesion Test The Zinc coating shall remain adherent to the steel



Diameter As per approved GTP

Tensile Strength/

Breaking Load

As per approved GTP






Torsion Test Min. 18 Twist on a gauge length of 100 x diameter of

wire


diameter equal to 4 x diameter of wire.

The wire shall not break.

Format of Record Applicable Codes Remarks

High Tensile

Galvanized Steel Wire




with basis


Testing


Date : Page

No

4.1 Chemical Analysis ChemicalIEC 888

As per approved GTP

Acceptance Norms










VADODARA.

51FO50

51FO50

71FO50

FO

FO

51FO40

51FO40

71FO40

FO

FO


4/10


5/10

Vendor's Code

1 2 3 4 5 6

3.0

3.1 Measurement

and Visual

At lthe beginning of each set-

up

IEC 1089/1991 QCI/F/03/04 A J S W/Y - N

3.2 Visual 100 % on each drum IEC 1089/1991 QCI/F/03/04 A J S W/Y - N

3.3 Visual 100 % on each drum IEC 1089/1991 Production log

book

A J S W/Y - N

3.4 Visual 100 % on each drum IEC 1089/1991 QCI/F/03/04 A J S W/Y - N

4.0

4.1 Physical At lthe beginning of each set-

up

IEC 1089/1991 QCI/F/03/04 A J S W/Y - N

4.2 Visual 100 % on each drum IEC 1089/1991 QCI/F/03/04 &

PRODUCTION LOG

SHEET

A J S W/Y - N

4.3 Visual 100% IEC 1089/1991 QCI/F/03/04 A J S W/Y - N

4.4 Visual 100% As per Spec. QCI/F/03/04 A J S W/Y - N

Lay Ratio/ Direction &

Compactness

A s per approved GTP

Check for Joints There shall be NO JOINT in on the outermost layer.

Joints are allowed in inner layers but no two such

joints shall be less than 15 meters apart in

completed conductor.

Surface smoothness of

Strands and stranded

conductor

The finished conductor shall be smooth, compact,

uniform and free from all imperfections including

kinks (protrusion of wires), wires cross over, over

riding, looseness (wire being dislocated by

finger/hand pressure and or unusual bangle noise on

tapping), Material inclusion such as

spills,splits,scale,inclusion,die

marks,scratches,abrasion,blow holes etc.The

finished conductor shall be smooth and good

workmanship.

Surface cleanliness Medium grade Kraft/crepe paper/ polythene sheet

shall be used in between the layers of conductor.

After reeling the conductor, the exposed surface of

the outermost layer of conductor shall be wrapped

with water proof thick bituminized paper or

polythene sheet to preserve the conductor from

dirt,girt and damage during handling and

transportation.

Pre-forming and post

forming of Steel core

Shall pass all the requirements.

Check for Joints There shall be NO JOINT

Surface smoothness The wire shall be free from defects

Final Conductor Stranding

Acceptance Norms Format of Record


Date : Page

No


Compactness

Min 16, Max 18, LH

Applicable Codes










VADODARA.

Remarks

Steel Stranding




with basis


Testing

51FO80 71FO80 FO FO 51FO50 51FO50 71FO50 FO FO 51FO40 51FO40 71FO40 FO FO


6/10

Vendor's Code

1 2 3 4 5 6

C.

2.0

2.1 - 20 % of the drums IEC 1089/1991 QCI/F/04/03/C A J S W/Z - N

2.2 - 100 % of the drums IEC 1089/1991 QCI/F/04/03/C A J S W/Z - N

3.0

3.1 Physical One sample from every 10

Drums or part thereof

IEC 1089/1991 QCI/F/04/03/C A J U W/Z - Y CIP

4.0

4.1 Dimensional One sample from every 10


IEC 889/1987 QCI/F/04/03/C A J U W/Z - Y

4.2 Mechanical One sample from every 10


IEC 889/1987 QCI/F/04/03/C A J U W/Z - Y

4.3 Electrical One sample from every 10Drums or part thereof

IEC 889/1987 QCI/F/04/03/C A J U W/Z - Y



IEC 889/1987 QCI/F/04/03/C A J U W/Z - Y

Acceptance Tests on Aluminium strands of Finished Conductor.

As per approved GTP QCI/F/04/03/C A J U

CIP

Wrapping Test Wrap-8, Unwrap-6 and wrap 6 turns on the wire

itself. The wire shall not crack or break.

W/Z - Y CIP4.5 UTS test on welded

joints of Aluminium

strands by cold pressure

butt welding machine

Me ch an ica l 5 sp ec im en ag ain st ea ch lot As pe r S pe cs

CIP

Breaking Load/ Tensile

strength

As per approved GTP

Resistance As per approved GTP


Compactness

As per approved GTP

Diameter of Aluminium

strands

As per approved GTP

Acceptance Tests of Finished Conductor.

Routine Test on

Finished Conductor

All acceptance tests as

per clause no. 3.0, 4.1 TO

4.4 and 5.0 ,

Shall pass all the requirements.

Check for Joints,Surface Shall pass all the requirements.

Section: FINAL TESTING




with basis


Testing

Date : Page

No

Acceptance Norms Format of Record Applicable Codes Remarks









VADODARA.

POWERGRID Rev. No. Valid upto : 3 YEARS.


51FO01 51FO01 71FO01 FO FO 51FO50 51FO50 71FO50 FO FO 51FO40 51FO40 71FO40 FO FO


7/10

Vendor's Code

1 2 3 4 5 6

5.0



IEC 888 QCI/F/04/03/C A J U W/Z - Y



IEC 888/1987 QCI/F/04/03/C A J U W/Z - Y



IS 398 (Part 2): 1996 QCI/F/04/03/C A J U W/Z - Y



IEC 888/1987 QCI/F/04/03/C A J U W/Z - Y



IEC 888/1987 QCI/F/04/03/C A J U W/Z - Y



IEC 888/1987 QCI/F/04/03/C A J U W/Z -

5.7 Chemical One sample from every 10


As per Tender Spec. QCI/F/04/03/C A J U W/Z -

5.8 Chemical One sample from every 10

Drums

IEC 888/1987 QCI/F/04/03/C A J U W/Z - Y

6.0

6.1 Visual &

Measurement

One sample from every 10


QCI/F/04/03/C A J U W/Z - Y CIP

CIP

Length measurement

Check for joints, surface

finish and length

measurement by

rewinding

No scale on the surface and the surface shall be free

from any imperfections. No joint on the outermost

layer. The Conductor length should be as per the

approved drum drawing /Technical specification and

Offered packing list.


The Zinc coating shall remain adherent to the steel



Diameter(HTGS WIRES) As per approved GTP

Y

Preece Test (Dip Test) As per approved GTP

Torsion Test As per approved GTP


diameter equal to 4 x diameter of wire.Adhesion Test

CIP

Tensile Strength/

Breaking Load

As per approved GTP







Acceptance Tests on Galvanised Steel strands of Finished Conductor.





VADODARA.


Date : Page

No




with basis


Testing







8/10

Vendor's Code

1 2 3 4 5 6

7.0



IS : 1778 QCI/F/02/04 A J U Y - Y CIP



IS 1778 Inspn. Report A J U Y - Y CIP

7.3 Chemical One sample per batch of paper - Independent Lab.

Report

D L V Z - N

7.4 Visual 100 % Drums IS : 1778 Inspn. Report A J U Y - Y CIP

Chemical Test on Packing

paper

Chloride - 0.05 % max., Sulphate-

0.25 % max., Copper - 0.01 %

Max., pH- 5.5 to 7.5

Acceptance Norms Format of Record Applicable Codes

Visual check of wooden

drums

The inner cheek of the flanges & drum barrels

surface shall be painted with Bitumen based paint.

Before reeling, card board or double corrugated or

Thick bituminized water proof bamboo paper shall

be secured to the drum barrel and inside of the

flanges of the drum by means of suitable adhesive

material.After reeling the conductor the exposed

surface of the outer layer of conductor shall be

wrapped with waterproof thick bituminized bamboo

paper or polyethylene sheet to preserve the

conductor from dirt, grit and damage during

transport and handling

Date : Page

No

Dimensional check of

wooden drums

As per Tender Specification .

Barrel Batten Test Barrel Baten strength Min. 300 Kgf.









VADODARA.


Remarks

Wooden Drums and




with basis


Testing


51FO31 51FO31 71FO31 FO FO4 51FO41 51FO41 71FO41 FO FO 51FO40 51FO40 71FO40 FO FO


9/10

Vendor's Code

1 2 3 4 5 6

8.0

8.1 Visual 100% As per Tender Specs Inspn. Report A J U Y - Y CIP

8.2 Visual 100% As per Tender Specs Joint inspection

report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP

8.10 Visual 100% As per Tender Specs Joint inspectionreport

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP

Size and Code Name of

Conductor

Net weight of conductor

in the Drum

As per Tender Specs

Length of Conductor As per Tender Specs

Gross weight of drum

after Lagging

As per Tender Specs

Tare weight withoutlagging

As per Tender Specs

As per Tender Specs

Arrow Marking for rolling

the conductor drum

As per Tender Specs

Application of water

proof paper

As per Tender Specs

Distance between

outermost layer and

inner surface of

protective laggings

( Min - 75mm )

As per Tender Specs

No. of turns in outer

most layer

As per Tender Specs

Contract/ Award Letter

no.

As per Tender Specs

Manufacturer's Name

and Address

As per Tender Specs

Drum No. As per Tender Specs

Packing, Marking and

Dispatch




with basis


Testing


Date : Page

No











VADODARA.

4 51FO41 51FO41 71FO41 FO FO 51FO40 51FO40 71FO40 FO FO


10/10

Vendor's Code

1 2 3 4 5 6


report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP


report

A J U Y - Y CIP

8.17 Visual 100% As per Tender Specs Joint inspectionreport

A J U Y - Y CIP

9.0

9.1 Physical 20% Drums received As per Tender Specs - - - U Z N N

9.2 Physical 100% As per Packing List - - - U Z N N

10.0

Visual 100% As per Tender Specs - - - U Z N N

Verification of No.of

Turns at outer layer and

its depth and lead

sealing by Powergrid.

As per Tender Specs

Inspection at Site

during stringing

Visual Examination for

surface

No surface defect/ damage

Name and address ofconsignee

As per Tender Specs

Inspection at Site on

Receipt

Length measurement by

Weighment of Drums

received.

As per Tender Specs

Tack welding on Nuts on

the barrel and Hub

Plates.

As per Tender Specs

Marking of CIP/MICC No. As per Tender Specs

Acceptance Norms Format of Record

Page

No

Position of conductor

ends

As per Tender Specs

Applicable Codes Remarks

A) Sealing of conductor

ends with heat

shrinkable sleeves and

signature of Inspecting

official at outer end.

B) Lead sealing with plierand identification no. at

both ends.

C) The ends shall be

secured with the drum

with the help of 'U'

clamps after covering the

conductor below clamps

with PVC adhesive tape

to avoid loosening of

conductor layers during

transit and handling.

As per Tender Specs







VADODARA.


Date :




with basis


Testing




51FO51 51FO51 71FO51 FO FO4 51FO41 51FO41 71FO41 FO FO 51FO40 51FO40 71FO40 FO FO

Documents

QAP-for-ACSR-Conductor.pdf