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QUALITY CONTROL MANUAL

FOR RGGVY WORKS

PROPRIETARY STATEMENT

This QUALITY CONTROL MANUAL FOR RGGVY WORKS is the property of the
Rural Electrification Corporation of India Limited, Core-4, SCOPE Complex Lodhi Road
New Delhi -110 016. Its contents shall not be reproduced either in part or in full without the
written permission of the REC
QUALITY CONTROL
MANUAL
FOR RGGVY WORKS

Section 1.1

APPROVAL STATEMENT

The Quality Control Manual is consists of 34 pages, Annexure-I of 6 pages, Annexure-II of


72 pages II and Annexure-III of 232 pages. The Manual lays the procedure for the
implementation of Quality Control mechanism for RGGVY works along with Formats and
Quality Plans for guidance. This is issued and controlled by the REC Quality Control
Coordinator as per the distribution mechanism placed at Section 1.6.

Recommended by

Dir. (Project), POWERGRID


CEO (NESC)
Sh Jogendra Singh, GM (QC-REC)
Sh. Atul trivedi, AGM (MOP-PGCIL)

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Section 1.2
TABLE OF CONTENTS
Section Description No. of Pages
No.
1.0 Proprietary Statement 01
1.1 Approval Statement 01
1.2 Table of Contents 02
1.3 Amendment Procedure 01
1.4 Amendment Record 01
1.5 List of Abbreviations 01
1.6 Distribution System 01
2.0 RGGVY Scheme Description 01
3.0 Scope & Applicability 01
4.0 Three Tier Quality Control Mechanism
4.1 Overview 03
4.4 Quality Control hierarchical Structure 01
5.0 Quality Control Methodology- Tier-I 07
6.0 Quality Control Methodology- Tier-II 02
7.0 Quality Control Methodology- Tier-III 01
8.0 Procedure of implementation of Three Tier QC Mechanism 02
9.0 INFORMATION FLOW PROCEDURE 01
10.0 Dispute Resolution 01
11.0 Guidelines for Quality Control during construction 03
Appendices
Appendix –I List of Equipment/material which shall have MQP 01
Tables
Table-I List of applicable REC standard specifications 02
TOTAL PAGES 34

Annexure-I Format for inspections


(i) FORMAT-A Contractor’s format for Field Quality for Villages 02
(ii) FORMAT-B Contractor’s format for Field Quality for Substations 01
(iii) FORMAT-C Contractor’s format for BOQ Verification for villages 01
(iv) FORMAT-D Inspection Format for TPIA/RQM/NQM 01
(v) FORMAT-E Format for Monthly Progress Report 01
TOTAL PAGES 06

Annexure-II Standard Field Quality Plan (Only for guiding purpose)


(1) Standard Field Quality Plan for Conductor, Earth wire & AB cable 08
(2) Standard Field Quality Plan for Cable 04
(3) Standard Field Quality Plan for Power Transformer 04
(4) Standard Field Quality Plan for Civil Works 04
(5) Standard Field Quality Plan for PSC POLES (11KV& LT), 07
Pole earthing and guy erection
(6) Standard Field Quality Plan for Pole Accessories 04
(7) Standard Field Quality Plan for ISO/AB SWITCH/ DO FUSE 03
(8) Standard Field Quality Plan for LA 02
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(9) Standard Field Quality Plan for Painting 01


(10) Standard Field Quality Plan for BPL connection 03
(11) Standard Field Quality Plan for Vacuum Circuit Breaker 03
(12) Standard Field Quality Plan for DT Structure and Components 18
(13) Standard Field Quality Plan for CT/PT 03
(14) Standard Field Quality Plan for Control & Relay Panel 03
(15) Standard Field Quality Plan for DC System 05
TOTAL PAGES 72

Annexure-III Standard Manufacturing Quality Plan as adopted by M/S


NESC/POWERGRID (Only for guiding purpose)

(i) Standard Manufacturing Quality Plan for 1.1kV LT XLPE AB Cable 06


(ii) Standard Manufacturing Quality Plan for 11kV XLPE Cable 06
(iii) Standard Manufacturing Quality Plan for 1.1kV LT PVC Cable 03
(iv) Standard Manufacturing Quality Plan for Three phase energy meters 07
(v) Standard Manufacturing Quality Plan for Single phase energy meters 06
(vi) Standard Manufacturing Quality Plan for 11kV AB Switch 11
(vii) Standard Manufacturing Quality Plan for 33 & 11kV VCB 10
(viii) Standard Manufacturing Quality Plan for 33kV CT 12
(ix) Standard Manufacturing Quality Plan for 33kV PT 10
(x) Standard Manufacturing Quality Plan for 33kV BPI 08
(xi) Standard Manufacturing Quality Plan for 11kV Disc Insulator 11
(xii) Standard Manufacturing Quality Plan for Pin Insulator upto 33kV 09
(xiii) Standard Manufacturing Quality Plan for Guy Strain Insulator 07
(xiv) Standard Manufacturing Quality Plan for Shackle Insulator 07
(xv) Standard Manufacturing Quality Plan for All Aluminium Conductors 09
(xvi) Standard Manufacturing Quality Plan for All Aluminium Alloy Conductors 10
(xvii) Standard Manufacturing Quality Plan for ACSR Conductors 06
(xviii) Standard Manufacturing Quality Plan for 11kV DO Fuse set 09
(xix) Standard Manufacturing Quality Plan for 11kV HG Fuse set 08
(xx) Standard Manufacturing Quality Plan for PSCC Poles 04
(xxi) Standard Manufacturing Quality Plan for LT Distribution BOX for DT 04
(xxii) Standard Manufacturing Quality Plan for Pole top Distribution BOX 04
(xxiii) Standard Manufacturing Quality Plan for Distribution transformers 51
(xxiv) Standard Manufacturing Quality Plan for Battery Chargers 08
(xxv) Standard Manufacturing Quality Plan for Ni-Cd Battery 06
TOTAL PAGES 232
GRAND TOTAL (including blank pages) 349

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Section 1.3

AMENDMENT PROCEDURE

1.3.1 All amendments to this Manual are approved by CMD.


1.3.2 The amendment record in Section 1.4 is duly filled in and signed by the controlled
copy holder.
1.3.3 After approval, the revised documents will be issued by the REC Quality Control
Coordinator (RQCC) to all controlled copyholders.
1.3.5 It is the responsibility of the controlled copyholders to destroy the superseded
versions of documents and replace the same with new version so as to ensure against
unintended use of obsolete documents.
1.3.6 It is also the responsibility of the controlled copyholders to fill in the Amendment
Records in Section 1.4 of their respective documents after taking action as per 1.3.5
above.
1.3.7 The revision will come into effect only after it is formally issued by RQCC.

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Section 1.4
AMENDMENT RECORD

Sl. No. Clause No. Page No. New Issue No./ Date

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Section 1.5
LIST OF ABBREVIATIONS/DEFINITIONS

REC Rural Electrification Corporation


RGGVY Rajiv Gandhi Gramin Vidutikaran Yojna
BPL Below Poverty Line
QCM Quality Control Mechanism
PQCC Project Quality Control Coordinator
RQCC REC Quality Control Coordinator
RQM REC Quality Monitor
NQM National Quality Monitor
MQP Manufacturing Quality Plan
FQP Field Quality Plan
BOQ Bill of Quantity
CPSU Central Public Sector Undertaking
QE Quality Engineer of Turnkey Contractor
MOP Ministry of Power
CPRI Central Power Research Institute
NABL National Accreditation Board of Laboratories
ERTL Electronics Regional Testing Laboratory
ERDA ELECTRICAL RESEARCH AND DEVELOPMENT ASSOCIATION
PIA Project Implementing Agency (Utility/CPSU)
TPIA Third Party Inspection Agency of PIA
Village Village means village with all associated Hamlets/Mauza/Dhani/Thanda etc.

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Section 1.6
DISTRIBUTION MECHANISM

This manual is a controlled document and copies are maintained by the RQCC. The holders
of controlled copy are responsible for the upkeep. Controlled copies are identified by specific
copy number and stamped as: CONTROLLED

Copy No. Designation of the Personnel


1. RQCC
2. GM (RGGVY)
3. ED (RGGVY)

Note: This Manual may be borrowed or reviewed by other concerned personnel and these
may not always reside permanently with the said holder. The manual is available on the
website of REC (www.recindia.nic.in). Uncontrolled copies of the Manual may be given to
the other personnel including customers. Hard copies/Photocopies of the Controlled copies
are not controlled. The manual is put on the website by IT Division on receipt of
authenticated copy from RQCC.

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Section 2.0 RGGVY SCHEME DESCRIPTION


(For information only – Not subject to assessment.)

Rajiv Gandhi Grameen Vidyutikaran Yojana- summary


1. Scheme in the XI- Plan for attaining the goal of providing access to electricity to all
households, electrification of about 1.15 lakh unelectrified villages and electricity
connections to 2.34 crore BPL households by 2009. The approval has been accorded
for capital subsidy of Rs. 28000 crore during the Eleventh Plan period, at this stage.
This is in continuation of Office Memorandum No. 44/19/2004-D (RE) dated 18th
March, 2005.

2. Rural Electrification Corporation (REC) would be the nodal agency for the scheme.

3. Ninety per cent capital subsidy would be provided towards overall cost of the projects
under the scheme excluding the amount of state or local taxes, which will be borne by
the concerned State/State utility. 10% of the project cost would be contributed by states
through own resources/loan from financial institution.

4. The states will finalise their Rural Electrification plans in consultation with Ministry of
Power and notify the same within six months. Rural Electrification plan will be
roadmap for generation, transmission and distribution of electricity in the state which
will ensure the achievements of objectives of the scheme.

5. For projects to be eligible for capital subsidy under the scheme, prior commitment of
the States would also be obtained before sanction of projects under the scheme for:
i) Guarantee by State Government for a minimum daily supply of 6-8 hours of
electricity in the RGGVY network with the assurance of meeting any deficit in
this context by supplying electricity at subsidized tariff as required under the
Electricity Act 2003.
ii) Deployment of franchisees for the management of rural distribution in projects
financed under the scheme and to undertake steps necessary to operationalise the
scheme.

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Section 3.0 Scope and Applicability

3.1 This manual describes the Quality Control Mechanism to be adopted for RGGVY
Scheme in the XI-Plan by project implementing agencies, turnkey contractors, third
party inspection agencies, REC Quality Control Coordinators & National Quality
Monitors.

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Section : 4.0 THREE TIER QUALITY CONTROL MECHANISM

4.1 OVERVIEW OF METHODOLOGY


4.1.1 In order to ensure proper Quality of materials as well as in installations in
RGGVY, three tier Quality Control Mechanism (QCM) has been developed. This
Quality Control Manual established three tier QCM. The basic framework of the
three tier QCM is stipulated below:
(i) TIER-I
The Project implementing agency (PIA) shall be responsible for first tier
quality control. PIA shall designate a senior level officer as Project
Implementing Agency’s Quality Control Coordinator (PQCC). PIA shall
prepare a detailed Quality Assurance Program, which should ensure quality
checks as below:
a) TURNKEY CONTRACTOR
™ Inspections of all material as per MQP/Drawings/Technical
Specifications
™ All villages to be inspected as per FQP
™ All 33/11 kV sub stations for quality of material as per
MQP/Drawings/Technical Specifications and works in the field as
per FQP.
™ 100% verification of BPL connections.
b) PROJECT IMPLEMENTING AGENCY
™ Inspections of material as stipulated in MQP for all
materials/equipment for which MQP requirement is indicated in
Appendix-I. For other items, inspections/testing/ witnessing of
acceptance tests shall be as per Drawings/Technical Specifications.
™ All villages to be inspected as per FQP
™ All 33/11 kV sub stations for quality of material as per
MQP/Drawings/Technical Specifications and works in the field as
per FQP.
™ 100% verification of BPL connections.
c) THIRD PARTY INSPCTION AGENCY of PIA (TPIA)
™ 10% randomly selected inspections as per MQP for Distribution
transformers, conductors, energy meters, poles and insulators at
pre-shipment stage at vendors’ works/testing labs.
™ 50 % Villages on random sampling basis including 100%
verification of BPL connections in 10% of 50% of villages
inspected i.e. 5% villages and in each of the remaining villages
inspected i.e. 45% villages, at least 5 BPL connections shall be
verified randomly selected from the list of connections
provided till the date of inspection.

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™ 33/11 kV sub stations for quality of works in the field on random


sampling basis
¾ 100 % new sub stations
¾ 50 % augmentation of sub stations

Detailed responsibilities of first tier quality control are stipulated in


Section-5.

(ii) TIER-II
Rural Electrification Corporation (REC) shall be responsible for second
tier Quality Control Mechanism. REC shall designate a dedicated senior
level officer as REC Quality Control Coordinator (RQCC) to coordinate
and oversee the implementation of Quality Control Manual for RGGVY
works.

For Second Tier Quality Control, REC shall appoint REC Quality Monitors
(RQM) for RGGVY projects. The second tier Quality control shall ensure
quality checks as below :

1. At least one inspection of major material like poles, transformers,


Conductors and energy meters at pre-shipment stage at vendors’
works on random sampling basis as per MQP.
2. 10 % villages on random sampling basis as per FQP.
3. 33/11 kV sub stations for quality of works in the field covering :
4. At least one new sub station.
5. At least one augmentation of sub station.
6. 100% verification of BPL connections in 25% of 10% villages
inspected and at least 5 randomly selected BPL connections in other
inspected villages i.e. 75% of 10% villages.
7. VIP references/complaints referred by REC relating to quality of
works.

The responsibility and methodology of second tier Quality Control is


detailed in Section-6.

(iii) TIER-III
MOP shall be responsible for third tier Quality Control Mechanism. For
this, independent evaluators shall be engaged, who will be designated as
National Quality Monitors (NQM). Third tier quality control shall ensure
quality checks as below:
1. 1 % Villages on random sampling basis as per FQP
2. 33/11 kV sub stations for quality of works in the field covering :
• At least one new sub station
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• At least one augmentation of sub station


3. 100% BPL service connection verification in 50% of villages
inspected i.e 0.5 % villages and in the remaining 0.5% villages at
least 5 BPL connections shall be verified on randomly selected from
the list of connections provided till the date of inspection.
4. Review of test records for major material like transformers, poles and
conductors etc. on random sampling basis.
5. Any other study of RGGVY assigned by MOP.

4.2 In this manual, Village means village with all associated hamlets/
Mauza/Dhani/Thanda etc.

4.3 Linking of Release of funds with Quality Control :

4.3.1 Installments to PIA’s shall be regulated based on the following methodology :

4.3.1.1 2nd Installment - After confirmation from PQCC that all MQP & FQP have been
agreed as per Quality Manual.

4.3.1.2 3rd Installment – After completion of infrastructure in at least 10% village with
satisfactory report by TPIA and at least 20% BPL connections in electrified
villages.

4.3.1.3 4th Installment – After completion of 100% villages and Sub Stations with
satisfactory report of PQCC/RQCC/NQM.

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4.4 QUALITY CONTROL STRUCTURE

MOP

TIER-III
NQM (National
Quality Monitor)

TIER-II
RQCC
RQM (REC Quality
(REC QUALITY Control
MONITORS) Coordinator)

TIER-I
PQCC
(PIA Quality Control
Coordinator)

TPIA
THIRD PARTY
MONITORING
AGENCY

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Section : 5.0 Tier-I QUALITY CONTROL METHODOLOGY

5.1 Tier – I quality control involves parallel quality control checks by the turnkey contractor,
PIA & Independent Third party inspection agency (TPIA).

5.2 The Project Implementing agency shall be responsible for quality checks through turnkey
contractor & independent third party inspection agency. PIA Quality Control Coordinator
(PQCC) nominated by PIA, shall be responsible for ensuring implementation of all
quality control checks under the first tier. PQCC shall be the nodal officer for any
information regarding inspection, testing and quality control under first tier.

5.3 PQCC shall ensure inspection of material to be supplied by various sub-vendors, at their
works, in line with Manufacturing Quality Plans (MQP) as finalized & agreed by PIA
with turnkey contractor. He shall inform the third party inspection agency & REC quality
coordinator (RQCC) of all the programs of testing of equipment at sub-vendors works so
that RQCC can also depute their representatives for witnessing pre-dispatch inspection at
the manufacturer’s works on sample-basis. In exceptional cases, where due to non-
availability of inspector from PIA/TPIA/RQCC, witnessing of testing may be waived by
PIA and inform to RQCC. However, testing shall be carried out in line with
MQP/IS/Specification and report shall be submitted to PQCC for approval.

5.4 Quality in the field shall be controlled in line with the Field quality plans (FQP) to be
finalized & agreed by PIA with turnkey contractor.

5.5 PQCC shall be the custodian of all manufacturing and field-quality plans. He shall ensure
that field-quality plan is available at all project sites, so that PIA/turnkey contractor/TPIA
shall carryout testing and checks as per field quality plan. The site personnel shall
maintain proper records of testing and checks made by them. The same shall be made
available to RQCC & NQM whenever required. The PQCC shall ensure that Quality
Control Manual and all the guidelines are strictly followed.

5.6 Wherever PIA have not formulated manufacturing and field quality plans with the turn-
key contractors/manufacturers, Standard quality plans which are enclosed in this manual
shall be used as guidance and MQP/FQP shall be finalized broadly based on these
standard MQP/FQP.

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5.7 Turnkey contractor’s set up for Quality Assurance and Audit

5.7.1 The turnkey contractor shall be primarily responsible for ensuring the quality
of material supplied & quality of works at site.

5.7.2 He shall submit all MQP and FQP to PQCC for approval and establish a
proper procedure to ensure checks as indicated in MQP & FQP for the
materials indicated in Appendix-I & works.

5.7.3 Turnkey contractor shall designate an experienced & qualified engineer as


Quality Engineer (QE) who shall be responsible for ensuring that all the
quality checks required are carried-out and shall ensure to keep proper records
for quality maintained at site.

5.7.4 Quality Assurance shall be undertaken in the following areas of the project
implementation:-

a) Quality of material/equipment being supplied.

b) Quality of works in the field.

5.7.5 Quality of material/equipment being supplied- For ensuring quality of


material/equipment, the following system/procedure shall be adopted:-

5.7.5.1 A standard manufacturing quality plan shall be agreed with the turnkey
contractor for every equipment/material as listed in Appendix-I which shall
include the process of manufacturing, sourcing of raw-materials, quality
checks of raw-material, stages of manufacturing, testing of final product –
both type tests and routine/acceptance tests.

5.7.5.2 The turnkey contractor shall select the sub-vendors of various equipment
based on a process, which ensures quality material in the project. Sub-vendors
of items listed in Appendix-I shall be approved by PIA.

5.7.5.3 QE shall ensure the presence of their qualified representative during type tests
and routine/acceptance tests, either at manufacturer’s premises or at
independent laboratories.

5.7.5.4 The type tests shall be carried out only at Govt. testing laboratories such as
CPRI, ERTL, ERDA or NABL Accredited Laboratories. Manufacturers may
carry out type tests at their works however in such cases testing shall be
carried out in presence of representative of TPIA or RQCC or PQCC.

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5.7.5.5 All materials shall be tested before dispatch in line with


MQP/Drawings/Technical Specifications.

5.7.6 Assurance of Quality at field- The turnkey contractor shall establish a


procedure for quality checks during execution of the project by finalizing field
quality plans (FQP) with the PIA. The detailed field quality plan shall be
made available and the same shall be explained to all the field engineers &
supervisors of the Turnkey contractor. The field quality plan document shall
clearly describe requirements for various raw materials used like steel, cement
and sand etc.

The Turnkey contractor shall submit quality audit reports, on periodic basis to
the PIA.

Following checks shall be carried out in the field:


™ All villages to be inspected as per FQP
™ All 33/11kV sub-stations for quality of material as per
MQP/Drawings/Technical Specifications and works in the field as per
FQP.
™ 100% verification of BPL connections.

5.8 PIA’s set up for Quality Assurance and Audit

5.8.1 PIA shall also depute its own teams to undertake quality audit for material and
field execution. PIA shall be fully responsible for ensuring the quality of
material supplied & quality of works at site. He shall put in place a proper
procedure to ensure checks as per MQP & FQP.

5.8.2 PIA shall designate an experienced & qualified engineer as Quality Control
Coordinator (PQCC) along with a dedicated team who shall be responsible for
ensuring that all the quality checks are carried-out and shall ensure to keep
proper records for quality maintained at site.

5.8.3 Third-party inspection agency, RQCC and NQM shall be given free access to
all technical records by PIA through PQCC.

5.8.4 Quality Assurance shall be undertaken in the following areas of the project
implementation:-

a) Quality of material/equipment being supplied.

b) Quality of works in the field.

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5.8.5 Quality of material/equipment being supplied- For ensuring quality of


material/equipment, the following system/procedure shall be adopted:-

5.8.5.1 A standard manufacturing quality plan shall be agreed with the turnkey
contractor for every equipment/material as listed in Appendix-I which shall
include the process of manufacturing, sourcing of raw-materials, quality
checks of raw-material, stages of manufacturing, testing of final product –
both type tests and routine/acceptance tests.

5.8.5.2 The turnkey contractor shall select the sub-vendors of various equipment
based on a process, which ensures quality material in the project. All sub-
vendors shall be approved by PIA.

5.8.5.3 PQCC shall ensure presence of their qualified representative during type tests
and routine/acceptance tests, either at manufacturer’s premises or at
independent laboratories.

5.8.5.4 The type tests shall be carried out only at Govt. testing laboratories such as
CPRI, ERTL, ERDA or NABL Accredited Laboratories. Manufacturers may
carry out type tests at their works however in such cases testing shall be
carried out in presence of representative of TPIA or RQCC or PQCC.

5.8.5.5 All materials shall be tested before dispatch in line with


MQP/Drawings/Technical Specifications.

5.8.6 Assurance of Quality at field- The PIA shall establish a procedure for quality
checks during execution of the project by finalizing field quality plans (FQP)
with the turn-key contractor. The detailed field quality plan shall be made
available and the same shall be explained to all the field engineers &
supervisors of PIA. The field quality document shall clearly describe
requirements for various raw materials used like steel, cement and sand etc.

The PIA shall submit a certificate to RQCC, certifying satisfactory quality


assurance for every project on completion of all quality checks. PIA shall also
forward summary of TPIA reports on field quality and action taken report to
RQCC on monthly basis.

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5.8.6.1 A list of BPL households shall be provided by PIA to REC. Payment for BPL
connections shall be released only after receipt of BPL LIST. BPL connections
shall be verified with respect to this list.

5.8.6.2 Following checks shall be carried out in the field:


• All villages to be inspected as per FQP
• All 33/11 kV sub stations for quality of material as per
MQP/Drawings/Technical Specifications and works in the field as per
FQP.
• 100% verification of BPL connections.

5.8.6.3 Proper records shall be maintained at field office of PIA for all the checks and
tests made by the PIA and TPIA and will be shown to RQM during their
inspection, if asked for.

5.9 Third Party inspection agency (TPIA) shall be engaged by PIA for carrying
out independent quality checks. Their responsibility will be to inspect material
at manufacturers’ works before dispatch and to ensure that the works in the
field are carried-out as per norms and standard engineering practices in line
with the manufacturing and field quality plans. TPIA shall depute their
personnel on receipt of notice from PQCC.

5.9.1 Quality Assurance shall be undertaken in the following areas of the project
implementation:-

c) Quality of material/equipment being supplied.

d) Quality of works in the field.

5.9.2 Quality of material/equipment being supplied.


TPIA shall ensure presence of their qualified representative in 10% randomly
selected inspections as per MQP for Distribution transformers, conductors,
energy meters, poles and insulators at pre-shipment stage at vendors’
works/testing labs.

5.9.3 Assurance of Quality at field- The detailed field quality plan shall be made
available and the same shall be explained to all the field engineers &
supervisors of TPIA.

Quality of works shall be verified with reference to FQP.

Reports of Field Quality checks shall be supported by photographs.

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The TPIA shall submit a report to PQCC, certifying satisfactory quality


assurance for every project on completion of all quality checks.

Following checks shall be carried out in the field:


ƒ 50 % Villages on random sampling basis including 100% verification of
BPL connections in 10% of 50% of villages inspected i.e. 5% villages
and in each of the remaining villages inspected i.e. 45% villages, at least
5 BPL connections shall be verified randomly selected from the list of
connections provided till the date of inspection.

ƒ 33/11 kV sub stations for quality of works in the field on random


sampling basis
¾ 100% New sub stations
¾ 50% Augmentation of sub stations (with min. one S/S)
ƒ BOQ verification

5.9.4 Stages and scope of Inspection:

5.9.4.1 1st Stage- On completion of infrastructure in 10% villages of the entire project
at site. Inspection shall be carried out as per FQP. Sampling shall be as
follows:
(a) 10% randomly selected villages
(b) All districts and all turnkey contractors shall be covered.
(c) Electrified as well as un-electrified villages will be covered.
(d) The sample should include villages covering the entire area in the
district.
(e) At least one New substation.
(f) At least one Augmentation of Substation.
5.9.4.2 2nd Stage- After completion of 90% works in the village, as notified by the
PQCC. Inspection shall be carried out as per FQP. Sampling shall be as
follows:
(a) 50% randomly selected villages as per FQP, including 10% villages
inspected in the 1st stage.
(b) All districts and all turnkey contractors shall be covered.
(c) Electrified as well as un-electrified villages will be covered.
(d) The sample should include villages covering the entire area in the
district.
(e) All New substations.
(f) 50 % Augmentation substations.
(g) 100% verification of BPL connections in 10% of villages inspected i.e.
5% villages and in each of the remaining villages inspected i.e. in 45%

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villages, at least 5 BPL connections shall be verified randomly selected


from the list of connections provided till the date of inspection.

5.9.5 Wherever works carried out are found unsatisfactory, compliance with respect
to rectification shall be submitted by PIA to TPIA and RQCC and the same
may be re-inspected by TPIA, if required. Recurrent adverse reports about
quality of works in any project will entail withholding of release of funds.

5.10 The turn-key contractor shall make necessary arrangements at site for
checking of earth-resistance, conductor size, route-length etc.
5.11 PQCC shall submit a monthly report to RQCC about the progress and quality-
checks carried-out.

Issued by REC Issue No.: 1.2

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Section : 6.0 Tier-II QUALITY CONTROL METHODOLOGY

6.1 REC shall be responsible for tier II quality control. REC shall nominate a
General Manager level executive as REC quality control coordinator (RQCC).
RQCC shall be the Nodal Officer of REC and shall be responsible for ensuring
compliance of Quality Control Manual.

6.2 REC may out-source the work of quality checks & inspections of Tier-II

6.3 Quality Assurance by REC Quality Monitors shall be undertaken in the


following areas of the project implementation:-
a) Quality of material/equipment being supplied.
b) Quality of works in the field.
c) BOQ verification
d) VIP references/complaints received by REC relating to quality of
works

6.4 Quality of material/equipment

Based on the information given by the PIA Quality Control Coordinator


(PQCC), REC Quality Control Coordinator (RQCC) shall deploy its’
representatives for pre-shipment inspection at the manufacturers’ works on
sample-basis. Major equipment like transformers/poles/conductor/meter shall
be inspected at manufacturer’s works on sample basis. RQCC shall witness the
inspection of material in line with MQP.

6.5 Quality of works in the field

6.5.1 RQCC shall depute its representatives for inspection in the field.
Stages and scope of Inspection:

6.5.1.1 1st Stage- On completion of 30 to 50% works of the entire project at site.
Inspection shall be carried out as per FQP. Sampling shall be as follows:
(a) 5% randomly selected villages
(b) All districts and all turnkey contractors shall be covered.
(c) Electrified as well as un-electrified villages will be covered.
(d) The sample should include villages covering the entire area in the
district.
(e) At least one New substation.
(f) At least one Augmentation of Substation.

Issued by REC Issue No.: 1.2

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6.5.1.2 2nd Stage- After completion of 90% works in the village, as notified by the
PQCC after completion of TPIA inspection. Inspection shall be carried out as
per FQP. Sampling shall be as follows:
1. 10% randomly selected villages, including 5% villages inspected in the
1st stage.
2. All districts and all turnkey contractors shall be covered.
3. Electrified as well as un-electrified villages will be covered.
4. The sample should include villages covering the entire area in the
district.
5. 25 % (at least one) New substations including substation inspected in
Stage-I.
6. 5 % (at least one) Augmentation substations including substation
inspected in Stage-I.
7. 100% verification of BPL connections in 25% of villages inspected i.e.
2.5% villages and in each of the remaining villages inspected i.e. 7.5%
villages, at least 5 BPL connections shall be verified on randomly
selected from the list of connections provided till the date of inspection.

Quality of works shall be verified with reference to FQP. Reports of Field


Quality checks may be supported by photographs.

6.6 Wherever works carried out are found unsatisfactory, compliance with respect
to rectification shall be submitted by PIA to RQCC and the same may be re-
inspected by RQM if required. Recurrent adverse reports about quality of
works in any project will entail withholding of release of funds.

6.7 VIP references/complaints received by REC relating to quality of works/non


completion of works etc. shall be taken up for verification by RQCC & if
required, shall issue necessary instruction to PQCC to attend to the
rectifications required. PQCC shall get rectifications done within 30 days &
submit a certificate for the same to RQCC.

Issued by REC Issue No.: 1.2

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Section : 7.0 Tier-III QUALITY CONTROL METHODOLOGY

7.1 MOP shall engage independent evaluators for evaluation and random quality
checks on supply and erection. They shall be designated as National Quality
Monitors (NQM).

7.2 Scope of works in the field


• 1% randomly selected villages as per FQP.
• At least one New substation.
• At least one Augmentation substations.
• 100% BPL service connection verification in 50% of villages
inspected i.e 0.5 % villages and in the remaining 0.5% villages at
least 5 BPL connections shall be verified on randomly selected
from the list of connections provided till the date of inspection.

7.3 The inspection frequency shall be as follows:

• As and when required by MOP.

7.4 Wherever works carried out are found unsatisfactory, compliance with respect
to rectification shall be submitted by PIA to RQCC duly verified/endorsed by
TPIA and the same may be re-inspected by RQM/NQM if required. Recurrent
adverse reports about quality of works in any project will entail withholding of
release of funds.

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Section : 8.0 PROCEDURE FOR IMPLEMENTATION OF THREE TIER QC


MECHANISM
8.1. PIA shall first nominate its PQCC who shall be nodal point for all agencies
regarding Quality Control and inform RQCC that PQCC had been nominated
alongwith his telephone nos., mobile nos, Fax nos. and E-Mail id for contact.
8.2. PQCC shall form his team for Quality Control and inform RQCC and Turnkey
contractor about his team.
8.3. PQCC shall forward monthly progress report on Quality Control to RQCC as per
FORMAT-E enclosed.
8.4. PQCC shall finalize MQP and FQP and forward a copy to his Quality Control team
and RQCC
8.5. Material Inspection
8.5.1. Turnkey Contractor shall inform to PQCC regarding raw material and in process
inspections and it is the responsibility of PQCC that all stage, raw material and in
process inspections as listed in MQP shall be carried out in presence of
representative of PQCC.
8.5.2. Program for inspections of finished product for Routine, Type and Acceptance tests
shall be furnished by Turnkey Contractor to PQCC well in advance at least 10 days
before the schedule date of inspection and the same shall confirmed by PQCC to
RQCC with the complete address, mobile nos of contact person. PQCC shall depute
its representative. It shall be ensured by PQCC that all tests shall be carried out in
presence of representative of PQCC.
8.5.3. TPIA shall ensure presence of their qualified representative during 10% inspections
either at manufacturer’s premises or at independent laboratories.
8.5.4. RQCC may send his representative based on random sampling basis. In case, RQCC
is not able to send his representative, inspections shall be carried out as scheduled in
presence of representative of PQCC and TPIA.
8.5.5. All routine, type and acceptance tests records of various equipment/material shall be
available with PQCC for each contract. The tests records may be reviewed by NQM
if required. PQCC and Turnkey Contractor shall ensure that it shall be possible to
trace out the equipment/material with respect to its tests records. PQCC and Turnkey
contractors shall formulate detailed procedure in respect to this.
8.5.6. RQCC and NQM may demand the tests records of any material during
village/substation inspection and that time PQCC representative should arrange the
tests records of these equipment and furnish them to NQM/RQCC within two weeks.

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8.6. FLOW CHART FOR PRE DESPATCH INSPECTIONS


Step-I Issue of inspection call by contractor 10 days in advance to
PQCC.
Step-II PQCC informs to TPIA/RQCC by E-mail/FAX/Telephone
Step-III PQCC deputes its representative to manufacturer works.
Step-IV RQCC/TPIA deputes its representative to manufacturer works
on random selection basis.
Step-V Inspections carried out as scheduled without waiting of
representative of TPIA/RQCC.
Step-VI Material shall be cleared by PQCC or his authorized
representative for dispatch.
Step-VII Records of inspections shall be submitted to PQCC.
8.7. FIELD INSPECTION
8.7.1. Contractor shall fill the Format-A, Format-B and Format-C as enclosed in
Annexure and may get verified by representative of PIA/TPIA/RQM/NQM
whoever be available.
8.7.2. Inspection by TPIA shall be as per clause no. 5.9.5 of this manual.

8.7.3. Inspection by REC quality monitors (RQM) shall be as per clause no 6.5.1 of this
manual.

8.7.4. Inspection by NQM shall be as per Clause no. 7.2 of this manual.

8.7.5. Inspecting agency TPIA/RQM/NQM shall give the report of their inspection as
per FORMAT-D enclosed in Annexure.

8.8. VIP references/complaints received by REC relating to quality of works/non


completion of works etc. shall be taken up for verification by RQCC & if
required, shall issue necessary instruction to PQCC to attend to the rectifications
required. PQCC shall get rectifications done within 30 days & submit a certificate
for the same to RQCC.

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Section : 9.0

9. INFORMATION FLOW PROCEDURE

9.1. Turnkey Contractor shall furnish all records of Quality of material/equipment and
inspection report of Field checks performed during execution/installation by him
to PQCC. The record must include at least followings:
a) Manufacturing Quality Plans (MQP) of equipment/material
b) FQP
c) List of sub-vendors
d) Acceptance tests report of equipment
e) Type tests reports of equipment
f) Routine tests reports of equipment
g) Field inspections reports as per FQP and in FORMAT-A, B and C

9.2. TPIA shall maintain the records of tests witnessed by them and furnish report in
Fornmat-D. Any discrepancy shall be notified to PQCC. TPIA shall submit bi-
monthly progress report and any other report as asked by PQCC.

9.3. PQCC shall submit monthly progress report regarding Quality to RQCC in the
FORMAT No.-E as enclosed.

9.4. RQCC shall submit monthly progress report regarding Quality to NQM in the
FORMAT No.-E.

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QUALITY CONTROL
MANUAL
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Section : 10.0
10. RESOLUTION OF DISPUTES
10.1. SETTLEMENT OF DISPUTES
10.1.1. Any dispute(s) or difference(s) arising out of or in connection with the different
tier of inspection shall, to the extent possible, be settled amicably between the
parties. Hierarchical structure shall be respected and decision of NQM shall be
final and binding. Wherever NQM is not able to inspect during a dispute, RQCC
decision shall be final and binding.
10.1.2. If any dispute or difference of any kind whatsoever shall arise between the PIA
and the Contractor, arising out of the Contract for the Quality of the Works after
inspection of TPIA or RQCC or NQM, whether during the progress of the Works
or after its completion or whether before or after the termination, abandonment or
breach of the Contract, it shall in the first place, be referred to and settled by PIA
within 30 days.

Issued by REC Issue No.: 1.2

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Section : 11.0 GUIDELINES FOR QUALITY CONTROL DURING


CONSTRUCTION
11.1 Documents required - The supervision and inspection shall be carried out
based on the following documents to be provided by the project implementing
agency (PIA) :-
(i) Approved route map with pole schedule.
(ii) Quality assurance plan agreed upon by the PIA and the executing
agency (turnkey contractor)
(iii) Contract documents/Letter of award & special conditions of the
contract
(iv) Technical specifications of the turnkey contract, for supply and
erection of all equipment and materials.
(v) Sanctioned detailed project report (DPR) for the project district
with all revisions/ modifications.
(vi) Relevant drawings/ blue prints, area distribution maps and
schematic diagrams.
(vii) REC Specifications and Construction Standards – [CD available at
REC for sale]
(viii) Booklet of the Amendments to REC Specification and
Construction Standards – [available at REC and also on the CD ]
(ix) Indian Electricity Rules (IER) [pl. see http:// powermin.nic.in
<Electricity Act 2003> < Rules under Act.]
(x) L2 network/barchart/PERT network
11.2 PROJECT MONITORING & SUPERVISION
11.2.1 Physical verification: Physical verification has to be carried out in project
villages, in each sanctioned project, in which electrification works & BPL
services have been reported by the PIA to have been completed or carried out.
11.2.2 Monitoring teams: The project is to be monitored by a dedicated monitoring
team. The verification will be based on the village wise progress reported
which will be provided periodically at the end of each month by PIA.
11.2.3 Monitoring Report of the Third Party Agency
The third party inspection agency will report the progress & quality of works
as per the Monitoring & Inspection Report Formats provided in these
guidelines. These formats cover the following:

Issued by REC Issue No.: 1.2

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QUALITY CONTROL
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1. Project Parameter
2. Highlights of major project monitoring observations of the project
3. Village snap shots of each village visited covering
(i) Physical performance in the village
(ii) Workmanship and construction standards
(iii) Quality of materials & equipment in the village
(iv) Adherence to Indian Electricity Rules
(v) Photographs of deficiencies & defects requiring rectification in
the village

11.2.4 Based on the report & recommendations of the TPIA/RQCC/NQM/PQCC, all


discrepancies and defects noted in the progress report shall be rectified and set
right within one month of submission of the report to PIA . A confirmation to
this effect will be sent by PIA to PQCC with copy endorsed to RQCC, New
Delhi for information and to ZM/CPM of concerned REC Project Office.

11.2.5 The TPIA/ RQM/ NQM team may re-visit if required, those areas / villages
where rectification has been carried out by the turnkey contractor, within one
month of confirmation from the PIA that necessary corrections have been
made and that turnkey contractor has taken remedial action and defects
observed had been rectified.

11.3 SUPERVISION OF QUALITY OF MATERIAL USED & WORKS


EXECUTED AND CONSTRUCTION STANDARDS ADOPTED
DURING CONSTRUCTION.

11.3.1 SUPERVISION - The supervision & inspection of quality of materials &


equipment used and works executed and construction standards adopted
during construction, should be guided by the relevant portions/ sections of
following guidelines and documents in the sequence they are mentioned
hereunder, for the type of works being undertaken as per the turnkey contract:-
(i) Approved Drawings.
(ii) The technical specifications, of the turnkey contract, for supply
and erection of all equipment and materials, including the scope of
works etc.
(iii) REC Specifications & Construction Standards and amendments to
REC Specification and Construction Standards, IS specifications
(iv) Indian Electricity Rules (IER)

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11.3.2 The monitoring/supervising team of the TPIA/PQCC/RQCC/NQM should


be familiar with specifications of the materials and equipment to be
erected/ installed as per the contract.
The important REC specifications for major & key material/ equipments and
the relevant IS standards/ specifications their code numbers generally
applicable to projects being implemented under the RGGVY scheme, which
need to be kept in consideration during the course of monitoring/ supervision/
inspection are detailed in Table-I below [to be read in conjunction with the
relevant construction standard]: -
11.4 ADHERENCE TO INDIAN ELECTRICITY RULES (IER)
The implementing agency shall adhere to the conditions stipulated in the
relevant sections of Indian Electricity Rules, 1956 (as amended upto
November. 2000 and subsequent amendments if any) in regard to construction,
erection and commissioning of electric supply lines (overhead and
underground) as well installations, systems and equipment, apparatus etc for
generation, transmission, supply and use of electrical energy as per the
purpose and objects of the Indian Electricity Act.

Issued by REC Issue No.: 1.2

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QUALITY CONTROL
MANUAL
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Appendix –I
List of Equipment/material which should have MQP

S.No. Equipment/material
1. Cable (Power/control/Aerial Bunched)
2. Transformers
3. Insulators (Disc/Pin/Post)
4. Conductors
5. CT/PTs
6. Vacuum Circuit Breaker
7. Isolator/AB Switch
8. Surge/Lightening Arrestor
9. HG/DO Fuse set
10. LT Distribution BOX
11. PSC/RCC Poles
12. Battery Chargers
13. ACDB/DCDBs
14. Energy Meters

Note:- Above List shall be updated by PIA as and when required.

Issued by REC Issue No.: 1.2

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QUALITY CONTROL
MANUAL
FOR RGGVY WORKS

TABLE-I EQUIPMENT SPECIFICATIONS

Sl. No. Particulars REC Code BIS code


A. Pre-stressed cement concrete poles [PCC]
1 For 11 KV and LT overhead lines 15/1979 IS: 1678/2905/7321
2 For 33 KV overhead lines 24/1987 IS: 1678/2905/7321
3 High tensile steel wires for PCC poles 62/1993 IS: 6003 or 1785
B. Bare conductors, insulated cables & wires
1 Bare Conductors – ACSR & AAC 1/1993 IS: 398
2 Bare Conductors – AAAC 33/1994 IS: 398
3 Aerial bunched cables (ABC) for 11 KV lines 64/1993 IS: 7098/8130/ 398/ ST-3 of IEC
502
4 11 KV XLPE cables 63/1993 IS: 7098/8130
5 Aerial bunched cables (ABC) for LT lines–1.1 KV 32/1984 IS: 10810/8130/6474/ 398
6 PVC insulated LT cables for LT services & DTs- 26/1983 IS: 694/4288/1554
1.1KV
7 PVC insulated LT cables with embedded bearer wire 27/1983 IS: 694/4288/1554
for LT services -1.1KV
8 Galvanised iron wires 45/1988 IS: 280/7887/4826
9 Galvanised iron stay wires 46/1988 IS: 2141/4826/6594/
C. Distribution & Power transformers
1 11 KV/433-250 volts for 16 & 25 KVA with 70/1993 IS: 1180/2026
amorphous metal core
2 Single phase distribution transformers (P to N) & (P 78/2007 & IS: 1180/2026
to P) Amd.-I
3 Transformer oil for power & distribution transfr. 39/1993 IS: 335/1866
4 33/11 KV step-down power transformers 7/1993 IS: 2026/2099/3347
5 On load tap changers for 33/11 KV transformers 17/1981 IS: 8468/2026
D. Insulators & fittings
1 Porcelain insulators & fittings for 11 KV O/h lines 3/1993 IS: 731/3188/2486
2 Preformed helically formed fittings 25/1983 IS: 12048/2486/2004

3 Porcelain insulators & fittings for LT O/h lines 4/1979 IS: 1445/7935/1445/
7935
4 Porcelain insulators & fittings for 33 KV O/h lines 13/1979 IS: 731/2486
5 Composite insulators 77/2007

Issued by REC Issue No.: 1.2

Issue Date : 7th April, 2008 Page 33 of 34


QUALITY CONTROL
MANUAL
FOR RGGVY WORKS

Sl. No. Particulars REC Code BIS code

E. Circuit breakers, Lightning Arrestors,


isolators switches, CT/PT etc
1 11 KV vacuum circuit breakers 22/1983 & IS: 13118/3156/ 2705
Amnd.-I
2 11 KV auto reclosers 38/1987 IS: 2516/2705/ ANSI IEEE
C37.60
3 11 KV lightning arrestors 10/1976 IS: 3070
4 11 KV drop out fuse cutouts for DTs 53/1987 IS: 9385/2633/1364
5 11 KV air-break switches 43/1987 IS: 9920
6 33 KV vacuum circuit breakers 12/1993 & IS: 13118/3156/2705
Amnd.-I
7 33 KV lightning arrestors 16/1981 IS: 3070
8 33 KV switch isolators 52/1987 IS: 9920/2544/5350/ 4736/
1161
9 33 KV load break switches 54/1993 IS: 9920/5561/4736/ 1161
10 LT circuit breakers 18/1983 IS: 2516
11 Miniature circuit breaker (MCB) 61/1993 IS: 8828
12 11 KV current transformers 59/1993 IS: 2705
13 11 KV voltage transformers 60/1993 IS: 3156
14 Danger Boards 57/1993 IS: 5/2551/8709
15 Ni-Cd. Battery & Battery Chargers for 34/2008
33kV S/S

Issued by REC Issue No.: 1.2

Issue Date : 7th April, 2008 Page 34 of 34


Annexure - I
fORMATS
Quality Control Manual

FORMAT-A
Format For Field Quality For Village With All Associated Hamlets/Mauza/Dhani/Thanda Etc.
( To Be Filled By Contractor)
Site Inspection Report Report No.
Site Inspection Was Carried Out On Report Date
Project Details
Contractor
Block
Village With All Associated Hamlets/Mauza/Dhani/Thanda Etc.
Census Code
Sl. Applicable Standard/Manual Item/Job Descrip- Confirm Compli- Deviations/ Corrective
No. tion ance Actions

A1- LT & 11kV Lines A1-POLES


1 REC Construction Manual and Pole-Concreting Yes/NO
Standards wherever applicable
2 REC Construction Manual and Base Plate Yes/NO
Standards
3 REC Construction Manual and Earthing Yes/NO
Standards
4 REC Construction Manual and Numbering, Anti- Yes/NO
Standards climbing, devices
& Danger Plate for
DT pole & wherever
applicable
A2-POLE ACCESSORIES & HARDWARES
1 REC Construction Manual and Mounting of Pole- Yes/NO
Standards Hardware’s & ac-
cessories
A3-STAY SET Yes/NO
1 REC Construction Manual and Provision as per Yes/NO
Standards contract and stan-
dards
2 REC Construction Manual and Proper Tightening Yes/NO
Standards
3
REC Construction Manual and Standards
Stay Set, Turn buckle & concreting -proper installation
Yes/NO
A4-JUMPERING
1 P.G. Clamps-provi- Yes/NO
sion & proper instal-
lation
B. DISTRIBUTION TRANSFORMER
1 REC Construction Manual and a. Mounting Yes/NO
Standards

36
2 REC Construction Manual and b.Termination Yes/NO
Standards through bi-mettalic
clamps
3 REC Construction Manual and c.Jumpering Yes/NO
Standards
4 REC Construction Manual and d.Earthing Yes/NO
Standards
5 REC Construction Manual and Pre-commissioning Yes/NO
Standards checks
C- TPMO/GO/AP SWITH
1 REC Construction Manual and Earthing & switch Yes/NO
Standards operation
2 REC Construction Manual and Jumpering from Yes/NO
Standards TPMO switch to
drop out fuse for Trf.
D-METERING DISTRIBUTION LT PANEL /SERVICE CONNECTION Yes/NO
1 REC Construction Manual and Termination of LT ca- Yes/NO
Standards ble, Bearer wire and
support at house
Energy meter & Yes/NO
earthing
2 REC Construction Manual and AB Cable with pierc- Yes/NO
Standards ing connector
Signed By
Representative of Turnkey Contractor
Representative of PQCC if checked
Representative of TPIA /RQM/NQM if checked

37
Quality Control Manual

FORMAT-B
FORMAT FOR FIELD QUALITY OF SUBSTATIONS ( TO BE FILLED BY CONTRACTOR)

Site Inspection Report Report No.


Site Inspection Was Carried Out On Report Date
Inspecting Officer
Project Details
Contractor
Substation Location
Sl. No. Rec Tech Specs Item/Job Description Confirm Compliance Deviations/ Corrective Actions
33kv/11kV Substation
REC Construction
1 Manual and Stan- Earthing Yes/NO
dards
REC Construction
2 Manual and Stan- Civil Works Yes/NO
dards
REC Construction
Construction and
3 Manual and Stan- Yes/NO
general layout
dards
REC Construction
Safety clearances
4 Manual and Stan- Yes/NO
as per IE rule.
dards
REC Construction Bimettalic terminal
5 Manual and Stan- connecters for trans- Yes/NO
dards former connections
REC Construction
6 Manual and Stan- Operation Yes/NO
dards
Signed By
Representative of Turnkey Contractor
Representative of PQCC if checked
Representative of TPIA /RQM/NQM if checked

38
FORMAT-C
CONTRACTOR’s FORMAT BOQ FOR VILLAGES with all associated Hamlets/Mauza/Dhani/Thanda etc.
( TO BE FILLED BY CONTRACTOR)
SITE INSPECTION REPORT REPORT NO.
SITE INSPECTION WAS CARRIED OUT ON REPORT DATE
PROJECT DETAILS
CONTRACTOR
BLOCK
VILLAGE
CENSUS CODE
S.No. Name of material/Items Unit Provision as per Approved drg. Quantity at site
(i)
PCC Poles
a) Single Pole
1. 8.5 Meter No.
2. 9.5 Meter No.
3. 11.0 Meter No.
4. Strut Pole No.
b) Double Pole
(ii) LT & 11 KV Conductor
length (ACSR/AAAC/
Length
a) Main Line & Size Mtr./mm
b) Spur Line & Size Mtr./mm
(iii) LT Cable Length Mtr.
(iv) Insulator (11 KV)
a) Disc. No.
(b)Pin No.
Insulator (LT)
a) Disc. No.
(b)Pin No.
(v) Ligthening arrester No.
(vi) Distribution Transfm.
a) 10 kVA No.
b)16 kVA No.
c) 25 kVA No.
(vii) Stay set No.
(viii) Service connections No.
Signed By
Representative of Turnkey Contractor
Representative of PQCC if checked
Representative of TPIA /RQM/NQM if checked

39
Quality Control Manual

FORMAT-D
Inspection Format For Tpia/Rqm/Nqm
Site Inspection Report No.
Site Inspection Was Carried Out On/ Report Date
Inspecting Agency
Inspecting Officer
Project Details
Contractor
Block
Village
Census Code
Discom’s Representative
Contractor
Sl. Reference Document Item/Job Whether Meet Construc- Deviations/ Corrective
No. Description tion Standard Actions
1 Quality Control Manual LT & 11kV Lines- YES/NO
POLE ERECTION
3 Quality Control Manual 11kV Line Erection YES/NO
4 Quality Control Manual Earthing YES/NO
5 Quality Control Manual DISTRIBUTION YES/NO
TRANSFORMER
-installation
6 Quality Control Manual TPMO/GO/AB YES/NO
switch -operation
7 Quality Control Manual METERING -DT/LT YES/NO
PANEL /SERVICE
CONNECTION
8 Quality Control Manual Substation Erection- YES/NO
Transformer, VCB,
CT/PT, C&R Panel,
Battery and Control
Room

9 DPR/Contract Docu- BOQ Verification YES/NO


ment
Signed By
DISCOM REC/NQM
CONTRACTOR
PQCC M/s RQM/NQM

40
FORMAT-E
Monthly Quality Control Report
Discom
Project Details
Contractor
Sl. No. Name Of Village Name Of District/Block Census Code Whether Comply The
Quality Control Manual
1
2
3
4
5
6
7
8
Signed By
DISCOM CONTRACTOR
PQCC

41
Annexure - iI
FQP
44
FIELD QUALITY PLAN-- CONDUCTOR, EARTH WIRE & AB CABLE ERECTION (HT &LT)

Item: CONDUCTOR, EARTH WIRE & AB CABLE (HT & LT)


Contractor/Sub Contractor/ Agency Name & Ad-
dress:
SYSTEM: CONDUCTOR, EARTH WIRE & AB CABLE
Quality Control Manual

SUB-SYSTEM: 1 CONDUCTOR(AAAC,AAC,ACSR) ERECTION


SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/
MENTS TOR/PQCC NQM
1 RECEIPT 1) RECEIPT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE STORES COMPONENETS
AND STOR- AT STORES CHECK CHLLAN LOT RECEIVED WITH THE REGISTER WHICH ARE
AGE DELIVERY CHLLAN/MDCC INSPECTED AND
DESCRIPTIONS CLEARED BY PIA
SHALL ONLY BE
ACCEPTED ON
RECEIPT
2) VISUAL C VISUAL 100% RANDOM DRUMS FOUND DAMAGED STORES
INSPECTION CHECK DURING TRANSIT ARE REGISTER
STACKED SEPARATELY
3) STORAGE C VISUAL 100% RANDOM STANDARD DRUMS ARE STORED ON STORES
CHECK PRACTICE HARD SURFACE AREA REGISTER
2 ERECTION 1) HAN- C VISUAL 100% RANDOM UTILITY SPEC- CONDUCTOR SHOULD SCRATCHES OR
OF CON- DLING OF IFICATION NOT BE DRAGGED ON THE DAMAGES TO THE
DUCTOR THE CON- or AS PER GROUND STRANDS WOULD
DUCTOR ACCEPTANCE OCCUR IF NOT
NORMS HANDLED PROP-
ERLY
2) SE- C VISUAL 100% RANDOM UTILITY SPEC- SEQUENCE OF RUNNING
QUENCE OF IFICATION OUT SHALL BE FROM TOP
CONDUC- or AS PER TO BOTTOM, i.e.. THE TOP
TOR EREC- ACCEPTANCE CONDUCTOR SHALL RUN
TION NORMS OUT FIRST, FOLLOWED BY
THE SIDE CONDUCTORS
SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/
MENTS TOR/PQCC NQM
3) STRING- C VISUAL 100% RANDOM UTILITY SPEC- ANY DAMAGES TO THE
ING OF THE IFICATION STRANDS SHALL BE RE-
CONDUC- or AS PER PAIRED WITH REPAIR
TORS ACCEPTANCE SLEEVES
NORMS

4) MID SPAN B VISUAL 100% RANDOM UTILITY SPEC- COMPRESSION TYPE ALL JOINTS
JOINTING IFICATION NOT MORE ONE JOINT PER AND SPLICES
or AS PER SUB CONDUCTOR PER SPAN SHOULD BE 15
ACCEPTANCE METERS AWAY
NORMS FROM THE POLE

5) BIND- C VISUAL 100% RANDOM UTILITY SPEC- AS PER THE REC SPECIFICA-
ING THE IFICATION TIONS
CONDUC- or AS PER
TOR TO THE ACCEPTANCE
INSULATOR NORMS

6) EREC- B VISUAL 100% RANDOM UTILITY SPEC- GUARDING SHALL BE PRO- THE GROUND
TION AT IFICATION VIDED AT MAJOR CROSS- CLEARANCES AT
ROAD or AS PER INGS ROAD CROSS-
CROSSINGS ACCEPTANCE INGS SHALL
NORMS BE AS PER
RELAVENT IE
RULES

7) ANTI- B VISUAL 100% RANDOM UTILITY SPEC- APPROVED DRAWINGS ss


CLIMBLING IFICATION
DEVICES or AS PER
ACCEPTANCE
NORMS

45
46
SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/
MENTS TOR/PQCC NQM
8) DANGER B VISUAL 100% RANDOM UTILITY SPEC- APPROVED DRAWINGS
BOARDS IFICATION
or AS PER
ACCEPTANCE
Quality Control Manual

NORMS

3 TENSION- 1) MEA- B VISUAL 100% RANDOM AS PER SAG- AS PER IE NORMS TENSIONING AND
ING AND SUREMENT TENSION SAGGNG OPERA-
SAGGING OF SAG- CHARTS TIONS ARE CARRIED
GING IN CALM WEATHER,
WHEN RAPID CHANG-
ES IN TEMPERATURE
ARE NOT LIKELY TO
OCCUR

4 CLIPPING 1) CLIPPING C VISUAL 100% RANDOM UTILITY SPEC- MANUFACTURER’S


THE CON- IFICATION RECOMMENDATION
DUCTOR IN or AS PER
POSITION ACCEPTANCE
NORMS

2) JUMP- C VISUAL 100% RANDOM UTILITY SPEC- JUMPERS FORMED TO TO ENSURE MAXI-
ERING AT IFICATION PARABOLIC SHAPE MUM CLEARANCE TO
SECTION or AS PER EQUIPMENT
AND ANGLE ACCEPTANCE
TOWERS NORMS

SUB-SYSTEM:2 ERECTION OF AERIAL BUNCHED CABLE


SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
4 RECEIPT 1) RECEIPT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE STORES COMPONENETS WHICH
AND STOR- AT STORES CHLLAN/ LOT RECEIVED WITH REGISTER ARE INSPECTED AND
AGE MDCC THE DELIVERY CHLLAN/ CLEARED BY PIA SHALL
MDCC DESCRIPTIONS ONLY BE ACCEPTED ON
RECEIPT

2) VISUAL C VISUAL 100% RANDOM DRUMS FOUND DAM- STORES


INSPECTION AGED DURING TRANSIT REGISTER
ARE STACKED SEPA-
RATELY

3) STORAGE C VISUAL 100% RANDOM STANDARD DRUMS ARE STORED ON STORES


PRACTICE HARD SURFACE AREA REGISTER

5 FIXING OF A) EYE
EYE HOOK HOOK
AND SUS- WITH POLE
PENSION / THROUGH
DEAD END BOLT
CLAMPS 1) CHECK C VISUAL 100% RANDOM UTILITY AS PER APPROVED SITE REGIS-
THE SPECIFICA- DRAWING TER
THREAD- TION or AS
INGS PER AC-
OVER THE CEPTANCE
THROUGH NORMS
BOLT
2) FIX THE C VISUAL 100% RANDOM UTILITY APPROVED DRAWING SITE REGIS-
THROUGH SPECIFICA- TER
BOLT INTO TION or AS
THE POLE PER AC-
CEPTANCE
NORMS

47
48
SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
3) CHECK C VISUAL 100% RANDOM UTILITY AS PER APPROVED SITE REGIS-
THE ALIGN- SPECIFICA- DRAWING TER
MENT OF TION or AS
BOLT WITH PER AC-
Quality Control Manual

THE POLE CEPTANCE


NORMS
B) EYE
HOOK WITH
EYE HOOK
CLAMP
1) CHECK C VISUAL 100% RANDOM UTILITY AS PER APPROVED SITE REGIS-
THE DIMEN- SPECIFICA- DRAWING TER
SIONS OF TION or AS
THE CLAMP PER AC-
AND FIX CEPTANCE
THE CLAMP NORMS
TO THE
POLE
2) CHECK C VISUAL 100% RANDOM UTILITY AS PER APPROVED SITE REGIS- THE CLAMP SHOULD BE
THE ALIGN- SPECIFICA- DRAWING TER EXACTLY PERPENDICU-
MENT OF TION or AS LAR TO POLE
CLAMP PER AC-
WITH THE CEPTANCE
POLE NORMS
C) CHECK C VISUAL 100% RANDOM STANDARD HOOKS SHALL BE SITE REGIS- WHERE EVER HOOKS
THE ALIGN- PRACTICE ERECTED AT SAME TER ARE MISALIGNED THERE
MENT OF ELEVATION SHOULD BE REPLACED
THE EYE BEFORE CONDUCT RING
HOOKS
ALONG THE
LINE
SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
D) FIXING C VISUAL 100% RANDOM UTILITY AS PER APPROVED SITE REGIS-
OF SUS- SPECIFICA- DRAWING TER
PENSION TION or AS
CLAMS / PER AC-
DEAD END CEPTANCE
CLAMPS NORMS
6 ERECTION 1) HAN- C VISUAL 100% RANDOM UTILITY CABLE SHOULD be care- CABLE SURFACE SHALL
OF CABLE DLING OF SPECIFICA- fully handled to avoid any BE FREE FROM FAULTS,
THE CABLE TION or AS damage FLAWS e.t.c
PER AC-
CEPTANCE
NORMS
2) SE- C VISUAL 100% RANDOM UTILITY SEQUENCE OF RUN-
QUENCE SPECIFICA- NING OUT SHALL BE
OF CABLE TION or AS FROM TOP TO BOTTOM,
ERECTION PER AC- i.e.. THE TOP CABLE
CEPTANCE SHALL RUN OUT FIRST,
NORMS FOLLOWED BY THE SIDE
CABLES
3) FIX THE C VISUAL 100% 10% UTILITY PIA SPECIFICATION/ AS
MESSEN- SPECIFICA- PER APPROVED DRAW-
GER WIRE TION or AS ING
OF AB PER AC-
CABLE TO CEPTANCE
CLAMPS NORMS
(SUSPEN-
SION/
DEAD END
CLAMP)
4) CHECK C VISUAL 100% RANDOM UTILITY AS PER THE STANDARD
THE TIGHT- SPECIFICA- PRACTICE
NESS OF TION or AS
CABLE WITH PER AC-
CLAMPS CEPTANCE

49
NORMS
50
SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
5) CHECK C VISUAL 100% RANDOM UTILITY AS PER IE RULES THE MINIMUM GROUND
THE SPECIFICA- CLEARANCES SHOULD
GROUND TION or AS BE MAINTAINED
CLEARANC- PER AC-
Quality Control Manual

ES AFTER CEPTANCE
ERECTION NORMS
OF THE AB
CABLE

SUB-SYSTEM:3 ERECTION OF EARTH WIRE


7 RECEIPT 1) RECEIPT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE STORES COMPONENETS WHICH
AND STOR- AT STORES CHECK CHLLAN LOT RECEIVED WITH REGISTER ARE INSPECTED AND
AGE THE DELIVERY CHLLAN CLEARED BY PIA SHALL
ONLY BE ACCEPTED ON
RECEIPT

2) VISUAL C VISUAL 100% RANDOM THE SURFACE OF STORES


INSPECTION CHECK EARTH WIRE SHOULD REGISTER
BE FREE FROM FLAWS
AND DUST

3) STORAGE C VISUAL 100% RANDOM STANDARD EARTH WIRE SHOULD STORES


CHECK PRACTICE BE STORED IN DRY REGISTER
AREAS

8 ERECTION 1) HAN- C VISUAL 100% RANDOM UTILITY Earth Wire should be care- SCRATCHES OR DAM-
OF EARTH DLING OF SPECIFICA- fully handled to avoid any AGES TO THE SURFACE
WIRE THE EARTH TION or AS damage WOULD OCCUR IF NOT
WIRE PER AC- HANDLED PROPERLY
CEPTANCE
NORMS
SL.NO MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERATION INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
2) EREC- C VISUAL 100% 10% UTILITY SEQUENCE OF RUNNING CHECK THE CLEARANCE
TION OF SPECIFICA- OUT SHALL BE FROM BETWEEN EARTH KNOB
EARTH TION or AS TOP TO BOTTOM, i.e. AND PIN INSULATORS
KNOB PER AC- THE TOP EARTH WIRE AND THE COMPONENTS
CEPTANCE SHALL RUN OUT FIRST, SHALL BE ERECTED AS
NORMS FOLLOWED BY THE SIDE PER DRAWING AND AS
EARTH WIRES PER SPEC
3) STRING- C VISUAL 100% RANDOM UTILITY ALL JOINTS SHALL BE GROUND CLEARANCES
ING OF SPECIFICA- COMPRESSION TYPE SHOULD BE MAINTAINED
THE EARTH TION or AS
WIRES PER AC-
CEPTANCE
NORMS

CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR

NAME/ SIGNATURE OF THE SUB-CONTRACTOR/ ERECTION AGENCY

51
52
PROJECT / UTILITY : ITEM : ERECTION WORK
CONTRACT No. SUB SYSTEM : CABLES
CONTRACTOR : QAP NO. :
PACKAGE: STANDARD FIELDQUALITY PLAN FOR REV. NO.:
Cable

DATE
Sr. No. CHARACTERISTICES / ITEMS Type of Instru- Class QUANTUM QUANTUM Reference Documents & “Format Of Remarks
Quality Control Manual

Check ments OF CHECK OF CHECK Acceptance Standard Records”


- CONTRAC- - TPIA/REC/
TOR/PQCC NQM
1 2 3 4 5 6 7 8 9
1 RECEIPT & STORAGE
1.1 Receiving inspection (Completeness of V - B 100% RANDOM Delivery Challan MRC
documents, test certificates, etc.)
1.2 Unloading V - B 100% RANDOM Instruction Manual -
1.3 Visual exmination V - B 100% RANDOM Packing list / Instruction -
Manual
1.4 Proper storage V - B 100% RANDOM Instruction Manual/ IS: -
1255
1.5 End Sealing ( Cable ends are sealed by V _ B 100% RANDOM IS: 1255 Site Record
PVC cap to avoid ingress of moisture )
2 PRE INSTALLATION
2.1 Unloading of Drums
A Check for drum mounting - cable wheel/ V - B 100% RANDOM IS: 1255 Site Record
jack
B Check for cable unwinding - cable wheel/ V - B 100% RANDOM IS: 1255 Site Record
jack
C Check for proper unrolling - Cable Wheel/ V - B 100% RANDOM IS: 1255 Site Record
Jack
D Check for cable end sealing V - B 100% RANDOM IS: 1255 Site Record
2.2 Availability of bricks at site for buried cables V - C 100% RANDOM Site Record
2.3 Excavation of trench for U/G cable laying V - C 100% RANDOM UTILITY SPECIFICA- Site Record
TION or AS PER AC-
CEPTANCE NORMS
Sr. No. CHARACTERISTICES / ITEMS Type of Instru- Class QUANTUM QUANTUM Reference Documents & “Format Of Remarks
Check ments OF CHECK OF CHECK Acceptance Standard Records”
- CONTRAC- - TPIA/REC/
TOR/PQCC NQM
1 2 3 4 5 6 7 8 9
2.4 Sand Cushioning for buried cables V - C 100% RANDOM Site Record

2.5 Ascertaining cable route and length V - B 100% 10% Cable Route Site Record
2.6 Conformity with cable schedule V - B 100% RANDOM Cable Schedule Site Record

2.7 Insulation resistance checking - Meggar Electrical Meggar A 100% 10% IS: 1255 Site Record
( 500 V for LT & 1000V for Cables upto
11kV)
2.8 Proper route maintaining during cable V - B 100% RANDOM Cable Route Site Record
laying
2.9 identification and dressing of cables V - B 100% RANDOM standard Practice Site Record
2.10 Use of trefoil clamps for single core cables V - B 100% RANDOM standard Practice Site Record

2.11 Proper verticality of multicore cables V - B 100% RANDOM standard Practice Site Record

3 INSTALLATION
3.1 Removal of wooden planks from cable V - B 100% RANDOM UTILITY SPECIFICA- -
drum TION or AS PER AC-
CEPTANCE NORMS

3.2 Check cable is not dragged on hard ground V - B 100% RANDOM UTILITY SPECIFICA- -
TION or AS PER AC-
CEPTANCE NORMS

3.3 Check size of cable & cutting of cable V - B 100% 10% UTILITY SPECIFICA- -
length TION or AS PER AC-
CEPTANCE NORMS

3.4 Check the separation between different V - B 100% RANDOM UTILITY SPECIFICA- -
types of cables laid nearby. TION or AS PER AC-
CEPTANCE NORMS

53
54
Sr. No. CHARACTERISTICES / ITEMS Type of Instru- Class QUANTUM QUANTUM Reference Documents & “Format Of Remarks
Check ments OF CHECK OF CHECK Acceptance Standard Records”
- CONTRAC- - TPIA/REC/
TOR/PQCC NQM
1 2 3 4 5 6 7 8 9
3.5 Check the laying of cables as per cable V - B 100% RANDOM UTILITY SPECIFICA- -
schedule. TION or AS PER AC-
CEPTANCE NORMS
Quality Control Manual

3.6 Check the cable tray are earthed as per the V - B 100% 10% UTILITY SPECIFICA- -
drawing. TION or AS PER AC-
CEPTANCE NORMS

3.7 Check the cable glands, lugs, ferrules, V - B 100% 10% UTILITY SPECIFICA- -
cable tag/ marker are provided as per TION or AS PER AC-
requirement. CEPTANCE NORMS

3.8 Check the cable cable drum/ cable to be V - B 100% RANDOM UTILITY SPECIFICA- -
laid for any external damage. TION or AS PER AC-
CEPTANCE NORMS

3.9 Check the availability and functionality of V - B 100% RANDOM UTILITY SPECIFICA- -
the rollers. TION or AS PER AC-
CEPTANCE NORMS

3.10 Check there are no damage / twisting of V - B 100% RANDOM UTILITY SPECIFICA- -
cables during laying. TION or AS PER AC-
CEPTANCE NORMS

3.11 Check that cables are protected from the V - B 100% RANDOM UTILITY SPECIFICA- -
sharp bends while laying. TION or AS PER AC-
CEPTANCE NORMS

3.12 Check that the power cables are separated V - B 100% RANDOM UTILITY SPECIFICA- -
from the control cables. TION or AS PER AC-
CEPTANCE NORMS
3.13 Check the phase matching at both end V - B 100% RANDOM UTILITY SPECIFICA- -
after each joint. TION or AS PER AC-
CEPTANCE NORMS
Sr. No. CHARACTERISTICES / ITEMS Type of Instru- Class QUANTUM QUANTUM Reference Documents & “Format Of Remarks
Check ments OF CHECK OF CHECK Acceptance Standard Records”
- CONTRAC- - TPIA/REC/
TOR/PQCC NQM
1 2 3 4 5 6 7 8 9
3.14 Check cable tags are provided at required V - B 100% RANDOM UTILITY SPECIFICA- -
intervals/required places and both end as TION or AS PER AC-
per cable schedule. CEPTANCE NORMS

3.15 Check the cables are dressed, clamped V - B 100% RANDOM UTILITY SPECIFICA- -
and supported properly as per the drawing. TION or AS PER AC-
CEPTANCE NORMS
3.16 Insulation Resistance Check Electrical Meggar B 100% 10% UTILITY SPECIFICA- Site Record
TION or AS PER AC-
CEPTANCE NORMS
3.17 Check whether some extra length ( 1.5 Physical - B 100% RANDOM UTILITY SPECIFICA- Site Record
mtr.) is kept in each cable run for future use TION or AS PER AC-
CEPTANCE NORMS
3.18 Check that all wall openings/ pipes/ sleeves Physical - B 100% RANDOM UTILITY SPECIFICA- Site Record
are sealed to avoid seepage of water TION or AS PER AC-
CEPTANCE NORMS
3.19 check that buried cables are covered with Physical - B 100% RANDOM UTILITY SPECIFICA- Site Record
sand layers and by protective bricks TION or AS PER AC-
CEPTANCE NORMS
3.20 Ensure that the location of underground Physical - B 100% RANDOM UTILITY SPECIFICA- Site Record
cable joints are identified. TION or AS PER AC-
CEPTANCE NORMS

CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY


Legends :
TC : Test Certificate
A -- CRITICAL
B -- MAJOR V : Verify
C-- MINOR EIC : Engineer In Charge

55
56
STANDARD FIELD QUALITY PLAN QP No. Re- Approved
for Power Transformer (Outdoor Type) viewed By:
By:
S.No. Activity and Characteristics/ instru- Class of Type of QUANTUM QUANTUM Reference Docu- Acceptance Format of Remarks
Operation ments Check Check OF CHECK OF CHECK ment Norms Records
- CON- - TPIA/REC/
TRACTOR NQM
Quality Control Manual

/PQCC
1 2 3 4 5 6 6 7 8 9 10
1.00 RECEIPT
1.01 Main Unit a) Physical damage & Oil B Visual 100% …. No Physical damage
leakage from valves/ flanges & Leakage from
& other part of body valves/ flanges and
other parts of main
unit.
1.02 b) Unloading with the help of B Physical 100% ….
lifting lugs & hydra on foun-
dation or at suiatble location
in absecnce of foundation.
c) Check S.No. & rating B Verify 100% …. BBU No.
1.03 Accessories/ a) Physical damage B Visual 100% …. No Physical damage
Loose Items
b) Unloading of Marshalling B Visual 100% ….
Box, radiator, Conservator
tank, Bucholz Relay, current
transformer, MOG, PRD,
Breather, Silica gel, terminal
Connector & boxes.
c) Leakage of oil from drums B Visual 100% …. No leakage Log Record
1.04 Accessories/ d) All Packing cases are C Visual 100% once …. No opening/ break- Log Record
Loose Items sealed/ packed with packing ing of seal/ packing
list
e) Verification of items as C Verify 100% once …. No shortage Log Record
per packing list
2.00 STORAGE
S.No. Activity and Characteristics/ instruments Class of Type of QUANTUM QUANTUM Reference Docu- Acceptance Format of Remarks
Operation Check Check OF CHECK OF CHECK ment Norms Records
- CON- - TPIA/REC/
TRACTOR NQM
/PQCC
1 2 3 4 5 6 6 7 8 9 10
2.01 a) Oil drums are placed at C Physical 100% once Manufacturer’s No leakage Log Record Surveilance
protected area & not stored on Instruction check by NE-
their side faces. Manual SCL Erection.
b) All components/ equipment C Visual 100% once Manufacturer’s …. Log Record Surveilance
are stored at suitable location Instruction check by NE-
till they are used for erection. Manual SCL Erection.
c) Fitting of breather on main C Visual 100% once Manufacturer’s …. Log Record Surveilance
unit in case of long storage Instruction check by NE-
period. Manual SCL Erection.
d) All instruments such C Physical 100% once Manufacturer’s …. Log Record Marshalling
as MOG, PRD, silica gel, Instruction box are stored
Marshalling Box, Breather, Manual vertical in their
terminal connector, bucholz respective
Relay, WTI, OTI, CT are stored cases.
indoor.
e) Flushing of radiators & B Physical 100% once …. No dirt should
pipes for missing blanks with remain inside the
oil and blanking of pipes and pipe & radiators and
radiator ends. blanking of pipe after
cleaning/ flushing.
f) Radiators, Pipes and con- B Physical 100% once Manufacturer’s ….
servator tanks are stored at Instruction
raised platform to avoid direct Manual
contact with water.
3.00 ERECTION
3.01 a) Availability of tools and B Visual 100% Manufacturer’s ….
tackles Instruction
Manual
b) Availability of transformer B Visual 100% …. ….
foundation as per drawing.

57
58
S.No. Activity and Characteristics/ instruments Class of Type of QUANTUM QUANTUM Reference Docu- Acceptance Format of Remarks
Operation Check Check OF CHECK OF CHECK ment Norms Records
- CON- - TPIA/REC/
TRACTOR NQM
/PQCC
1 2 3 4 5 6 6 7 8 9 10
c) Fixing and greasing of rollers B Physical 100% …. ….
Quality Control Manual

with transformer for smooth


shifting of main unit from stor-
age area to site of erection.
d) Shifting/ haulage of main unit B Physical 100% …. ….
from storage area upto founda-
tion site with the help of hydra,
ropes, pulleys etc.
e) Installation of Transformer on B Visual 100% Manufacturer’s ….
its foundation Instruction
Manual &
NESCL layout
Drawing
f) Ensure radiators were in B Visual 100% …. ….
flushed condition before erec-
tion with main unit.
g) mounting of pipes, radia- B Visual 100% …. ….
tors, explosion vent, cable box,
earthing flat as per drawing.
h) Availability of required capac- B Visual 100% …. ….
ity filteration machine and its
healthiness.
I) Prior to start of vacuum B Test 100% Manufacturer’s ….
test, breakdown voltage of oil Instruction
sample taken from separate Manual
tank in which oil is stored for
filtration.
j) Drying out of transformer with B Visual 100% Manufacturer’s ….
complete assembly with help of Instruction
machine. Manual
S.No. Activity and Characteristics/ instruments Class of Type of QUANTUM QUANTUM OF Reference Acceptance Format of Remarks
Operation Check Check OF CHECK CHECK - TPIA/ Document Norms Records
- CON- REC/NQM
TRACTOR
/PQCC
1 2 3 4 5 6 6 7 8 9 10
k) Oil filling in transformer B Test 100% Manufacturer’s ….
under vacuum through filtration Instruction Manual
machine.
l) Testing of oil after completion B Test 100% Manufacturer’s ….
of filtration. Instruction Manual
m) Oil level & leakage in trans- B Test 100% Manufacturer’s ….
former tank, radiators. Instruction Manual
n) Wiring and termination of B Physical 100% Manufacturer’s ….
cable from instrument, Bucholz Instruction Manual
Relay, OTI/WTI, MOG. & Wiring Details/
Drgs.
o) Tap switch position B Physical 100% Manufacturer’s ….
Instruction Manual
& Wiring Details/
Drgs.
p) Polarity and connection of B Physical 100% Manufacturer’s ….
CTs with leads, otherwise CTs Instruction Manual
secondary to be shorted. & Wiring Details/
Drgs.
q) IR value between terminal B Physical 100% …. ….
and flange bushing.
r) Earthing of Transformer as B Physical 100% As per drawing As per drawing
per drawing and IE rules.
s) General appearance for paint B Physical 100% …. ….
condition.(Retouching of paint if
required.)
t) Whole assembly for tightness B Physical 100% …. ….
and general appearance.
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR NAME/ SIGNATURE OF THE SUB-CONTRACTOR/ ERECTION AGENCY

59
60
FIELD QUALITY PLAN FOR CIVIL WORKS QAP NO. :
REV. NO.:
DATE :
1 DOCUMENTS AND DRAWING
1.1 Check that the instruction B Physical 100% RANDOM Bill of Material Office record
manuals for all equipments
have been received.
Quality Control Manual

1.2 Check that the approved civil B Physical 100% RANDOM Bill of Material Office record
foundation plan of equipment
are available.

2 CIVIL WORKS FOR EQUIPMENT FOUNDATIONS

2.1 Earth Work


2.1.1 Before excavation
2.1.1.1 Chck the pegs conditions as per Measure Tape B Visual 100% RANDOM As per site As per site EIC Office record
line and alignment w.r.t. existing EIC
structure
2.1.1.2 Checking of pit marking as per Measure Tape B Visual 100% RANDOM Foundation Foundation plan
drawing. plan

2.1.2 Excavation work


2.1.2.1 Checking of pit marking / loca- Measure Tape B Physical 100% RANDOM Foundation Foundation Plan Site record
tion Plan
2.1.2.2 Check the dimension of pit at Measure Tape B Physical 100% RANDOM Foundation Foundation Plan Site record
bottom (Lx Bx D) Plan
2.1.2.3 Check the type of soil, if BC soil Measure Tape B Physical/ 100% RANDOM Foundation Foundation Plan Site record
is confirmed follow the instruc- Hammer- Plan
tion on drawing for stone soling ing crobar
Sr. No. ACTIVITY AND OPERATION Characteristics / Class Type of QUANTUM QUANTUM Reference Acceptance “Format Of Remarks
Instruments of Check OF CHECK OF CHECK Documents Norms Records”
Check - CONTRAC- - TPIA/REC/
TOR/PQCC NQM
2.1.2.4 Check the type of soil, if Non Measure Tape B Physical/ 100% RANDOM Foundation Foundation Plan Site record
BC soil is confirmed follow the Hammer- Plan
drawing. ing crobar

2.3 Shuttering
2.3.1 Check the shuttering board Measure tape B Visual 100% RANDOM Foundation Foundation Plan Site record
which are made to shape with Plan
steel tape including cleaning &
proper surface preparation .
2.3.2 Placment of shuttering boards Tackiling equip- B Visual 100% RANDOM Foundation Foundation Plan Site record Required
including supports, tie rod etc. ment Plan as per site
condition
2.3.3 Measurement, line and level Steel tape & B Visual 100% RANDOM Foundation Foundation Plan Site record
with steel tape & water level. water level Plan
2.3.4 Check placement, alignment Measure tape B Visual 100% RANDOM Foundation Foundation Plan Site record
& embedment of anchor bolts, Plan
Check no oil on inserts (For
foundation bolts)
2.3.5 Check bolt setting with tem- Measure tape B Visual 100% RANDOM Foundation Foundation Plan Site record
plates. Plan

2.4 Cement
2.4.1 Cement - Received from Sup- Review of TC/ As A Visual One of con- RANDOM IS: 11269 Manufacturer’s Site Record
plier per IS signment Test Certificate
2.4.2 Setting Time & Compressive Review of TC/ As A Visual One of con- RANDOM IS: 11269 Manufacturer’s Site Record
strength per IS signment Test Certificate

2.5 Reinforced Steel


2.5.1 Visual Examination to ensure B Visual 100% RANDOM IS: 1786 & Approved Draw- Site Record
free from cracks, surface flaws, Approved ings
imperfect edges and dimen- Drawings
sional checks

61
62
Sr. No. ACTIVITY AND OPERATION Characteristics / Class Type of QUANTUM QUANTUM Reference Acceptance “Format Of Remarks
Instruments of Check OF CHECK OF CHECK Documents Norms Records”
Check - CONTRAC- - TPIA/REC/
TOR/PQCC NQM
2.5.2 Cutting, Bending, placing of Tackling Equip- B Visual 100% RANDOM Approved Approved Draw- Site Record
reinforced steel bars & lapping ment Drawings ings

2.6 Concreting
Quality Control Manual

2.6.1 Mixing of cement (OPC, 53 Tackling equip- B Visual 100% RANDOM As per As per instructions Site record
Grade, ISI mark), sand & ment instructions of of manufacturer’s
coarse aggregate as per ratio manufactur-
1:4:8/1:2:4/1:5:8/ 1:1.5:3 er’s
2.6.2 Check workability of concrete Tackling equip- B Visual 100% RANDOM As per As per instructions Site record
ment instructions of of manufacturer’s
manufactur-
er’s
2.6.3 Placing concrete, poking and Tackling equip- B Visual 100% RANDOM As per As per instructions Site record
compacting. ment instructions of of manufacturer’s
manufactur-
er’s
2.6.4 Testing of concrete cubes for Compression A Third One set per RANDOM IS 456, IS 516 IS 456, IS 516 Site record
compression strength. 7 Days machine party lab substation
or 28 Days. test
2.6.5 Check whether curing period of C Visual 100% RANDOM Visual check Visual check for Site record
the foundation is completed. for min 7 days min 7 days
2.6.6 Check the backfilling and Tackling equip- A Visual 100% RANDOM Foundation Foundation Plan Site record
compaction is completed upto ment Plan
ground level.

2.7 Masonary work


2.7.1 Check the proportion, mixing & Tackling equip- B Visual Random RANDOM Foundation Foundation Plan Site record
placement of mortar. ment Plan
2.7.2 Plumb & alignment Tackling equip- B Visual Random RANDOM Foundation Foundation Plan
ment Plan
2.7.3 Curing B Visual 100% RANDOM Visual check Visual check for Site record
for min 7 days min 7 days
Sr. No. ACTIVITY AND OPERATION Characteristics / Class Type of QUANTUM QUANTUM Reference Acceptance “Format Of Remarks
Instruments of Check OF CHECK OF CHECK Documents Norms Records”
Check - CONTRAC- - TPIA/REC/
TOR/PQCC NQM
2.7.4 Control brick height “ In day Measure tape B Visual 100% RANDOM Foundation Foundation Plan
work” Plan

2.8 Plastering work


2.8.1 Plastering thickness and even- B Visual Random RANDOM Visual check Visual check
ness
2.8.2 Mortar mix / proportion Tackling equip- B Visual Random RANDOM Foundation Foundation Plan Site record
ment Plan
2.8.3 Check the placement, thickness Tackling equip- B Visual Random RANDOM Foundation Foundation Plan Site record
of plaster, line & level of plaster ment Plan
2.8.4 Curing B Visual 100% RANDOM Visual check Visual check for Site record
for min 7 days min 7 days

Legends :
“CLASS OF CHECK:
A -- CRITICAL -- TO BE WITNESSED BY PIA SITE AND SURVEILLANCE BY PIA, CC.
B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND PIA SITE
C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY PIA SITE”

TC : Test Certificate
V : Verify
W : Witness
EIC : Engineer In Charge

63
64
FIELD QUALITY PLAN-- PSC POLES (11KV& LT), POLE EARTHING AND GUY
ERECTION
Item: PSCC Poles(11KV& LT)
QP No:
Contractor’s Name:
REV.No:
Sub Contractor/ agency Name & Address:
Quality Control Manual

Sub-system: POLE ERECTION ,EARTHING, GUY ERECTION DATE:

PAGE:
SL.NO MAIN ACTIV- CHARAC- CLASS OF TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE FORMAT OF RE MARKS
ITY& OPERA- TERISTICS CHECK CHECK OF CHECK OF CHECK ENCE NORMS RECORD
TION / INSTRU- - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
1 RECEIPT AND 1) RECEIPT C VISUAL 100% RANDOM SUPPLIER CORRELATION OF SUPPLIER TC POLES WHICH ARE
STORAGE AT STORES TC THE LOT RECEIVED INSPECTED AND
WITH THE TC CLEARED BY PIA
SHALL ONLY BE AC-
CEPTED ON RECEIPT
2) VISUAL C VISUAL 100% RANDOM BROKEN, DAMAGED SITE REGISTER
INSPECTION POLES SHALL BE
STACKED SEPA-
RATELY
3) PROPER C VISUAL 100% RANDOM UTILITY / “1)POLES SHALL BE SITE REGISTER
STORAGE REC SPECI- STACKED IN SUCH
FICATION or A MANNER THAT
AS PER AC- BROAD SIDE IS
CEPTANCE VERTICAL.
NORMS 2)EACH TIER IN THE
STACK IS SUPPORT-
ED ON WOODEN
SLEEPERS LOCAT-
ED AT 1.2Mtr APART,
WOODEN SUP-
PORTS ALIGNED IN
VERTICAL LINE. “
SL.NO MAIN ACTIV- CHARAC- CLASS OF TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
ITY& OPERA- TERISTICS CHECK CHECK OF CHECK OF CHECK ENCE RECORD
TION / INSTRU- - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
2 TRANSPOR- TRANSPOR- C VISUAL 100% - UTILITY “1)POLES SHALL BE
TATION OF TATION SPECIFICA- TRANSPORTED WITH
POLES TION or AS BROAD FACES PLACED
PER AC- VERTICALLY
CEPTANCE 2)SUPPORTS ARE LO-
NORMS CATED AT 1.2Mtr APART
THROUGH OUT THE
LENGTH OF THE POLE”
3 PRE INSTAL- AVAIL- C VISUAL 100% RANDOM UTILITY / “1)ENSURE APPROVED SITE REGISTER
LATION ABILITY OF CHECK REC SPECI- DRAWINGS FOR INSTAL-
APPROVED FICATION or LATION OF THE POLES
DRAWINGS AS PER AC- ARE AVAILABLE AT WORK
ALL CON- CEPTANCE PLACE
STRUCTION- NORMS 2)ENSURE ALL CON-
AL MATE- STRUCTION MATERIAL
RIAL. LIKE BOULDERS, SAND ,
CEMENT , STONE CHIPS
ARE ALSO AVAILABLE AT
WORK PLACE “
AVAILABILITY C VISUAL 100% 100% ROUTE SITE REGISTER
OF ROUTE SURVEY
SURVEY MAP REPORT
AT WORK
PLACE
4.INSALATION OF POLES
4.1 EXCAVATION 4.1.1) C VISUAL 100% RANDOM UTILITY / PIT LONGITUDINAL AXIS SITE REGISTER “CONTROLLED
OF PIT MANUAL REC SPECI- SHOULD BE IN THE DI- BLASTING IS
EXCAVATION FICATION or RECTION OF THE LINE PERMITTED IN
/ CON- AS PER AC- CASE OF HARD
TROLLED CEPTANCE OR ROCKY SOILS
BLASTING NORMS (IN CASE OF
INHABITED LOCA-
TION DRILLING/
CHIPPING TO BE
RESORTED TO)”

65
66
SL.NO MAIN ACTIV- CHARAC- CLASS OF TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
ITY& OPERA- TERISTICS CHECK CHECK OF CHECK OF CHECK ENCE RECORD
TION / INSTRU- - CONTRAC- - TPIA/REC/ DOCUMENT
MENTS TOR/PQCC NQM
4.1.2 )SIZE C DIMEN- 100% RANDOM UTILITY / 0.6M X 1.2M (OR) SITE REGISTER IN HARD ROCK LOCA-
OF PIT SIONAL REC SPECI- 0.6Dia X 1.5M Depth TIONS ONE Mtr. DEEP
FICATION or HOLE AND Dia OF 1.2
AS PER AC- TIMES THE BOTTOM
CEPTANCE DIMENSION OF THE
Quality Control Manual

NORMS POLE.
4.1.3) PLANT- C DIMEN- 100% 5% UTILITY / 1.5 m ABOVE PRE- SITE REGISTER IN CASE OF BLACK
ING DEPTH SIONAL REC SPECI- CAST SLAB COTTON & WET SOILS
IN GROUND FICATION or PLANTING DEPTH
AS PER AC- INCREASED BY 0.2 Mtr
CEPTANCE
NORMS
4.2 BASE FOUN- BASE CON- C MEA- 100% 5% UTILITY / M-15 GRADE SIZE SITE REGISTER EQUIVALENT SIZE
DATION CRETE SURE- REC SPECI- 0.45M X 0.45M X STONE PLATE CAN
MENT FICATION or 0.075 m ALSO BE USED
AS PER AC- WHERE EVER FOUND
CEPTANCE ECONOMICAL
NORMS
4.3 POLE EREC- 4.3.1) POLE C VISUAL 100% RANDOM UTILITY / “1)POLES SHALL BE
TION ERECTION REC SPECI- LIFTED TO THE PIT
FICATION or WITH THE HELP OF
AS PER AC- WOODEN SUP-
CEPTANCE PORTS
NORMS 2)THE POLE SHALL
BE KEPT IN VERTI-
CAL POSITION WITH
THE HELP 25mm
MANILA ROPES.”
4.3.2) ALIGN- C SPIRIT 100% RANDOM UTILITY / SITE REGISTER
MENT & LEVEL REC SPECI-
VERTICAL- FICATION or
ITY IN BOTH AS PER AC-
DIRECTIONS CEPTANCE
NORMS
SL.NO MAIN CHARACTERISTICS CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ACTIVITY& / INSTRUMENTS OF CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
OPERATION CHECK - CON- - TPIA/REC/
TRACTOR/ NQM
PQCC
4.3.3) BACK FILLING C VISUAL 100% RANDOM UTILITY / WITH BRICK SITE REGISTER TEMPORARY ANCHORS
REC SPECI- BATS AND SHALL BE REMOVED
FICATION or COMPACTED IN ONLY AFTER THE POLE
AS PER AC- LAYERS IS SET IN THE FOUNDA-
CEPTANCE TION AFTER COMPACT-
NORMS ING THE SOIL.
4.3.4) CONCRETING C “MEA- 100% 10% UTILITY / SITE REGISTER AT ALL TAPPING POINTS,
OF FOUNDATIONS SURE REC SPECI- DEAD END POLES,
EMENT” FICATION or AT DT LOCATIONS, AT
AS PER AC- ALL POINTS AS PER
CEPTANCE REC CONSTRUCTION
NORMS DRAWING AT 1 km OF
LAST JAMA FILLED
STRUCTURE, BOTH
SIDE POLES OF NALLA
CROSSINGS, ROAD
CROSSING, RAILWAY
CROSSINGS, AT DP , 4P
STRUCTURE.
5.1) COIL TYPE C VISUAL 100% 5% UTILITY / REC CON- SITE REGISTER
EARTHING REC SPECI- STRUCTION
FICATION or STANDARD J-1
AS PER AC-
CEPTANCE
NORMS
6 COIL TYPE a) EXCAVATION OF C VISUAL/ 100% RANDOM UTILITY / REF: REC SITE REGISTER
EARTHING PIT SIZE (DIA-600 X DIMEN- REC SPECI- CONSTRUC-
INSTALLA- 1500 mm) SIONAL FICATION or TION STAN-
TION AS PER AC- DARD -J-1
CEPTANCE
NORMS
b)INSTALEARTHING C VISUAL 100% RANDOM UTILITY / ENSURE THE SPIRAL
SPIRAL REC SPECI- WIRE IS 4mm GI WIRE
FICATION or
AS PER AC-
CEPTANCE

67
NORMS
68
SL.NO MAIN CHARACTERISTICS / CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE- RE MARKS
ACTIVITY& INSTRUMENTS OF CHECK OF CHECK OF CHECK DOCUMENT NORMS CORD
OPERATION CHECK - CON- - TPIA/REC/
TRACTOR/ NQM
PQCC
c) FILL THE PIT B VISUAL 100% RANDOM UTILITY / REC
WITH ALTERNATE SPECIFICA-
LAYERS OF 300mm TION or AS
WITH CHARCOAL PER ACCEP-
Quality Control Manual

AND SALT UPTO 1.2 TANCE NORMS


Mtr.OF DEPTH FROM
BOTTOM OF THE
PIT.
d) CONNECTION C VISUAL 100% RANDOM UTILITY / REC
BETWEEN THE SPI- SPECIFICA-
RAL WIRE AND POLE TION or AS
EARTH WIRE PER ACCEP-
TANCE NORMS
6.1) PIPE/ ROD TYPE C VISUAL 100% 5% UTILITY / REC REC CON- SITE REGISTER AT BOTH SIDES
EARTHING SPECIFICA- STRUCTION OF RAILWAY,
TION or AS STANDARD J-2 ROAD, DRAIN,
PER ACCEP- TELECOM, RIVER
TANCE NORMS CROSSINGS
7 PIPE TYPE a) EXCAVATION OF C VISUAL 100% RANDOM UTILITY / REC REF: REC CON- SITE REGISTER
EARTHING PIT SIZE BY 0.6M Dia SPECIFICA- STRUCTION
INSTALLA- X 2.7M DEPTH TION or AS STANDARD- J-2
TION PER ACCEP-
TANCE NORMS
b) INSTALL 40 Dia GI C VISUAL 100% RANDOM UTILITY / REC
PIPE WITH 12 Dia SPECIFICA-
HOLES IN THE PIT. TION or AS
PER ACCEP-
TANCE NORMS
c) FILL THE PIT WITH B VISUAL 100% RANDOM UTILITY / REC
ALTERNATE LAYERS SPECIFICA-
OF 300mm CHAR TION or AS
COAL AND SALT. PER ACCEP-
TANCE NORMS
SL.NO MAIN CHARACTERISTICS / CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ACTIVITY& INSTRUMENTS OF CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
OPERATION CHECK - CON- - TPIA/REC/
TRACTOR/ NQM
PQCC
d) CONNECTION C VISUAL 100% RANDOM UTILITY / REC
BETWEEN THE PIPE SPECIFICA-
AND POLE WITH TION or AS
8mm SWG WIRE PER ACCEP-
TANCE NORMS
8 STAY / GUY 8.1) LOCATION FOR C VISUAL 100% 5% UTILITY / REC THE GUY SETS ARE
ERECTION THE GUY SETS SPECIFICA- ERECTED AT ANGLE
TION or AS LOCATIONS , DEAD
PER ACCEP- END LOCATIONS , T
TANCE NORMS - Off POINTS , STEEP
GRADIENT LOCA-
TIONS, DOUBLE POLE
STRUCTURES.
8.2) EXCAVATION OF C DIMEN- 100% 5% UTILITY / REC REC CON-
PIT SIZE 0.5M X 0.5M SIONAL SPECIFICA- STRUCTION
X 1.6M TION or AS STANDARD G-1
PER ACCEP-
TANCE NORMS
8.3)SIZING OF AN- C DIMEN- 100% 5% UTILITY / REC REC CON-
CHOR PLATE SIONAL SPECIFICA- STRUCTION
TION or AS STANDARD K-1
PER ACCEP-
TANCE NORMS
8.4)GROUTING OF C DIMEN- 100% 5% UTILITY / REC IF GUY WIRE IS
ANCHOR PLATE AND SIONAL SPECIFICA- FOUND HAZARD-
ANCHOR ROD WITH TION or AS OUS IT SHOULD BE
EARTH FILLING PER ACCEP- PROTECTED WITH
TANCE NORMS ASBESTOS PIPE FILL
WITH CONCRETE
8.5)ANGLE BE- B “MEA- 100% 5% UTILITY / REC REC CON-
TWEEN STAY WIRE SURE SPECIFICA- STRUCTION
AND POLE EMENT” TION or AS STANDARD G-1
PER ACCEP-
TANCE NORMS

69
70
SL.NO MAIN CHARACTERISTICS / CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ACTIVITY& INSTRUMENTS OF CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
OPERATION CHECK - CON- - TPIA/REC/
TRACTOR/ NQM
PQCC
8.6)ERECTION OF C VISUAL 100% 50% UTILITY / REC REC CON- GUY INSULATORS
GUY INSULATOR SPECIFICA- STRUCTION ARE ERECTED AT
TION or AS STANDARD G-1 HEIGHT OF 3050 mm
PER ACCEP- FROM THE GROUND .
Quality Control Manual

TANCE NORMS
8.7) ERECTION C VISUAL 100% 50% UTILITY / REC REC CON- TURN BUCKLE ARE
TURNBUCKLE SPECIFICA- STRUCTION MOUNTED HALF WAY
TION or AS STANDARD G-1 IN THE WORKING PO-
PER ACCEP- SITION , THUS GIVING
TANCE NORMS THE Max. MOVEMENT
FOR TIGHTENING
AND LOOSENING
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
NAME/ SIGNATURE OF THE SUB-CONTRACTOR/ ERECTION AGENCY
FIELD QUALITY PLAN--ERECTION OF 11KV POLE ACCESSORIES
Contractor’s Name: Item: ERECTION OF 11KV POLE ACCESSORIES FQP No:
Sub Contractor/ agency Name & Address: Sub-system: G.I COMPONENTS, INSULATORS, HARDWARE FIT- REV.No:
TINGS, DANGER BOARDS, ANTI-CLIMBING DEVICES, GUARDING
DATE:
PAGE:
MS GALVANIZED COMPONENTS
SL.NO MAIN ACTIV- CHARAC- CLASS OF TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ITY& OPERA- TERISTICS/ CHECK CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
TION INSTRUMENTS - CONTRAC- - TPIA/REC/
TOR/PQCC NQM
1 RECEIPT AND 1) RECEIPT C VISUAL 100% RANDOM CORRELATION STORES REG- COMPONENTS
STORAGE AT STORES CHECK OF THE LOT ISTER WHICH ARE
RECEIVED WITH INSPECTED
TC AND CLEARED
BY PIA SHALL
ONLY BE AC-
CEPTED ON
RECEIPT
2) VISUAL C VISUAL 100% RANDOM DAMAGED AND STORES REG-
INSPECTION CHECK GALVANIZATION ISTER
DEFECTIVE
COMPONENTS
ARE TO BE
STACKED SEPA-
RATELY
3) PROPER 0 VISUAL 100% RANDOM UTILITY / REC ALL G.I. COMPO- STORES REG-
STORAGE CHECK SPECIFICA- NENTS SHOULD ISTER
TION or AS PER BE STACKED
ACCEPTANCE ON WOODEN
NORMS SLEEPERS AND
THE STORAGE
AREA SHALL BE
FREE FROM WA-
TER LOGGING

71
72
SL.NO MAIN ACTIV- CHARAC- CLASS OF TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ITY& OPERA- TERISTICS/ CHECK CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
TION INSTRUMENTS - CONTRAC- - TPIA/REC/
TOR/PQCC NQM
2 FIXING OF MS 1) V- CROSS C VISUAL 100% 10% UTILITY / REC AS PER AP- SITE REGIS- CROSS ARMS
COMPONENTS ARM WITH CHECK SPECIFICA- PROVED DRAW- TER ARE TO BE
CROSS ARM TION or AS PER ING FIXED AT THE
BACK CLAMP ACCEPTANCE MARKINGS
NORMS PROVIDED ON
Quality Control Manual

THE POLES
2) HORIZON- C WATER 100% 10% APPROVED APPROVED
TAL ALIGN- LEVEL DRAWING DRAWING
MENT OF
CROSS ARMS
WITH POLE
3) TOP CLEAT C VISUAL 100% 10% UTILITY / REC AS PER AP- SITE REGIS- TOP CLEATS
WITH BACK CHECK SPECIFICA- PROVED DRAW- TER ARE TO BE
CLAMP TION or AS PER ING FIXED AT THE
ACCEPTANCE MARKINGS
NORMS PROVIDED ON
THE TOP OIF
THE POLE
4) VERTICAL C WATER 100% 10% APPROVED APPROVED
ALIGNMENT LEVEL DRAWING DRAWING
OF TOP CLEAT
WITH POLE
5) TIGHT- C ERECTION 100% 10% APPROVED THE COMPO- SITE REGIS-
ENING MS CHECK DRAWING NENTS SHOULD TER
COMPONENTS BE FIXED RIGID
WITH NUTS, ENOUGH TO
BOLTS AND WITH STAND ALL
WASHERS THE FORCES
INSULATORS WITH PINS
3 RECEIPT AND 1) RECEIPT C VISUAL 100% RANDOM UTILITY / REC CORRELATION SITE REGIS- COMPONENTS
STORAGE AT STORES CHECK SPECIFICA- OF THE LOT TER WHICH ARE
TION or AS PER RECEIVED WITH INSPECTED AND
ACCEPTANCE THE CHP DE- CLEARED BY
NORMS SCRIPTIONS PIA SHALL ONLY
BE ACCEPTED
ON RECEIPT
SL.NO MAIN ACTIV- CHARACTERIS- CLASS OF TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ITY& OPERA- TICS/ INSTRU- CHECK CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
TION MENTS - CONTRAC- - TPIA/REC/
TOR/PQCC NQM
2) VISUAL C VISUAL 100% RANDOM THE SURFACE STORES REG- DAMAGED IN-
INSPECTION CHECK OF THE INSULA- ISTER SULAOTRS ARE
TORS ARE TO TO BE STACKED
BE THOROUGH- SEPARATELY
LY CHECKED
AND CLEANED
,

THREADING OF
THE INSULATOR
THIMBLE TO BE
CHECKED
3) PROPER C VISUAL 100% RANDOM STANDARD STORES REG-
STORAGE CHECK PRACTICE ISTER
4 FIXING OF 1) CHECK C VISUAL 100% RANDOM UTILITY / REC AS PER AP- SITE REGIS- AT GROUND
INSULATORS THREADING CHECK SPECIFICA- PROVED DRAW- TER LEVEL THIS
OVER THE PINS TION or AS PER ING PREASSEMBLY
AND INSULA- ACCEPTANCE CHECK IS DONE
TOR THIMBLES NORMS FOR PROPER AS-
AND CHECK SEMBLY
THE ALIGN-
MENT OF PIN
WITH INSULA-
TOR
2) ASSEMBLING C VISUAL 100% RANDOM APPROVED APPROVED
THE GI PIN AND DRAWING DRAWING
INSULATORS
3) FIXING THE C VISUAL 100% RANDOM UTILITY / REC AS PER AP- SITE REGIS- ON ALL THE
PIN INSULA- CHECK SPECIFICA- PROVED DRAW- TER POLES IN THE
TOR TO THE TION or AS PER ING STRAIGHT LINE
CROSSARMS ACCEPTANCE PIN INSULATORS
AND POLE TOP NORMS SHALL BE USED.
BRACKET DISC INSULATORS
ARE USED AT
DEAD END AND
ANGLE LOCA-
TIONS

73
74
SL.NO MAIN ACTIV- CHARACTERIS- CLASS OF TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ITY& OPERA- TICS/ INSTRU- CHECK CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
TION MENTS - CONTRAC- - TPIA/REC/
TOR/PQCC NQM
4) CHECK THE B DIMEN- RANDOM RANDOM UTILITY / REC APPROVED FOR CHECKING
CLEARANCES SIONAL SPECIFICA- DRAWING THE CLEARANCES
BETWEEN THE TION or AS PER SUITABLE TEM-
INSULATORS ACCEPTANCE PLATE/ JIGS ARE
Quality Control Manual

NORMS TO BE USED
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
NAME/ SIGNATURE OF THE SUB-CONTRACTOR/ ERECTION AGENCY
FIELD QUALITY PLAN FOR ISOLATOR, AB ITEM : ERECTION WORK
SWITCH/DO FUSE SUB SYSTEM : ISO/AB SWITCH/ DOFUSE
QAP NO. :
REV. NO.:
DATE :
Sr. No. CHARACTERISTICES / Type of Check Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
ITEMS OF CHECK OF CHECK ments & Acceptance Records”
- CONTRAC- - TPIA/REC/ Standard
TOR/PQCC NQM
1 2 3 4 5 6 7 8 9
1 RECEIPT & STORAGE
1.1 Receiving inspection V - B 100% RANDOM Delivery Challan MRC
(Completeness of docu-
ments, test certificates,
instruction manual etc.)
1.2 Unloading V - B 100% RANDOM Instruction Manual -
1.3 Visual exmination for V - B 100% RANDOM Packing list / Instruc- -
damage & defects tion Manual
1.4 Proper storage V - B 100% RANDOM Instruction Manual -

2 PRE INSTALLATION
2.1 Availability of instruction V - B 100% RANDOM List of approved -
manual and drawing, drawing / Instruction
lifting arrangement Manuals
2.2 Availability of all materials V - B 100% RANDOM Packing list, Approved -
drawing & Bill Of
Material
2.3 Foundation (If required) V - B 100% RANDOM Civil foundation -
drawing
2.4 Verticality of support V - B 100% 50% GA/ Structural draw- -
structure ing

3 INSTALLATION

75
3.1 Rating plate details V - B 100% RANDOM instruction manual Site record
76
Sr. No. CHARACTERISTICES / Type of Check Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
ITEMS OF CHECK OF CHECK ments & Acceptance Records”
- CONTRAC- - TPIA/REC/ Standard
TOR/PQCC NQM
3.2 Check for proper slinging V - B 100% RANDOM Instruction Manual -
& lifting
3.3 Check for the tightness of V - B 100% 50% Instruction Manual -
base bolts & other bolted
joints preferably by torque
Quality Control Manual

wrench.
3.4 Check level & alignment V - B 100% 50% Instruction Manual -
of the base, housing as-
sembly and flanges.
3.5 Ensure proper erection V - B 100% 50% Instruction Manual Site record
of poles, main blade &
drive assembly as per
approved drgs.
3.6 Check for the alignment V - B 100% 50% Instruction Manual Site record
of isolator and verticality
of isolator / AB switch /
DO Fuse.
3.7 Check for the clearance V - B 100% 50% As per IS 10118 -
between live part to earth.
3.8 Check for no vibration V - B 100% 50% Instruction Manual -
or rotation of contacts of
insulators during isolator
operation. (Electrical &
Mechanical)
3.9 Check for the provision of V - B 100% 50% Instruction Manual -
earthing and earth con-
nection.
3.10 Check operation of the V - B 100% 50% Instruction Manual -
isolator by rotating one of
the insulator stack manu-
ally and adjust the length
of the crossed tandem as-
sembly to ensure proper
engagement of contacts
during closing.
Sr. No. CHARACTERISTICES / Type of Check Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
ITEMS OF CHECK OF CHECK ments & Acceptance Records”
- CONTRAC- - TPIA/REC/ Standard
TOR/PQCC NQM

4 PRE COMMOSSIONING
4.1 Check for visual damage V - B 100% 50% Instruction Manual TC
to any parts including
porcelain isolator.
4.2 Check manual / opera- V - B 100% 50% Instruction Manual TC
tion and inter locks.
4.3 IR Value Test Megger B 100% 50% Instruction Manual TC
a. Between each pole to
earth.
4.4 Ground connections V - B 100% 50% Instruction Manual TC
4.5 Check continuity Electrical Multimeter B 100% 50% Instruction Manual Site Record

CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY


Legends :
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
TC : Test Certificate EIC : Engineer In Charge
MRC : Material Reciept Certificate
V : Visual

77
78
FIELD QUALITY PLAN FOR LA ITEM : ERECTION WORK
SUB SYSTEM : Lighning Arrestor
QAP NO. :
REV. NO.:
Sr. No. CHARACTERISTICES / Type of Instruments Class QUANTUM OF QUANTUM OF Reference Docu- “Format Of Remarks
ITEMS Check CHECK - CON- CHECK - TPIA/ ments & Accep- Records”
TRACTOR/PQCC REC/ NQM tance Standard
Quality Control Manual

1 2 3 4 5 6 7 8 9
1 RECEIPT & STORAGE
1.1 Receiving inspection V - B 100% RANDOM Delivery Challan MRC
(Completeness of docu-
ments, test certificates,
instruction manual etc.)
1.2 Unloading V - B 100% RANDOM Instruction Manual -
1.3 Visual exmination for V - B 100% RANDOM Packing list / In- -
damage & defects struction Manual
1.4 Proper storage V - B 100% RANDOM Instruction Manual -
2 PRE INSTALLATION
2.1 Availability of instruction V - B 100% RANDOM List of approved -
manual and drawing, drawing / Instruc-
lifting arrangement tion Manuals
2.2 Availability of all materi- V - B 100% RANDOM Packing list, Ap- -
als proved drawing &
Bill Of Material
2.3 Verticality of support V - B 100% 50% GA/ Structural -
structure drawing
3 INSTALLATION
3.1 Rating plate details V - B 100% RANDOM instruction manual Site record
3.2 Check cleanliness of Test Meggar B 100% 10% Instruction manual -
surfaces of the ar-
rester and check Megger
value.
3.3 Check base of the surge V - B 100% 50% Instruction manual -
arrestor.
Sr. No. CHARACTERISTICES / Type of Instruments Class QUANTUM OF QUANTUM OF Reference Docu- “Format Of Remarks
ITEMS Check CHECK - CON- CHECK - TPIA/ ments & Accep- Records”
TRACTOR/PQCC REC/ NQM tance Standard
1 2 3 4 5 6 7 8 9
3.4 Check the tightness of V - B 100% 50% Instruction manual -
equipment base with
structure.
3.5 Ensure that the explo- V - B 100% 50% Instruction manual -
sion vent of the LA is
away from adjacent
critical equipment.
3.6 Check earthing provision V - B 100% 50% Instruction manual -
and connection tight-
ness.
3.7 Check clearance be- V - B 100% 50% Instruction manual -
tween live part to earth
part.
3.8 Check overall alignment V - B 100% 50% Instruction manual -
of LA.
3.9 Mounting height of LA Measure - B 100% RANDOM Instruction manual Site record
4 PRE COMMISSIONING
4.1 IR Value test Test Meggar A 100% 10% Instruction manual TC
4.2 Check for resistance of Test - B 100% 10% Instruction manual TC
ground connection.
4.3 Earth continuity test Test Earth Megger B 100% 10% Instruction manual TC
4.4 Final Document review V - B 100% RANDOM instruction manual / TC
final document list

CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY


Legends :
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
TC : Test Certificate
MRC : Material Reciept Certificate
V : Visual
EIC : Engineer In Charge

79
80
FIELD QUALITY PLAN FOR PAINTING ITEM : ERECTION WORK
SUB SYSTEM : PAINTING
QAP NO. :
REV. NO.:
DATE :
Sr. No. CHARACTERIS- Type of Instruments Class QUANTUM OF QUANTUM OF Reference Docu- “Format Of Remarks
TICES / ITEMS Check CHECK - CON- CHECK - TPIA/ ments & Accep- Records”
TRACTOR/PQCC REC/ NQM tance Standard
1 2 3 4 5 7 8 9
Quality Control Manual

1 RECEIPT & STOR-


AGE
1.1 Recveiving inspection V C 100% RANDOM Delivery Challan & MRC
Specification
1.2 Proper storage V C 100% RANDOM 5% Site Records
2 PAINTING
2.1 De rusting from struc- V Wire Brush, B 100% RANDOM As per EIC -
tutres & other rusted emery paper
part of the equipment
2.2 Red oxide zinc V Paint brush B 100% RANDOM As per EIC / IS Site Records
chromate paint on 2074
steel structures - Two
Coats
2.3 Synthetic enamel V Paint brush B 100% RANDOM As per EIC / IS Site Records
paint - Two Coats or 2932
more coats
2.4 Aluminimum Paint V Paint brush B 100% RANDOM As per EIC / IS Site Records
- Two Coats or more 2339
coats
2.5 Final document - - B 100% RANDOM Final document list Site Records
review

CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY


Legends :
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
TC : Test Certificate
MRC : Material Reciept Certificate V : VISUAL
FIELD QUALITY PLAN

Item: ERECTION OF BPL CONNECTION


Sub-system:

SL.NO MAIN CHARACTERIS- CLASS OF TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ACTIVITY& TICS / INSTRU- CHECK CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
OPERATION MENTS - CONTRAC- - TPIA / REC
TOR/ PQCC / NQM
SECTION 1 : BOUGHT OUT ITEMS OF BPL CONNECTION
1 RECEIPT 1) RECEIPT AT C VISUAL 100% RANDOM APPROVED APPROVED MAKE STORES
AND STOR- STORES CHECK BOM AND OF THE ITEM REGISTER
AGE APPROVED
DRAWING
2) VISUAL IN- C VISUAL 100% RANDOM DAMAGED AND DE- STORES THE METER
SPECTION CHECK FECTIVE COMPO- REGISTER BOARD SHALL BE
NENTS ARE TO BE OF TEAK WOOD
REPLACED WITH QUALITY OR
GOOD ONE HARD WOOD
3) PROPER C VISUAL 100% RANDOM STANDARD STANDARD PRAC- STORES
STORAGE CHECK PRACTICE TICE REGISTER
SECTION : 2 FIXING OF BOARDS AND ACCESSORIES
2 FIXING OF 1) IDENTIFYING C VISUAL 100% RANDOM AS PER AS PER APPROVED SITE REGIS- CLEARANCE
BOARDS AND MARKING CHECK SPECIFICA- DRAWING TER SHALL BE
AND AC- THE POSITIONS TION MAINTAINED AS
CESSORIES WHERE THE PER APPROVED
COMPONENTS DRAWING AND
ARE TO BE AS PER SPECIFI-
ERECTED CATION
2) FIXING THE C VISUAL 100% RANDOM AS PER AS PER APPROVED SITE REGIS- THE SURFACE
SERVICE SUP- CHECK SPECIFICA- DRAWING TER OF ALL SUP-
PORTS AND TION PORTS SHOULD
GUYS BE CLEANED .

81
82
SL.NO MAIN CHARACTERIS- CLASS OF TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ACTIVITY& TICS / INSTRU- CHECK CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
OPERATION MENTS - CONTRAC- - TPIA / REC
TOR/ PQCC / NQM
“3) FIXING OF C DIMEN- 100% RANDOM AS PER AS PER APPROVED SITE REGIS-
THE WOODEN SIONAL SPECIFICA- DRAWING TER
BOARDS TION
( METER BOARD
Quality Control Manual

AND SWITCH
BOARD )”
4) FIXING OF ALL C VISUAL 100% RANDOM AS PER AS PER APPROVED SITE REGIS-
OTHER ACCES- CHECK SPECIFICA- DRAWING TER
SORIES TION
SECTION : 3 STRINGING OF SERVICE CABLE
3 STRINGING 1) HANDLING OF C VISUAL 100% RANDOM AS PER CABLE SHOULD SITE REGIS- CABLE SURFACE
OF SERVICE THE CABLE CHECK SPECIFICA- NOT BE DRAGGED TER SHALL BE FREE
CABLE TION ON THE GROUND FROM FAULTS,
FLAWS e.t.c
2) SEQUENCE C VISUAL 100% RANDOM AS PER SEQUENCE OF SITE REGIS-
OF CABLE EREC- CHECK SPECIFICA- RUNNING OUT TER
TION TION SHALL BE FROM
TOP TO BOTTOM,
i.e.. THE TOP CABLE
SHALL RUN OUT
FIRST, FOLLOWED
BY THE SIDE
CABLES
3) FIX THE G.I C VISUAL 100% RANDOM AS PER SPECIFICATION / SITE REGIS-
WIRE OF SER- CHECK SPECIFICA- AS PER APPROVED TER
VICE CABLE TO TION DRAWING
CLAMPS
4) CHECK THE C VISUAL 100% RANDOM AS PER AS PER THE STAN- SITE REGIS-
TIGHTNESS OF CHECK SPECIFICA- DARD PRACTICE TER
SERVICE CABLE TION
WITH CLAMPS
SL.NO MAIN CHARACTERIS- CLASS OF TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE FORMAT OF RE MARKS
ACTIVITY& TICS / INSTRU- CHECK CHECK OF CHECK OF CHECK DOCUMENT NORMS RECORD
OPERATION MENTS - CONTRAC- - TPIA / REC
TOR/ PQCC / NQM
5) CHECK C VISUAL 100% RANDOM AS PER THE AS PER IE RULES SITE REGIS- THE MINIMUM
THE GROUND CHECK REC SPECIFI- TER GROUND CLEAR-
CLEARANCES CATIONS ANCES SHOULD
AFTER EREC- BE MAINTAINED
TION OF THE
SERVICE CABLE
SECTION : 4 EARTHING ARRANGEMENT
4 EARTHING 1) LOCAL C VISUAL 100% RANDOM STANDARD IS 3043 SITE REGIS-
ARRANGE- EARTHING OF CHECK PRACTICE / IS TER
MENT BPL HOUSE 3043
HOLD
2) EARTHING C VISUAL 100% RANDOM STANDARD IS 3043 SITE REGIS-
OF GI SUPPORT CHECK PRACTICE / IS TER
WIRE 3043
SECTION : 5 CHARGING OF BPL CONNECTION
4 CHARGING 1) CHECK THE C TEST 100% RANDOM STANDARD STANDARD PRAC- SITE REGIS-
OF BPL CONTINUITY OF PRACTICE TICE TER
CONNEC- CONNECTION
TION 2) CONNECTION C VISUAL 100% RANDOM STANDARD STANDARD PRAC- SITE REGIS- TAKE LINE
OF SERVICE CHECK PRACTICE TICE TER CLEAR ON POLE
LINE TO THE FROM WHICH
POLE SERVICE LINE TO
BE TAPPED
3) CHARGING OF C VISUAL 100% RANDOM STANDARD STANDARD PRAC- SITE REGIS- CHECK FOR ANY
SERVICE CON- CHECK PRACTICE TICE TER ABNORMALITIES
NECTION AT THE BOARD

CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
NAME/ SIGNATURE OF THE SUB-CONTRACTOR/ ERECTION AGENCY

83
84
FIELD QUALITY PLAN FOR VCB
SUB SYSTEM :
QAP NO. :
REV. NO.:
DATE :
Sr. No. CHARACTERISTICS / ITEMS Type of Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
Check OF CHECK OF CHECK ments & Accep- Records”
- CONTRAC- - TPIA/REC/ tance Standard
Quality Control Manual

TOR/PQCC NQM
1 2 3 4 5 6 7 8 9

1 RECEIPT & STORAGE


1.1 Receiving inspection (Complete- V - B 100% RANDOM Delivery Challan MRC
ness of documents, test certificates,
instruction manual etc.)
1.2 Unloading V - B 100% RANDOM Instruction Manual -
1.3 Visual exmination for damage and V - B 100% RANDOM Packing list / Instruc- -
defects tion Manual
1.4 Proper storage V - B 100% RANDOM Instruction Manual -

2 PRE INSTALLATION
2.1 Availability of instruction manual and V - B 100% RANDOM List of Approved -
drawing, lifting arrangement drawing/ Instruction
Manual
2.2 Availability of all materials V - B 100% RANDOM Packing list ,Ap- -
proved drawing & Bill
of Material
2.3 VCB foundation V - B 100% RANDOM Civil foundation -
drawing
2.4 VCB Support structure ( Level & V - B 100% 50% GA/ Structural draw- -
Verticality ) ing

3 INSTALLATION
3.1 Before erection check adequacy of V - B 100% RANDOM instruction manual -
lifting device.
Sr. No. CHARACTERISTICS / ITEMS Type of Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
Check OF CHECK OF CHECK ments & Accep- Records”
- CONTRAC- - TPIA/REC/ tance Standard
TOR/PQCC NQM
3.2 Ensure that breaker are V - B 100% RANDOM instruction manual -
erected with proper handling
equipment, check slings,
dereck/tripod & rope .
3.3 Ensure erection has been V - B 100% RANDOM GA / equipment detail -
done as per approved drawing drawing
and manual.
3.4 Check for Individual pole and V - B 100% 50% instruction manual -
CB alignment.
3.5 Check for the tightness of pole V - B 100% 50% instruction manual -
base bolt with structure.
3.6 Check for the checknut tight- V - B 100% 10% instruction manual -
ness of tie rod. (if applicable)
3.7 Check for cable termination, V - B 100% 50% instruction manual -
ferrules and cable tags are
provided (with proper lugs and
glands)
3.8 Lubricate all the moving parts V - B 100% RANDOM instruction manual -
of the CB.
3.9 Earthing of support structure & V - B 100% 50% instruction manual -
VCB frame.

4 PRE-COMMISSIONING
4.1 Check correct installation of V - B 100% 50% instruction manual -
circuit breaker & operating
mechanism as per instruction
manual.
4.2 Insulation resistance of each Test Megger A 100% 10% instruction manual TC
pole
4.3 Insulation resistance of control Test Megger A 100% 10% instruction manual TC
circuits, motor etc.

85
86
Sr. No. CHARACTERISTICS / ITEMS Type of Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
Check OF CHECK OF CHECK ments & Accep- Records”
- CONTRAC- - TPIA/REC/ tance Standard
TOR/PQCC NQM
4.4 Resistance of closing & trip- Test Multimeter A 100% 10% instruction manual TC
ping coils.
4.5 Minimum pick up volts of coils Test Multimeter A 100% 10% instruction manual TC
4.6 Contact resistance Test Multimeter A 100% 10% instruction manual TC
Quality Control Manual

4.7 Breaker closing & tripping time V - A 100% 10% instruction manual TC
4.8 Functional checking of all ac- Test Multimeter B 100% 10% instruction manual TC
cessories.
4.9 Functional checking of control Test Multimeter B 100% 10% instruction manual TC
circuits, tripping through pro-
tective relays and auto reclose
operation.
4.10 Final document review V - B 100% RANDOM instruction manual/fi- TC
nal document list

CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY


Legends :
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
TC : Test Certificate
MRC : Material Reciept Certificate
V : Visual
EIC : Engineer In Charge
FIELD QUALITY PLAN

Item: DTR STRUCTURE AND COMPONENTS


Sub-system: ERECTION TRANSFORMER STRUCTURE

SECTION - I : MS GALVANIZED COMPONENTS


S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
1 RECEIPT 1) RECEIPT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE SITE REGISTER COMPONENTS WHICH
AND STOR- AT STORES CHALLAN LOT RECEIVED WITH ARE INSPECTED AND
AGE THE DELIVERY CHAL- CLEARED SHALL ONLY
LAN / MDCC DESCRIP- BE ACCEPTED
TIONS
2) VISUAL C VISUAL 100% RANDOM DAMAGED AND GALVA- STORES REGIS-
INSPECTION NISATION DEFECTIVE TER
COMPONENTS ARE TO
BE STACKED SEPA-
RATELY
3) PROPER C VISUAL 100% RANDOM UTILITY / ALL G.I. COMPONENTS STORES REGIS-
STORAGE REC SPECI- SHOULD BE STACKED TER
FICATION or ON WOODEN SLEEP-
AS PER AC- ERS AND THE STOR-
CEPTANCE AGE AREA SHALL BE
NORMS FREE FROM WATER
LOGGING
2 FIXING OF 1) CHECK C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER BOTH THE POLES
MS COM- THE ALIGN REC SPECI- DRAWING SHOULD BE PARALLEL
PONENTS MENT OF FICATION or TO EACH OTHER AND
TWO POLES AS PER AC- SHOULD BE PLANTED
CEPTANCE AT SAME DEPTH
NORMS
2) FIX THE C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER CHECK THE ALIGNMENT
TOP CHAN- REC SPECI- DRAWING OF THE TOP CHANNEL
NEL FICATION or WITH THE POLE
AS PER AC-
CEPTANCE

87
NORMS
88
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
3) FIX THE C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER THESE FISH PLATE
FISH PLATE REC SPECI- DRAWING SHOULD BE PLACED
FICATION or RIGIDLY AND HOLES
AS PER AC- ARE TO BE CHECKED
CEPTANCE
Quality Control Manual

NORMS
3) FIX THE C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER ANGLES SHOULD BE
BELTING REC SPECI- DRAWING FIXED FROM SPECIFIED
ANGLES FICATION or FROM GROUND
WITH BELT- AS PER AC-
ING ANGLE CEPTANCE
BACK NORMS
CLAMP
4) HORIZON- C DIMEN- 100% RANDOM APPROVED APPROVED DRAWING SITE REGISTER
TAL ALIGN- SIONAL DRAWING
MENT OF
THE BELT-
ING ANGLE
WITH
POLES
5) FIX THE C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER THE BOLTS AND NUTS
BRACING REC SPECI- DRAWING SHALL BE TIGHT
ANGLES FICATION or ENOUGH TO HOLD THE
WITH BRAC- AS PER AC- BRACING TO THE POLE
ING ANGLE CEPTANCE
CLAMP NORMS
6) ALIGN- C DIMEN- 100% RANDOM APPROVED APPROVED DRAWING SITE REGISTER THE ANGLE BETWEEN
MENT OF SIONAL DRAWING THE TWO BRACING
THE BRAC- SHOULD BE 900 AND
ING ANGLE SHOULD BE RIGID
WITH BELT- ENOUGH TO BEAR THE
ING ANGLES FORCES
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
3 STAY / GUY 8.1) LOCA- C VISUAL 100% 50% UTILITY / SITE REGISTER AS PER APPROVED
ERECTION TION FOR REC SPECI- DRAWING THE NUMBER
THE GUY FICATION or OF STAYS ARE TO BE
SETS AS PER AC- ERECTED
CEPTANCE
NORMS
8.2) EXCA- C DIMEN- 100% RANDOM UTILITY / REC CONSTRUCTION SITE REGISTER
VATION OF SIONAL REC SPECI- STANDARD G-1
PIT SIZE FICATION or
0.5M X 0.5M AS PER AC-
X 1.6M CEPTANCE
NORMS
8.3)SIZING C DIMEN- 100% RANDOM UTILITY / REC CONSTRUCTION SITE REGISTER
OF ANCHOR SIONAL REC SPECI- STANDARD K-1
PLATE FICATION or
AS PER AC-
CEPTANCE
NORMS
8.4)GROUT- C DIMEN- 100% 50% UTILITY / SITE REGISTER IF GUY WIRE IS
ING OF SIONAL REC SPECI- FOUND HAZARDOUS IT
ANCHOR FICATION or SHOULD BE PROTECT-
PLATE AND AS PER AC- ED WITH ASBESTOS
ANCHOR CEPTANCE PIPE FILL WITH CON-
ROD WITH NORMS CRETE
EARTH FILL-
ING
8.5)ANGLE B “MEA- 100% 50% UTILITY / REC CONSTRUCTION SITE REGISTER
BETWEEN SURE REC SPECI- STANDARD G-1
STAY WIRE EMENT” FICATION or
AND POLE AS PER AC-
CEPTANCE
NORMS
8.6)EREC- C VISUAL 100% 50% UTILITY / REC CONSTRUCTION SITE REGISTER GUY INSULATORS ARE
TION OF REC SPECI- STANDARD G-1 ERECTED AT HEIGHT
GUY INSU- FICATION or OF 3050 mm FROM THE
LATOR AS PER AC- GROUND .
CEPTANCE

89
NORMS
90
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
8.7) EREC- C VISUAL 100% 50% UTILITY / REC CONSTRUCTION SITE REGISTER TURN BUCKLE ARE
TION TURN- REC SPECI- STANDARD G-1 MOUNTED HALF WAY IN
BUCKLE FICATION or THE WORKING POSI-
AS PER AC- TION , THUS GIVING
CEPTANCE THE Max. MOVEMENT
Quality Control Manual

NORMS FOR TIGHTENING AND


LOOSENING
8.8) EN- C VISUAL 100% RANDOM STANDARD APPROVED DRAWING SITE REGISTER
SURE THE PRACTICE
RIGIDNESS
OF THE
STRUC-
TURE
SECTION - II : FIXING OF INSULATORS
4 RECEIPT 1) RECEIPT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE SITE REGISTER COMPONENTS WHICH
AND STOR- AT STORES CHALLAN LOT RECEIVED WITH ARE INSPECTED AND
AGE THE DELIVERY CHAL- CLEARED BY PIA SHALL
LAN / MDCC DESCRIP- ONLY BE ACCEPTED ON
TIONS RECEIPT
2) VISUAL C VISUAL 100% RANDOM THE SURFACE OF THE STORES REGIS- DAMAGED INSULATORS
INSPECTION INSULATOR IS TO BE TER ARE TO BE STACKED
THROUGHLY CHECKED SEPARATELY
AND CLEANED,

THE THREADING OF
THE INSULATOR IS TO
BE CHECKED
3) PROPER C VISUAL 100% RANDOM STANDARD STORES REGIS-
STORAGE PRACTICE TER
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
5 FIXING OF 1) CHECK C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER
INSULA- THREADING REC SPECI- DRAWING
TORS OVER THE FICATION or
PINS AND AS PER AC-
INSULA- CEPTANCE
TORS AND NORMS
CHECK THE
ALIGNMENT
OF PIN
WITH INSU-
LATOR
2) ASSEM- C VISUAL 100% RANDOM APPROVED APPROVED DRAWING
BLING THE DRAWING
GI PIN AND
INSULA-
TORS
3) FIX THE C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER PIN INSULATORS SHALL
PIN INSULA- REC SPECI- DRAWING BE TIGHTENED RIGIDLY
TOR OVER FICATION or TO WITH STAND THE
THE FISH AS PER AC- LOAD.
PLATES CEPTANCE
NORMS
4) CHECK B DIMEN- RANDOM RANDOM UTILITY / APPROVED DRAWING FOR CHECKING THE
THE CLEAR- SIONAL REC SPECI- CLEARANCES SUITABLE
ANCES FICATION or TEMPLATE/ JIGS ARE TO
BETWEEN AS PER AC- BE USED
THE INSU- CEPTANCE
LATORS NORMS
5) NOW FIX C VISUAL 100% RANDOM UTILITY / AS PER APPROVED SITE REGISTER DEPENDING ON TYPE
THE RE- REC SPECI- DRAWING OF LOCATION T&C OR
SPECTIVE FICATION or B&S ARE TO BE USED
DISC IN- AS PER AC- AS PER APPROVED
SULATORS CEPTANCE DRAWING
WITH DISC NORMS
INSULATOR
CLAMPS

91
92
S. MAIN CHARACTERIS- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TICS/INSTRU- OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- MENTS CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION TOR/PQCC NQM
6) CHECK THE B DIMEN- RANDOM RANDOM UTILITY / APPROVED DRAWING FOR CHECKING THE
CLEARANCES SIONAL REC SPECI- CLEARANCES SUIT-
BETWEEN THE FICATION or ABLE TEMPLATE/
INSULATORS AS PER AC- JIGS ARE TO BE
CEPTANCE USED
Quality Control Manual

NORMS
SECTION - III : FIXING OF 11KV HG FUSE
6 RECEIPT 1) RECEIPT AT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE STORES REGIS- COMPONENTS
AND STOR- STORES CHALLAN LOT RECEIVED WITH TER WHICH ARE IN-
AGE THE DELIVERY CHAL- SPECTED AND
LAN CLEARED SHALL
ONLY BE ACCEPTED
ON RECEIPT
2) VISUAL C VISUAL 100% RANDOM DAMAGED AND DEFEC- STORES REGIS- MAJOR DAMAGED
INSPECTION TIVE EQUIPMENT TER MATERIAL SHALL BE
SHALL BE STACKED DISCARDED.
SEPARATELY
3) PROPER C VISUAL 100% RANDOM UTILITY / THE HG FUSE COM- STORES REGIS-
STORAGE REC SPECI- PONENTS SHALL BE TER
FICATION or STORED ON WOODEN
AS PER AC- PLATFORM OF 300mm
CEPTANCE DEPTH
NORMS
7 FIXING OF 1) RATING C VISUAL 100% 10% STANDARD APPROVED DRAWINGS STORES REGIS-
HG FUSE PLATE DETAILS PRACTICE TER
SET 2) CHECK C VISUAL 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
LEVEL & ALIGN- PRACTICE
MENT OF THE
BASE, HOUS-
ING ASSEMBLY
& FLANGS
3) CHECK B VISUAL 100% RANDOM STANDARD INSTRUCTION MANUAL SITE REGISTER
FOR THE PRACTICE / APPROVED DRAWING\
CLEARANCE
BETWEEN
LIVE PART TO
EARTH
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
SECTION - IV : ERECTION AND COMMISSIONING OF LINE SECTIONALIZER / AB SWITCH
8 RECEIPT 1) RECEIPT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE STORES REGIS- COMPONENTS WHICH
AND STOR- AT STORES CHALLAN LOT RECEIVED WITH TER ARE INSPECTED AND
AGE THE DELIVERY CHAL- CLEARED SHALL ONLY
LAN BE ACCEPTED ON
RECEIPT
2) VISUAL C VISUAL 100% RANDOM DAMAGED AND DEFEC- STORES REGIS- MAJOR DAMAGED
INSPECTION TIVE EQUIPMENT TER MATERIAL SHALL BE
SHALL BE STACKED DISCARDED.
SEPARATELY
3) PROPER C VISUAL 100% RANDOM STANDARD THE AB SWITCH COM- STORES REGIS-
STORAGE PRACTICE PONENTS SHALL BE TER
STORED ON WOODEN
PLATFORM OF 300mm
DEPTH
9 FIXING A) INSTAL-
OF LINE LATION
SECTION- 1) RAT- C VISUAL 100% 10% STANDARD APPROVED DRAWING SITE REGISTER
ALIZER/ AB ING PLATE PRACTICE
SWITCH DETAILS
2) CHECK C VISUAL 100% RANDOM STANDARD INSTRUCTION MANUAL SITE REGISTER
FOR PRACTICE
PROPER
SLING AND
LIFTING
3) CHECK C VISUAL 100% RANDOM STANDARD INSTRUCTION MANUAL SITE REGISTER
TIGHTNESS PRACTICE
OF BASE
BOLTS AND
OTHER
BOLTED
JOINTS BY
TORQUE
WRENCH

93
94
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
4) CHECK C VISUAL 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
LEVEL & PRACTICE
ALIGN-
MENT OF
THE BASE,
Quality Control Manual

HOUSING
ASSEMBLY
& FLANGES
5) ENSURE C VISUAL 100% RANDOM STANDARD APPROVED DRAWING SITE REGISTER
PROPER PRACTICE
ERECTION
OF POLES,
MAIN
BLADE
& DRIVE
ASSEMBLY
AS PER
APPROVED
DRAWINGS
6) CHECK C VISUAL 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
FOR THE PRACTICE / APPROVED DRAWING\
ALIGNMENT
AND VERTI-
CALITY OF
SECTIONAL-
IZER
7) CHECK B VISUAL 100% RANDOM STANDARD INSTRUCTION MANUAL SITE REGISTER
FOR THE PRACTICE / APPROVED DRAWING\
CLEARANCE
BETWEEN
LIVE PART
TO EARTH
S. MAIN CHARACTER- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& ISTICS/IN- OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- STRUMENTS CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION TOR/PQCC NQM
9) CHECK C VISUAL 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
FOR NO VI- PRACTICE
BRATION OR
ROTATION OF
CONTACTS
INSULATORS
DURING
ISOLATOR
OPERATION
10) CHECK C VISUAL 100% 50% STANDARD APPROVED DRAWING SITE REGISTER
FOR THE PRACTICE
PROVISION
OF EARTHING
AND EARTH
CONNECTION
11) CHECK B VISUAL 100% 50% STANDARD INSTRUCTION MANUAL SITE REGISTER ENSURE THE ENTIRE
OPERATION PRACTICE / APPROVED DRAW- STRUCTURE SHOULD
OF THE ING\ BE RIGID AND CHECK
ISOLATOR THE RIGIDNESS BY
BY ROTAT- OERATING THE AB
ING ONE OF SWITCHES
THE INSULA-
TOR STACK
MANUALLY
AND ADJUST
THE LENGTH
OF THE
CROSSED
TANDEM
ASSEMBLY
TO ENSURE
PROPER
ENGAGE-
MENT OF
CONTACTS
DURING
CLOSING.

95
96
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK ENCE RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/ DOCUMENT
TION MENTS TOR/PQCC NQM
10 PRE COM- 1) CHECK C VISUAL 100% RANDOM STANDARD INSTRUCTION MANUAL SITE REGISTER
MISSION- FOR VISUAL PRACTICE / APPROVED DRAWING\
ING DAMAGE TO
ANY PARTS
INCLUDING
Quality Control Manual

PORCELAIN
ISOLATOR
2) CHECK B VISUAL 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
MANUAL / CHECK PRACTICE / APPROVED DRAWING\
OPERTION
AND INTER
LOCKS
3) IR VALUE B VISUAL 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
BETWEEN CHECK PRACTICE / APPROVED DRAWING\
EARTH TO
POLE
4) GROUND C VISUAL 100% RANDOM STANDARD INSTRUCTION MANUAL SITE REGISTER
CONNEC- CHECK PRACTICE / APPROVED DRAWING\
TIONS
5) CHECK B VISUAL 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
CONTINUITY CHECK PRACTICE / APPROVED DRAWING\
SECTION - V : ERECTION & COMMISSIONING OF DTRS
11 RECEIPT 1) RECEIPT C VISUAL 100% RANDOM DELIVERY CORRELATION OF THE STORES REGIS- TRANSFORMERS AND
AND STOR- AT STORES CHALLAN LOT RECEIVED WITH TER ACCESSORIES IN-
AGE THE DELIVERY CHAL- CLUDING LAs WHICH
LAN / MDCC DESCRIP- ARE INSPECTED AND
TIONS CLEARED SHALL ONLY
BE ACCEPTED ON
RECEIPT
2) VISUAL C VISUAL 100% RANDOM APPROVED DAMAGED COMPO- STORES REGIS- MAJOR DAMAGED
INSPECTION DRAWING NENTS SHALL BE TER MATERIAL SHALL BE
STAGED SEPARATELY DISCARDED.
S. MAIN CHARACTERIS- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE- RE MARKS
NO ACTIVITY& TICS/INSTRU- OF CHECK OF CHECK - OF CHECK ENCE CORD
OPERA- MENTS CHECK CONTRAC- - TPIA/REC/ DOCUMENT
TION TOR/PQCC NQM
3) PROPER STOR- C VISUAL 100% RANDOM UTILITY / THE TRANSFORMERS STORES REGISTER
AGE REC SPECI- AND THE ACCES-
FICATION or SORIES SHALL BE
AS PER AC- STACKED ON DRY
CEPTANCE LEVELLED AND RAISED
NORMS PLATFORM. ALL PIPE
WORK CONSERVA-
TORS, RADIATORS
SHOULD BE STORED
WITH THEIR BLANKING
PLATES IN POSITION
HEATERS IN THE
MARSHELLING BOX
SHOULD BE KEPT
ENERZIZED TO AVOID
CONDENSATION
12 ERECTION 1) ENSURE THE C VISUAL 100% 50% STANDARD AS PER APPROVED SITE REGISTER
OF TRANS- REGIDNESS OF PRACTICE DRAWING
FORMERS THE STRUCTURE
OVER WHICH
TRANFORMER IS
TO BE ERECTED

2) LIFTING OF C VISUAL 100% RANDOM AS PER “VERTICALITY OF THE SITE REGISTER


THE TRANFORM- MANUFAC- TRANFORMERS SHALL
ERS TURER IN- BE MAINTAINED
STRUCTION HV / LV ORIENTATION
MANUAL OF THE TRANFORMER
SHALL BE CHECKED”

3) ENSURE PRO- C VISUAL 100% 10% STANDARD THERE SHOULD NOT SITE REGISTER THE BOLTS AND
POER SITTING PRACTICE BE ANY MOVEMENT NUTS SHALL BE
OF THE TRANS- OF THE TRANFORMER TIGHT ENOUGH
FORMER OVER AND TRANSFORMER TO HOLD THE
THE STRUCTURE SHALL BE FIXED RIG- TRANSFORMER
IDLY TO THE STRUC- WITHOUT ANY
TURE SHAKE

97
98
S. MAIN CHARACTERIS- CLASS TYPE OF QUANTUM QUANTUM REFER- ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TICS/INSTRU- OF CHECK OF CHECK - OF CHECK ENCE RECORD
OPERA- MENTS CHECK CONTRAC- - TPIA/REC/ DOCUMENT
TION TOR/PQCC NQM
4) HV / LV POSI- C VISUAL 100% RANDOM AS PER AS PER APPROVED SITE REGISTER AIR CLEARANCE
TION MANUFAC- DRAWING SHOULD BE AS PER
TURER IN- APPROVED DRAW-
STRUCTION ING
MANUAL
Quality Control Manual

5) OTHER ACCES- C VISUAL 100% 50% AS PER AS PER APPROVED SITE REGISTER AIR CLEARANCES
SORIES LIKE LAs, MANUFAC- DRAWING SHOULD BE AS PER
BUSHINGS, CON- TURER IN- APPROVED DRAW-
NECTORS ETC. STRUCTION ING
ARE ERECTED MANUAL
13 PRE 1) INSULATION A TEST 100% 10% UTILITY / SITE REGISTER A 5 KV MEGGER
COMMIS- RESISTANCE REC SPECI- PREFERABLY MO-
SIONING FICATION or TOR OPERATED
CHECKS AS PER AC- SHOULD BE USED
CEPTANCE FOR MEASURING
NORMS HIGHER VALUES.
BUSHINGS ARE
THROUGHLY
CLEANED BE-
FORE TAKING
IR VALUES. IR
VALUES BETWEEN
WINDINGS AND
BETWEEN WIND-
INGS TO EARTH
ARE CHECKED.
WHILE CHECKING
THESE VALUES, NO
EXTERNAL LINES
or LIGHTNING AR-
RESTERS SHOULD
BE IN CIRCUIT.
2) OIL DIEELEC- A TEST 100% 10% AS PER IN- IS : 335 SAMPLES SITE REGISTER
TRIC STRENTH STRUCTION FROM TOP AND BOT-
TEST MANUAL TOM OF TRANFORMER
ARE TESTED, IF
REQUIRED
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/
TION MENTS TOR/PQCC NQM
3) GENERAL
CHECKS
a) ALL OIL C VISUAL 100% RANDOM AS PER IN- SITE REGISTER
VALVES STRUCTION
ARE IN MANUAL
CORRECT
POSITION,
CLOSED OR
OPENED AS
REQUIRED
b) ALL AIR C TEST 100% RANDOM AS PER IN- SITE REGISTER
POCK- STRUCTION
ETS ARE MANUAL
CLEARED
c) THER- C TEST 100% RANDOM AS PER IN- SITE REGISTER
MOMETER STRUCTION
POCKETS MANUAL
ARE FILLED
WITH OIL
d) OIL IS AT B TEST 100% RANDOM AS PER IN- SITE REGISTER
CORRECT STRUCTION
LEVEL IN MANUAL
THE TRAN-
FORMERS
e) EARTH- C TEST 100% 50% AS PER IN- SITE REGISTER
ING CON- STRUCTION
NECTIONS MANUAL
ARE DONE
f) ARCING C TEST 100% 10% AS PER IN- SITE REGISTER
HORN GAPS STRUCTION
ON BUSH- MANUAL
INGS ARE
PROPERLY
ADJUSTED

99
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS

100
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/
TION MENTS TOR/PQCC NQM
14 ENERZISA- CHARGING A VISUAL 100% 10% AS PER IN- NO ABNORMILITY SITE REGISTER ABNORMILITIES IF
TION THE TRANS- STRUCTION SUCH AS VIBRATION NOTICED SHOULD BE
FORMER MANUAL OF THE PARTS, HUM CORRECTED AFTER
NOISE SHOULD BE FEW HOURS OF ENER-
ABSORBED ZISATION AT NO LOAD.
Quality Control Manual

SECTION - VI : EARTHING OF DTR STATION


15 IDENTIFI- 1) IDEN- A VISUAL 100% 10% AS PER REFERE REC CON- SITE REGISTER
CATION TIFY THE APPROVED STRUCTION STAN-
OF THE LOCATION DRAWING DARDS
EARTH WHERE THE
PITS AND EARTHING
EARTHING IS TO BE
EQUIP- DONE
MENT
2) IDENTIFY A VISUAL 100% 10% AS PER REFERE REC CON- SITE REGISTER
THE TRANS- APPROVED STRUCTION STAN-
FORMER DRAWING DARDS
NEUTRAL
TERMINAL,
LA TERMI-
NAL AND
OTHER
ACCESSO-
RIES
16 PIPE TYPE 1) EXCAVA- C VISUAL 100% RANDOM AS PER REFERE REC CON- SITE REGISTER
EARTHING TION OF PIT APPROVED STRUCTION STAN-
INSTALLA- SIZE DRAWING DARDS J2
TION OF 2) INSTALL C VISUAL 100% 10% AS PER REFERE REC CON- SITE REGISTER
DP STRUC- 40 DIA GI APPROVED STRUCTION STAN-
TURE PIPE WITH DRAWING DARDS J2
12 DIA
HOLES IN
THE PIT
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/
TION MENTS TOR/PQCC NQM
3) FILL THE A VISUAL 100% 10% AS PER REFERE REC CON- SITE REGISTER IN CASE OF THE
PIT WITH APPROVED STRUCTION STAN- ORDINARY SOILS
ALTERNATE DRAWING DARDS J2 WHERE PIPE COULD
LAYERS HAMOURED IN, TREAT-
OF 300 mm MENT OF THE PIT WITH
CHAR COAL CHARCOAL AND SALT
AND SALT IS NOT NECESSARY
4) CON- C VISUAL 100% 10% AS PER REFERE REC CON- SITE REGISTER
NECTIONS APPROVED STRUCTION STAN-
BETWEEN DRAWING DARDS J2
THE PIPE
AND POLE
WITH 8mm
SWG WIRE
5) CONNECT C VISUAL 100% 10% AS PER THERE SHOULD NOT SITE REGISTER
THE EQUIP- APPROVED BE ANY LOOSE CON-
MENT TO BE DRAWING NECTIONS
EARTHED
AND THE
PIPE
EARTHE
TERMINALS
WITH GI
WIRE
17 TESTING TESTING OF A TEST 100% 10% STANDARD INSTRUCTION MANUAL SITE REGISTER
OF EARTH EARTHING PRACTICE
RESISTIV-
ITY
SECTION - VII : ERECTION OF DANGER BOARDS AND ANTICLIMBING DEVICES
18 1) FIXING C VISUAL 100% 50% INSTRUC- APPROVED DRAWINGS SITE REGISTER THE LANGUAGE OF
OF DANGER TION AND REC SPECIFICA- LETTERINGS SHALL
BOARDS MANUAL TION NO 57 CONFIRM TO RULE NO
35 OF IE RULES 1956
AND SHALL BE IN HIN-
DHI OR ENGLISH AND
IN LOCAL LANGUAGE
WITH SIGN OF SKULL

101
AND BONES
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS

102
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/
TION MENTS TOR/PQCC NQM
2) EREC- C VISUAL 100% 50% INSTRUC- APPROVED DRAWINGS SITE REGISTER
TION TION
OF ANTI MANUAL
CLIMBING
DEVICES
Quality Control Manual

- BARBED
WIRE
SECTION - VIII : ERECTION AND COMMISSIONING OF LT DISTRIBUTION BOXES
19 INSTALLA- 1) RECEIPT C VISUAL 100% 5% DELIVERY CORRELATION OF THE STORES REGIS- COMPONENTS WHICH
TION AT STORES CHALLAN LOT RECEIVED WITH TER ARE INSPECTED AND
THE DELIVERY CHAL- CLEARED SHALL ONLY
LAN BE ACCEPTED ON
RECEIPT
2) VISUAL C VISUAL 100% 5% APPROVED DAMAGED COMPO- STORES REGIS- MAJOR DAMAGED
INSPEC- DRAWING NENTS SHALL BE TER MATERIAL SHALL BE
TION STACKED SEPARATELY DISCARDED.
3) PROPER C VISUAL 100% 5% UTILITY / THE TRANSFORMERS STORES REGIS-
STORAGE REC SPECI- AND THE ACCES- TER
FICATION or SORIES SHALL BE
AS PER AC- STACKED ON DRY
CEPTANCE LEVELLED AND RAISED
NORMS PLATFORM. ALL PIPE
WORK CONSERVA-
TORS, RADIATORS
SHOULD BE STORED
WITH THEIR BLANKING
PLATES IN POSITION
HEATERS IN THE
MARSHELLING BOX
SHOULD BE KEPT
ENERZIZED TO AVOID
CONDENSATION
4) EREC- C VISUAL 100% 10% STANDARD AS PER APPRROVED SITE REGISTER
TION OF PRACTICE DRAWINGS
LT DISTRI-
BUTION
BOXES
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/
TION MENTS TOR/PQCC NQM
2) EREC- C VISUAL 100% 50% INSTRUC- APPROVED DRAWINGS SITE REGISTER
TION TION
OF ANTI MANUAL
CLIMBING
DEVICES
- BARBED
WIRE
SECTION - VIII : ERECTION AND COMMISSIONING OF LT DISTRIBUTION BOXES
19 INSTALLA- 1) RECEIPT C VISUAL 100% 5% DELIVERY CORRELATION OF THE STORES REGIS- COMPONENTS WHICH
TION AT STORES CHALLAN LOT RECEIVED WITH TER ARE INSPECTED AND
THE DELIVERY CHAL- CLEARED SHALL ONLY
LAN BE ACCEPTED ON
RECEIPT
2) VISUAL C VISUAL 100% 5% APPROVED DAMAGED COMPO- STORES REGIS- MAJOR DAMAGED
INSPECTION DRAWING NENTS SHALL BE TER MATERIAL SHALL BE
STACKED SEPARATELY DISCARDED.
3) PROPER C VISUAL 100% 5% UTILITY / THE TRANSFORMERS STORES REGIS-
STORAGE REC SPECI- AND THE ACCES- TER
FICATION or SORIES SHALL BE
AS PER AC- STACKED ON DRY
CEPTANCE LEVELLED AND RAISED
NORMS PLATFORM. ALL PIPE
WORK CONSERVA-
TORS, RADIATORS
SHOULD BE STORED
WITH THEIR BLANKING
PLATES IN POSITION
HEATERS IN THE
MARSHELLING BOX
SHOULD BE KEPT
ENERZIZED TO AVOID
CONDENSATION
4) EREC- C VISUAL 100% 10% STANDARD AS PER APPRROVED SITE REGISTER
TION OF LT PRACTICE DRAWINGS
DISTRIBU-
TION BOXES

103
S. MAIN CHARAC- CLASS TYPE OF QUANTUM QUANTUM REFERENCE ACCEPTANCE NORMS FORMAT OF RE MARKS

104
NO ACTIVITY& TERISTICS/ OF CHECK OF CHECK OF CHECK DOCUMENT RECORD
OPERA- INSTRU- CHECK - CONTRAC- - TPIA/REC/
TION MENTS TOR/PQCC NQM
5) EARTH- B VISUAL 100% 10% STANDARD AS PER APPRROVED SITE REGISTER COVER OF THE BOX IS
ING OF PRACTICE DRAWINGS ALSO TO BE EARTHED
LTDB BY WAY OF FLEXIBLE
COPPER LINK OF SUIT-
ABLE DIMENSION
Quality Control Manual

CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR

NAME/ SIGNATURE OF THE SUB-CONTRACTOR/ ERECTION AGENCY


FIELD QUALITY PLAN FOR CT & PT ITEM : ERECTION WORK
SUB SYSTEM : CT/ PT
QAP NO. :
REV. NO.:
DATE :
Sr. No. CHARACTERISTICES Type of Check Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
/ ITEMS OF CHECK OF CHECK ments & Accep- Records”
- CONTRAC- - TPIA/REC/ tance Standard
TOR/PQCC NQM
1 2 3 4 5 6 6 7 8 9
1 RECEIPT & STORAGE
1.1 Receiving inspection V - B 100% RANDOM Delivery Challan & MRC / Check List
(Completeness of docu- Specification
ments, test certificates,
instruction manual etc.)
1.2 Unloading V - B 100% RANDOM Instruction Manual -
1.3 Visual exmination for V - B 100% RANDOM Packing list / Instruc- -
damage & defects tion Manual
1.4 Proper storage V - B 100% RANDOM Instruction Manual -

2 PRE INSTALLATION
2.1 Availability of instruction V - B 100% RANDOM List of approved -
manual and drawing, drawing / Instruction
lifting arrangement Manuals
2.2 Availability of all materi- V - B 100% RANDOM Packing list, Ap- -
als proved drawing & Bill
Of Material
2.3 CT foundation V - B 100% RANDOM Civil foundation -
drawing
2.4 Vertically of support V - B 100% RANDOM GA/ Structural draw- -
structure ing

3 INSTALLATION
3.1 Rating plate details V - B 100% RANDOM instruction manual Site record

105
Sr. No. CHARACTERISTICES Type of Check Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks

106
/ ITEMS OF CHECK OF CHECK ments & Accep- Records”
- CONTRAC- - TPIA/REC/ tance Standard
TOR/PQCC NQM
1 2 3 4 5 6 6 7 8 9
3.2 Check that the C.T. V - B 100% RANDOM As per EIC/SLD -
have been installed in
proper polarity (P1 &
Quality Control Manual

P2 position)
3.3 Check for the tightness V - B 100% RANDOM instruction manual -
of equipment base bolts
with
3.4 Check overall alignment V - B 100% RANDOM instruction manual -
of C.T.
3.5 Check for the primary V - B 100% RANDOM Rating plate -
ratio connected as per
requirement.
3.6 Earthing of support V - B 100% RANDOM instruction manual -
structure & CT frame.
3.7 Check provision of V - B 100% RANDOM instruction manual -
earthing and tightness
of earthing connection.
3.8 Check for the tightness V - B 100% RANDOM instruction manual -
of clamps/ connectors.
3.9 Check for secondary ter- V - B 100% RANDOM instruction manual -
mination tightness and
crimping of leads.
3.10 Check the cable tags V - B 100% RANDOM Cable schedule -
and ferrules are pro-
vided
3.11 Ensure that unused V - B 100% RANDOM instruction manual -
secondary core are cor-
rectly shorted.
3.12 R,Y,B identification V - B 100% RANDOM - -
3.13 Check for oil leackages V - B 100% RANDOM instruction manual / Site record
No leackages
Sr. No. CHARACTERISTICES Type of Check Instruments Class QUANTUM QUANTUM Reference Docu- “Format Of Remarks
/ ITEMS OF CHECK OF CHECK ments & Accep- Records”
- CONTRAC- - TPIA/REC/ tance Standard
TOR/PQCC NQM
1 2 3 4 5 6 6 7 8 9
3.14 Check verticality of V - B 100% RANDOM instruction manual Site record
equipment on support
structure

4 PRE COMMISSIONING
4.1 Measure IR value using Megger A 100% 10% instruction manual TC
meggar
a. Primary to secondary Test
cores and earth with
2.5 kV.
b. Between secondary Test
cores.
c. Between secondary Test
to earth.
4.2 Check polarity. Test Multimeter/ A 100% 10% instruction manual TC
Dry cell / SLD
4.3 Check for CT ratio Test Primary A 100% 10% instruction manual TC
by primary Injection injection kit
method.
4.4 Magnetising curve Test - B 100% RANDOM instruction manual TC
4.5 Final document review - - B 100% RANDOM instruction manual/fi- TC
nal document list

CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY


Legends :
CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR
TC : Test Certificate
MRC : Material Reciept Certificate
V : Visual
EIC : Engineer In Charge

107
ITEM : ERECTION WORK

108
FIELD QUALITY PLAN FOR Control & Relay Panel
SUB SYSTEM : Control & Relay Panel
QAP NO. :
REV. NO.:
DATE :
Sr. No. CHARACTERISTICES Type of Instruments Class QUANTUM QUANTUM OF Reference “Format Of Remarks
/ ITEMS Check OF CHECK CHECK - TPIA/ Documents & Records”
- CONTRAC- REC/NQM Acceptance
Quality Control Manual

TOR/PQCC Standard
1 2 3 4 5 6 6 7 8 9
1 RECEIPT & STORAGE
1.1 Receiving inspection V - B 100% RANDOM Delivery Challan MRC / Check
(Completeness of docu- & Specification List
ments, test certificates,
instruction manual etc.)
1.2 Unloading V - B 100% RANDOM Instruction Site record
Manual
1.3 Visual exmination for V - B 100% RANDOM Packing list Site record
damage & defects / Instruction
Manual
1.4 Proper storage V - B 100% RANDOM Instruction -
Manual
2 PRE INSTALLATION
2.1 Availability of instruction V - B 100% RANDOM List of ap- Site record
manual and drawing, proved drawing
lifting arrangement / Instruction
Manuals
2.2 Availability of all materi- V - B 100% RANDOM Packing list, Ap- Site record
als proved drawing
& Bill Of Material
2.3 Panel inatallation space V - B 100% RANDOM Control room -
detail
3 INSTALLATION
3.1 Rating plate details V - B 100% RANDOM instruction Site record
manual
Sr. No. CHARACTERISTICES Type of Instruments Class QUANTUM QUANTUM OF Reference “Format Of Remarks
/ ITEMS Check OF CHECK CHECK - TPIA/ Documents & Records”
- CONTRAC- REC/NQM Acceptance
TOR/PQCC Standard
1 2 3 4 5 6 6 7 8 9
3.2 Verticality & levelling Measure - B 100% RANDOM instruction Site record
of panels on support manual
stuctures.
3.3 Check earth bus con- V - B 100% RANDOM instruction Site record
nection manual
3.4 Check the floor leveling V - B 100% RANDOM As per site -
where the panels are to conditionss
be installed.
3.5 Check the physical con- V - B 100% RANDOM Specification Site record
diton of the panels after
opening the packing
and verify the material
as per BOM.
3.6 Ensure the panels V - B 100% RANDOM Erection manual -
are lifted using proper
slings/ tackles.
3.7 Check the panels are V - B 100% RANDOM As per site -
levelled, aligned and conditionss
erected properly.
3.8 Removal of top and V - B 100% RANDOM Approved panel -
side blanking plates. drawing
3.9 Inter panel wiring is V - B 100% RANDOM Approved panel -
comleted as per draw- drawing
ing.
3.10 Check the tightness of V - B 100% RANDOM Approved panel -
inter panel nuts and drawing
bolts, Main bus, earth
bus connection etc.
3.11 Checked for broken V - B 100% RANDOM Approved panel -
glass, switch handle, drawing
lamp cover etc.
3.12 Glanding of external V - B 100% RANDOM Approved panel -
cables drawing

109
Sr. No. CHARACTERISTICES Type of Instruments Class QUANTUM QUANTUM OF Reference “Format Of Remarks

110
/ ITEMS Check OF CHECK CHECK - TPIA/ Documents & Records”
- CONTRAC- REC/NQM Acceptance
TOR/PQCC Standard
1 2 3 4 5 6 6 7 8 9
3.13 Blanking of unused V - B 100% RANDOM Approved panel -
cable entry locks drawing
3.14 Proper sealing & lock- V - B 100% RANDOM Approved panel -
ing arrangement of drawing
Quality Control Manual

panel door
4 PRE COMMISSIONING
4.1 Circuit diagram check V - B 100% RANDOM Approved panel TC
drawing
4.2 Auxiliary power supply Test Multimeter B 100% RANDOM Approved panel TC
test drawing
4.3 Functional & operation V - B 100% RANDOM Approved panel TC
test of fittings on the drawing
panels.
4.4 Relay settings as per V - B 100% RANDOM Approved panel TC
recommendation drawing
4.5 Scheme check V - B 100% RANDOM Approved panel TC
drawing
4.6 IR Value check Electrical Megger A 100% RANDOM Instruction site record
manual
4.7 Secondary injection test Electrical Injection kit A 100% RANDOM Instruction site record
for relays manual
4.8 Check minimum pick Electrical Voltmeter A 100% RANDOM Instruction site record
up & drop out voltage manual
of all coils & auxiliary
contacts
4.9 Final document review V - B 100% RANDOM Approved panel TC
drawing / Final
document list
CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY
Legends :
“CLASS OF CHECK:
A -- CRITICAL
B -- MAJOR
C-- MINOR MRC : Material Reciept Certificate TC : Test Certificate V : Visual
EIC : Engineer In Charge
ITEM : ERECTION WORK
SUB SYSTEM : DC SYSTEM
QAP NO. :
REV. NO.:
DATE :
Sr. No. CHARACTERISTICES / Type of Instruments Class Quantum/ Reference Docu- “Format Of Remarks
ITEMS Check Frequency ments & Accep- Records”
tance Standard
1 2 3 4 5 6 7 8 9

1 RECEIPT & STORAGE


1.1 Receiving inspection (Com- V - B 100% Delivery Challan & MRC / Check List / DC
pleteness of documents, NESCL Specification / 06
test certificates, instruction
manual etc.)
1.2 Unloading V - B 100% Instruction Manual -
1.3 Visual exmination for dam- V - B 100% Packing list / Instruc- -
age & defects tion Manual
1.4 Proper storage V - B 100% Instruction Manual -

2 PRE INSTALLATION
2.1 Availability of instruction V - B 100% List of approved -
manual and drawing, lifting drawing / Instruction
arrangement Manuals
2.2 Availability of all materials V - B 100% Packing list, Ap- -
proved drawing & Bill
Of Material
2.3 Completion of civil / ventila- V - B 100% Control room detail -
tion requirement of battery
room.

3 INSTALLATION - BATTERY
3.1 Rating plate details V - B 100% instruction manual Site record

111
Sr. No. CHARACTERISTICES / Type of Instruments Class Quantum/ Reference Docu- “Format Of Remarks

112
ITEMS Check Frequency ments & Accep- Records”
tance Standard
3.2 Check availability of safety V - B 100% BOM / NESCL -
devices, water and first aid Specifcation
box.
3.3 Check installation of V - B 100% Instruction Manual -
batteries and rack as per
Quality Control Manual

approved layout.
3.4 Check the specific gravity of
the electrolyte prior to pour-
ing in the cells.
3.5 Check for availability of V - B 100% Instruction Manual -
electrolyte level up to
required level and there is
no leakage.
3.6 Check alignment and level V - B 100% Instruction Manual -
of each cell
3.7 Check for tightness inter cell V - B 100% Instruction Manual -
connection and application
of grease.
3.8 Check for provision of earth- V - B 100% Instruction Manual -
ing and tightness of earthing
connection. Ensure cell are
not earth any where.
3.9 Check all cell no. are proper- V - B 100% Instruction Manual -
ly fixed and are visible.
3.10 The cabling from Battery V - B 100% Instruction Manual -
Charger to first, last and tap
cells is completed.
3.11 Check all the cells are con- V - B 100% Instruction Manual -
nected in correct polarity.
3.12 Painting of battery stand V - B 100% Instruction Manual -

4 INSTALLATION - BATTERY
CHARGER
Sr. No. CHARACTERISTICES / Type of Instruments Class Quantum/ Reference Docu- “Format Of Remarks
ITEMS Check Frequency ments & Accep- Records”
tance Standard
4.1 Rating plate details V - B 100% instruction manual Site record
4.2 The quantity, ratings, type V - B 100% Instruction Manual -
and make of the devices are
as per the BOM as given in
approved drawings.
4.3 No physical damages are V - B 100% Instruction Manual -
there in any devices of the
panels and replacement of
damaged parts.
4.4 The inter panel Earth bus V - B 100% Instruction Manual -
connections and connec-
tion to the earthing grid are
tightened properly.
4.5 Fuses provided are of rating V - B 100% Instruction Manual -
as shown in the approved
drawings.
4.6 Check that the labeling of V - B 100% Instruction Manual -
devices is as per the ap-
proved drawings.
4.7 Check the wiring is com- V - B 100% Instruction Manual -
pleted as per the approved
drawings.
4.8 External cabling and V - B 100% Instruction Manual -
termination with glands is
completed as per the Cable
schedule.
4.9 Cable tags, ferrules for V - B 100% Instruction Manual -
cores are provided as per
cable schedule.
4.10 Dressing and clamping of V - B 100% Instruction Manual -
cables is done properly.

113
Sr. No. CHARACTERISTICES / Type of Instruments Class Quantum/ Reference Docu- “Format Of Remarks

114
ITEMS Check Frequency ments & Accep- Records”
tance Standard
4.11 Check the phases sequence V - B 100% Instruction Manual -
of the Mains supply to the
battery charger.
4.12 Check functioning of all V - B 100% Instruction Manual -
relays/meters/selector
Quality Control Manual

switches etc.
4.13 All alarms & annunciations, V - B 100% Instruction Manual -
indications are functioning
properly.
4.14 Check the Float & Boost V - B 100% Instruction Manual -
charger operation, set the
o/p voltage (if reqd).
4.15 Check the current limiting V - B 100% Instruction Manual -
feature of charger & set the
current limit (if reqd).
4.16 IR Value check Measure - A 100% Instruction Manual

5 PRE-COMMISSIONING
5.1 Check that all the assembly V - B 100% Instruction Manual TC
activities are completed.
5.2 The cabling from Battery V - B 100% Instruction Manual TC
Charger to first, last and tap
cells is completed.
5.3 Check the polarity of the Test Multimeter B 100% Instruction Manual Site Record
DC connection from Battery
charger to Battery.
5.4 Check that the charging V - A 100% Instruction Manual/IS TC
& discharging cycle is 1651
completed as per guidelines
of manufacturer to prove
battery AH capacity at 10 hr
discharge rate.
Sr. No. CHARACTERISTICES / Type of Instruments Class Quantum/ Reference Docu- “Format Of Remarks
ITEMS Check Frequency ments & Accep- Records”
tance Standard
5.5 Recharge Electrical - B 100% Instruction Manual Site record
5.6 Final document review V - B 100% Approved panel TC
drawing / Final docu-
ment list

CONTRACTOR’S SIGNATURE NAME & SIGN OF APPROVING AUTHORITY


Legends :
“CLASS OF CHECK:
A -- CRITICAL -- TO BE WITNESSED BY NESCL SITE AND SURVEILLANCE BY NESCL, CC.
B -- MAJOR -- TO BE WITNESSED BY CONTRACTOR AND NESCL SITE
C-- MINOR -- TO BE WITNESSED BY CONTRACTOR AND SURVEILLANCE BY NESCL SITE”
TC : Test Certificate
MRC : Material Reciept Certificate
V : Visual
EIC : Engineer In Charge

115
Annexure - i
II
MANUFACTURE’S NAME MANUFACTURING QUALITY PLAN

118
& ITEM: 11 KV HT XLPE QP NO: PROJECT/UTILITY:
ADDRESS: AERIAL BUNCHED REV.NO: PACKAGE:
CABLE (3X35+70)
SUB-SYSTEM: DATE: CONTRACT NO:
No.of pages:5 MAIN-CONTRACTOR:
Sl. Compo- Characteristics Class Type of Quantum Reference Acceptance Format Agency Remarks
No nent & Check of Check Document Norms of Re-
Quality Control Manual

operation cords
1 2 3 4 5 6 7 8 9 D 10 11
SECTION: 1 RAW MATERIALS M C N
1 Alumini- a) Diameter Major Measure- One “Manu- IS 8130 QC P V V Review of manufactur-
um Rod ment sample facturer , IS 613 report ers test certificates
from each Specifica- & NESCL at the time of final
lot tion Spec. inspection
& IS
5484”
b) Tensile Strength Major Test do do do do P V V do
c) Elongation Major Test do do do do P V V do
d) Resistivity / Major Electrical do do do do P V V do
Conductivity Test
2 Alloy Rod a) Diameter Major Measure- One “Manu- IS 398 & QC P V V Review of manufactur-
ment sample facturer NESCL report ers test certificates
from each Specifica- Spec. at the time of final
lot tion inspection
& IS
9997”
b) Tensile Strength Major Test do do do do P V V do
c) Elongation Major Test do do do do P V V do
d) Resistivity / Major Electrical do do do do P V V do
Conductivity Test
3 XLPE a) Hot set Critical Test One “Manu- IS 7098 QC P V V Review of manufactur-
Com- sample facturer (part-II) and report ers test certificates
pound from each Specifi- NESCL at the time of final
lot cation & Spec. inspection
As per
IS 7098
(part-II)”
1 2 3 4 5 6 7 8 9 D 10 11
b) Tensile Strength Major Test do do do do P V V do
c) Elongation Major Test do do do do P V V do
“d) Volume Resis- Major Electrical do do do do P V V do
tivity Test
(Insulation Resis-
tance)”
e) Thermal Age- Critical Test do do do do P V V do
ing Shelf Life-One
Year Contamina-
tion & Voids
4 Messen- a) Diameter Major Measure- One “Manufac- As per IS QC P V V “Review of Manufac-
ger Wire ment sample turer Speci- 398 & NES- report turer’s Test Certificate
from each fication& IS CL Spec. at the time of final
lot 398” inspection”
b) Tensile Strength Major Test do do do do P V V do
c) Elongation Major Test do do do do P V V do
SECTION: 2 IN PROCESS INSPECTION M C N
5 “Wire a) Dimension Major Measure- 10% IS 8130, IS 8130, QC P V V Review of manufactur-
Drawing ment IS 398 & IS 398 & report ers test certificates
( Alu- P.S NESCL at the time of final
minium/ Spec. inspection
Alloy)” b) Tensile Strength Major Test do do do do P V V do
c) Wrapping test Major Test do do do do P V V do
d) Surface Finish Major Visual do do do do P V V do
6 “Strand- a) Dimension Major Measure- 100% IS 8130 & IS 8130 QC P V V Review of manufactur-
ing ment IS 398 & ,IS 398 & report ers test certificates
Phase/ P.S NESCL at the time of final
Messen- Spec. inspection
ger Wire” b) No./ Diameter of Major Visual do do do do P V V do
Wire
c) Sequence Major Visual do do do do P V V do
d) D.C Conductor Major Electrical do do do do P V V do
Resistance Test
e) Surface Finish Major Visual do do do do P V V do
f) Lay length, com- Major Visual do do do do P V V do
pact & ovality

119
1 2 3 4 5 6 7 8 9 D 10 11

120
g) Direction of lay Major Visual do do do do P V V do
h) Tensile Strength Major Test One “Manu- IS 398 & do P V V do
sample facturer NESCL
from each Specifica- Spec.
lot tion
& IS 398”
i) Elongation Major Test do do do do P V V do
Quality Control Manual

j) UTS Major Test do do do do P V V do


7 Insulation a) Type of compo- Major Visual 100% IS 7098 IS 7098 QC P V V Review of manufactur-
nent (part-II) (part-II) , report ers test certificates
& P.S P.S and at the time of final
Approved inspection
Data Sheet
b) Diameter of Major Measure- do do do do P V V do
conductor / core ment
Thickness
c) Thickness Major Measure- 100% do do do P V V do
ment
d) Colour Major Visual do do do do P V V do
e) Identification Major Visual do do do do P V V do
Ridge
f) Surface Finish Major Visual do do do do P V V do
g) Embossing Major Visual do do do do P V V do
h) Curing Major Visual do do do / By Hot do P V V do
water
i) Hot set test Major Test 1 spool do do do P V V do
j) Tensile Strength Major Test do do do do P V V do
k) Elongation Major Test do do do do P V V do
l) Volume Major Electrical do do do do P V V do
Resistivity Test
m) Spark Test Major Electrical do do do do P V V do
Test
1 2 3 4 5 6 7 8 9 D 10 11
8 Laying Up a) Core Sequence Major Visual 100% IS 7098 IS 7098 QC P V V Review of manufactur-
(part-II) & (part-II) & report ers test certificates
P.S A.D.S at the time of final
inspection
b) Laid Up diam- Minor Measure- do do do do P V V do
eter ment
c) Length Major Measure- do do do do P V V do
ment
9 Copper a) Dimension of Major Measure- 100% IS 7098 IS 7098 QC P V V Review of manufactur-
Tape Tape ment (part-II) & (part-II) & report ers test certificates
P.S A.D.S at the time of final
inspection
b) Surface finish Minor Visual do do do do P V V do
c) Overlap in cop- Major Visual do do do do P V V do
per tape
d) Continuity Major Electrical do do do do P V V do
Test
10 Outer a) Type of compo- Major Visual 100% IS 7098 IS 7098 QC P V V Review of manufactur-
Sheath nent (part-II) & (part-II) & report ers test certificates
P.S A.D.S at the time of final
inspection
b) Colour of Major Visual do do do do P V V do
Sheath
c) Embossing Minor Visual do do do do P V V do
d) Surface finish Minor Visual do do do do P V V do

SECTION: 3 Final Testing M C N


11 Routine a) Conductor re- Major Electrical 100% IS 7098 IS 7098 QC √ P V V Routine test certificate
test sistance Test (part-II) & (part-II) & report will be furnished for
P.S A.D.S verificationduring final
inspection
b) High Voltage Major Electrical do do do do √ P V V do
Test
c) Partial Dis- Major Electrical do do do do √ P V V do
charge Test Test

121
1 2 3 4 5 6 7 8 9 D 10 11

122
12 All Type Type Tests Major Electrical Sample IS 7098 IS 7098 Type √ V V V Type Test Clearance
Tests Test (part-II) & (part-II) & Test from NESCL Engi-
as per P.S A.D.S Report neering
NESCL
Technical
Specifica-
tion
Quality Control Manual

13 Accep- a) Conductor resi- Major Electrical As per As per IS As per IS Accep- P W W


tance test tance Test sampling 7098(Pt- 7098(Pt- tance
on Cable plan of IS II) II), A.D.S test Cer-
7098(Pt- & NESCL tificate
II) Specifica-
tion
b) Test for thick- Major Test do do do do P W W
ness & Dimension
of insulation in-
cluding eccentricity
& ovality
c) Thickness of Major Test do do do do P W W
sheath
d) Hot set test for Major Test do do do do P W W
insulation
e) Partial dis- Major Electrical do do do do P W W
charge test Test
f) Tensile strength Major Test do do do do P W W
& elongation at
break for insulation
& sheath
g) High voltage Major Electrical do do do do P W W
test Test
h) Insulation Re- Major Electrical do do do do P W W
sistance ( V. R) Test
k) Wrapping Test Major Test do do do do P W W
l) Tensile Strength Major Test do do do do P W W
for Aluminum
1 2 3 4 5 6 7 8 9 D 10 11
14 Accep- a) Breaking Load Major Test As per As per IS As per IS do P W W
tance test Test sampling 398(Pt-II) 398(Pt-II)
on mes- plan of IS
senger 398(Pt-II)
wire
b) Elonagtion Major Test As per As per IS As per IS do P W W
sampling 398(Pt-II) 398(Pt-II)
plan of IS
398(Pt-II)
c) Resistance Test Major Test As per As per IS As per IS do P W W
sampling 398(Pt-II) 398(Pt-II)
plan of IS
398(Pt-II)
15 Packing & Major Visual Random NESCL NESCL do P V V
Marking specifica- specifica-
tion tion
*-All type tests to be carried out as per NESCL specification & Contract Agreement .
√ - Record identified’√’ “”tick mark”” shall be essentially included by supplier in QA Documentations.

Note: Manufacturing, inspection & testing as per IS 7098 (pt-II) P.S= Plant Standard M= Manufacturer
P= Performed By A.D.S= Approved Data Sheet N= Customer (NESCL)
V= Verified By M/I=Minor C = Contactor
W= Witness of test SIGNATURE OF THE CONTRACTOR
M/A= Major SIGNATURE OF THE MANUFACTURER

123
MANUFACTURER’S NAME & ADDRESS: MANUFACTURING QUALITY PLAN

124
ITEM: 11 KV QP NO: PROJECT/UTILITY:
XLPE INSULATED REV.NO: PACKAGE:
CABLE(3X95sq.mm)
SUB-SYSTEM: DATE: CONTRACT NO:
No.of pages:4 MAIN-CONTRACTOR:
Sl. Compo- Characteristics Class Type of Quantum Reference Accep- Format of Agency Remarks
No nent & Check of Check Document tance Records
Quality Control Manual

operation Norms
1 2 3 4 5 6 7 8 9 D 10 11
SECTION: 1 RAW MATERIALS M C N
1 Aluminium a) Diameter Major Measure- One “Manufac- As per QC report P V V Review of Manufac-
Rod ment sample turer Specifi- IS 8130 turer’s
from each cation & As per Test Certificate at the
lot & IS 5484” NESCL time of final inspection
Spec
b) Tensile Major Test do do do do P V V do
Strength
c) Elongation Major Test do do do do P V V do
d) Resistivity / Major Electrical do do do do P V V do
Conductivity Test
2 XLPE a) Hot set Major Test One Manufacturer As per IS QC report P V V Review of Manufac-
sample Specification 7098 and turer’s
from each & As per IS NESCL Test Certificate at the
lot 7098 Spec time of final inspection
b) Tensile Major Test do do do do P V V do
Strength
c) Elongation Major Test do do do do P V V do
“d) Volume Re- Major Electrical do do do do P V V do
sistivity Test
( Insulation Re-
sistance)”
e) Thermal Critical Test do do do do P V V do
Ageing Shelf
Life-One Year
Contamination &
Voids
1 2 3 4 5 6 7 8 9 D 10 11
3 Copper a) Dimension Major Measure- One “Manufac- As per QC report P V V “ Review of Manufac-
Tape ment sample turer Specifi- IS 8130 turer’s
from each cation & As per Test Certificate at the
lot & As per NESCL time of final inspec-
P.S “ Spec tion”
b) Resistivity / Major Electrical do do do do P V V do
Conductivity Test
c) Elongation Major Test do do do do P V V do
d) Yield Strength Major Test do do do do P V V do
4 PVC a) Tensile Major Test One “Manufac- As per QC report P V V “ Review of Manufac-
Com- Strength sample turer Specifi- IS 5831 turer’s
pound from each cation & As per Test Certificate at the
lot & As per IS NESCL time of final inspec-
5831” Spec tion”
b) Elongation Major Test do do do do P V V do
c) Thermal Sta- Critical Test do do do do P V V do
bility
d) Thermal Ag- Critical Test do do do do P V V do
ing
e) Loss in mass Major Test do do do do P V V do
5 Armour a) Dimension Major Measure- 10% “Manufac- As per IS QC report P V V “ Review of Manufac-
ment turer Specifi- 3975 & As turer’s
cation perNES- Test Certificate at the
& IS 3975” CL Spec time of final inspec-
tion”
b) Tensile Major Test do do do do P V V do
Strength
c) Elongation Major Test do do do do P V V do
d) Resistivity Major Electrical do do do do P V V do
Test
e) Torsion / Major Test do do do do P V V do
Winding
f) Weight of Zinc Critical Chemical do do do do P V V do
coating
g) Dip Test Critical Chemical do do do do P V V do

125
1 2 3 4 5 6 7 8 9 D 10 11

126
SECTION: 2 IN PROCESS INSPECTION M C N
6 Wire a) Dimension Major Measure- 10% IS 8130, IS As per QC report P V V Review of the records
Drawing ment 398 & P.S IS 8130, at the time of final
( Alumini- IS 398 & inspection
um) NESCL
Spec
b) Tensile Major Test do do do do P V V do
Quality Control Manual

Strength
c) Wrapping test Major Test do do do do P V V do
d) Surface Fin- Major Visual do do do do P V V do
ish
7 Stranding a) Dimension Major Measure- 100% IS 8130 & IS As per IS QC report P V V do
ment 398 & P.S 8130 &
IS 398 &
NESCL
Spec
b) No./ Diameter Major Visual do do do do P V V do
of Wire
c) Sequence Major Visual do do do do P V V do
d) Conductor Major Electrical do do do do P V V do
Resistance Test
e) Surface Major Visual do do do do P V V do
Finish
f) Lay length, Major Visual do do do do P V V do
compact & oval-
ity & Direction
8 Insulation a) Type of Major Visual _ IS 7098 & As per QC report P V V do
component P.S IS 7098,
P.S and
Approved
Data
Sheet
b) Thickness Major Measure- 100% do do do P V V do
ment
c) Colour Major Visual do do do do P V V do
d) Surface Major Visual do do do do P V V do
Finish
1 2 3 4 5 6 7 8 9 D 10 11
e) Curing Major Visual do do do do P V V do
f) Hot set test Major Test 1 spool do do do P V V do
g) Tensile Major Test do do do do P V V do
Strength
h) Elongation Major Test do do do do P V V do
i) Volume Resis- Major Electrical do do do do P V V do
tivity Test
9 Copper a) Dimension of Major Measure- 100% IS 7098 & IS 7098 QC report P V V do
Taping Tape ment P.S & A.D.S
b) Surface finish Major Visual do do do do P V V do
c) Over lapping Major Visual do do do do P V V do
d) Continuity Major Electrical do do do do P V V do
Test
10 Laying Up a) Core Se- Major Visual 100% IS 7098 & “ IS 7098 QC report P V V do
quence P.S & A.D.S
By hot
water”
b) Laid Up diam- Major Measure- do do IS 7098 do P V V do
eter ment & A.D.S
c) Length Major Measure- do do IS 7098 do P V V do
ment & A.D.S
11 Inner a) Type of com- Major Visual 100% IS 7098 & IS 7098 QC report P V V do
Sheath ponent P.S & A.D.S
b) Colour of Major Visual do do do do P V V do
Sheath
c) Surface finish Major Visual do do do do P V V do
d) Diam- Major Measure- do do do do P V V do
eter Over inner ment
Sheath
12 Armour a) No. of strip Major Visual 100% IS 7098(Pt- IS QC report P V V do
II) & P.S 7098(Pt-II)
& A.D.S
b) Lay length & Major Measure- do do do do P V V do
Direction ment
c) Coverage Major Measure- do do do do P V V do

127
ment
1 2 3 4 5 6 7 8 9 D 10 11

128
d) Diameter Major Measure- do do do do P V V do
Over Armour ment
13 Outer a) Type of com- Major _ 100% IS 7098(Pt- IS QC report P V V do
Sheath pound II) & P.S 7098(Pt-II)
& A.D.S
b) Sheath thick- Major Measure- do do do do P V V do
ness ment
Quality Control Manual

c) Colour of Major Visual do do do do P V V do


Sheath
d) Diameter over Major Measure- do do do do P V V do
sheath ment
e) Surface Fin- Major Visual do do do do P V V do
ish
f) Embossing Major Visual do do do do P V V do
g) Sequential Major Visual do do do do P V V do
marking
SECTION: 3 Final Testing M C N
14 Routine a) Conductor Major Electrical 100% As per IS IS QC report √ P V V Routine test certificate
test resistance Test 7098(Pt-II) 7098(Pt-II) will be furnished for
& A.D.S verification during final
inspection
b) High Voltage Major Electrical do do do do √ P V V do
Test
c) Partial Dis- Major Electrical do do do do √ P V V do
charge Test Test
15 All Type Type Tests Critical Electrical Sample As per IS IS QC report √ V V V Type Test Clearance
tests Test 7098(Pt-II) 7098(Pt-II) from NESCL Engi-
as per & A.D.S neering Department
NESCL
Technical
Specifica-
tions
16 Accep- a) Conductor Critical Electrical As per As per IS As per IS Accep- P W W
tance test resitance Test sampling 7098(Pt-II) 7098(Pt- tance test
plan of IS II), A.D.S Certificate
7098(Pt- & NESCL
II) Specifica-
tion
1 2 3 4 5 6 7 8 9 D 10 11
b) Tensile test Critical Test do do do do P W W
c) Wrapping Test Critical Test do do do do P W W
d) Test for thick- Critical Test do do do do P W W
ness of insula-
tion and sheath
e) Hot set test Critical Test do do do do P W W
for insulation
f) Partial dis- Critical Electrical do do do do P W W
charge test Test
g) Tensile Critical Test do do do do P W W
strength & elon-
gation at break
for insulation &
outer sheath
h) High voltage Critical Electrical do do do do P W W
test Test
i) Insulation re- Critical Electrical do do do do P W W
sistance ( V. R) Test
14 Packing & Pre-Despatch Major Visual Random NESCL NESCL do P V V
Marking packing specification specifica-
tion
*-All type tests to be carried out as per NESCL specification.
√ - Record identified’√’ “”tick mark”” shall be essentially included by supplier in QA Documentations.
Note: Manufacturing, inspection & testing as per IS 7098 (pt-II) PS = Plant Standard M= Manufacturer
P= Performed By ADS = Approved Data Sheet N= Customer (NESCL)
V= Verified By C = Contactor
W= Witness of test SIGNATURE OF THE CONTRACTOR
SIGNATURE OF THE MANUFACTURER

129
MANUFACTURE’S NAME & ADDRESS: MANUFACTURING QUALITY PLAN

130
ITEM: LT PVC Un- QP NO: PROJECT/UTILITY:
Armoured Cable REV.NO: PACKAGE: Guna
SUB-SYSTEM: DATE: CONTRACT NO: IVRCL…, Myur
No of pages:3 MAIN-CONTRACTOR:
Sl. Compo- Characteristics Class Type of Quantum Reference Accep- Format of Agency Remarks
No nent & Check of Check Document tance Records
operation Norms
Quality Control Manual

1 2 3 4 5 6 7 8 9 D* ** 10 11
SECTION: 1 RAW MATERIALS M C N
1 Aluminium a) Dimension M/A Physical One IS 5484 & IS 5484 QC report P V V Review of Supplier’s
Rod sample P.S & NESCL Test Certificate at the
from Spec. time of final inspection
each lot
b) Tensile Strength M/A Physical do do do QC report P V V do
c) Elongation M/A Physical do do do QC report P V V do
d) Resistivity / Con- M/A Electrical do do do QC report P V V do
ductivity
2 “PVC for a) Thermal Stabilty M/A Physical One IS 1554 IS 1554 QC report P V V Review of Supplier’s
insulation sample (Pt-1) &P.S (Pt-1) Test Certificate at the
(Type-A)” from NESCL time of final inspection
each lot Spec.
b) Tensile Strength M/A Physical do do do QC report P V V do
c) Elongation M/A Physical do do do QC report P V V do
“d) Volume Resis- M/A Electrical do do do QC report P V V do
tivity
(Insulation Resis-
rance)”
3 “PVC for a) Specific Gravity M/A Physical One IS 5831 & IS 5831 QC report P V V “Review of Supplier’s
Sheath sample P.S & NESCL Test Certificate at the
(Type- from Spec. time of final inspec-
ST1)” each lot tion”
b) Thermal Stabilty M/A Physical do do do QC report P V V do
c) Tensile Strength M/A Physical do do do QC report P V V do
d) Elongation M/A Physical do do do QC report P V V do
1 2 3 4 5 6 7 8 9 D* ** 10 11
4 Wooden Dimension M/I Measure- As per IS IS 10418 & IS 10418 QC report P V V do
Drum ment 10418 P.S & NESCL
Spec.
SECTION: 2 IN PROCESS INSPECTION M C N
5 Wire a) Dimension M/A Measure- 10% IS 8130 IS 8130 & QC report P V V “Review of Supplier’s
Drawing ment A.D.S Test Certificate at the
time of final inspec-
tion”
b) Tensile Strength M/A Physical do do do do P V V do
c) Wrapping test M/A Physical do do do do P V V do
6 Insulation a) Thickness M/A Measure- 100% IS 1554 IS 1554 QC report P V V do
(Extru- ment (Pt-I) & P.S (Pt-I)
sion) NESCL
Spec.&
A.D.S
b) Surface Finish M/A Visual do do do do P V V do
c) Spark Test M/A Electrical do do do do P V V do
d) Colour M/A Visual do do do do P V V do
e) Tensile Strength M/A Physical do do do do P V V do
f) Elongation M/A Physical do do do do P V V do
7 Outer d) Surface Finish M/A Visual 100% IS 1554 IS 1554 QC report P V V “Review of Supplier’s
Sheath (Pt-I) & P.S (Pt-I) Test Certificate at the
NESCL time of final inspec-
Spec.& tion”
A.D.S
b) Sheath Thick- M/A Measure- do do do do P V V do
ness ment
c) Diameter Over M/A Measure- do do do do P V V do
outer sheath ment
d) Tensile Strength M/A Physical do do do do P V V do
f) Elongation M/A Physical do do do do P V V do
f) Embossing M/A Visual do do do do P V V do

131
1 2 3 4 5 6 7 8 9 D* ** 10 11

132
SECTION: 3 Final Testing M C N
8 Routine a) Conductor resis- Critical Electrical 100% As per “As per QC report √ P V V Routine test certificate
test tance IS1554(Pt- IS1554 will be furnished for
I)/1988 (Pt-I) verification during final
/1988” inspection
b) High Voltage Critical Electrical do do do do √ P V V do
9 Type Test Type Tests Critical Electrical Sample As per “As per Type Test V V V Type Test Clearance
Quality Control Manual

IS1554(Pt- IS1554 Report from NESCL Engi-


I)/1988 (Pt-I) neering Department
/1988”
10 Accep- a) Conductor resi- Critical Electrical As per As per As per IS, QC report P W W
tance test tance sampling IS1554(Pt- A.D.S &
plan of IS I)/1988 NESCL
1554(Pt- Specifica-
I)/1988 tion
b) Test for thick- Critical Physical do do do do P W W
ness of insulation &
sheath
c) Tensile strength Critical Physical do do do do P W W
& elongation test for
Insulation & Sheath
d) High voltage test Critical Electrical do do do do P W W
e) Annealing ( for Critical Electrical do do do do P W W
Copper)
f) Wrapping for Critical Electrical do do do do P W W
Aluminium
g) Tensile for Alu- Critical Electrical do do do do P W W
minium
h) Insulation Resis- Critical Electrical do do do do P W W
tance ( V. R)
11 Packing & Major Visual Random NESCL NESCL do P V V
Marking specification specifica-
tion
P.S= Plant Standard M= Manufacturer
P= Performed By A.D.S= Approved Data Sheet N= Customer (NESCL)
V= Verified By M/I=Minor C = Contactor
W= SIGNATURE OF THE CONTRACTOR
Witness of test
M/A= Major SIGNATURE OF THE MANUFACTURER
MANUFACTURING QUALITY PLAN
PROJECT/ UTILITY :
ITEM: THREE PHASE QP NO.: PACKAGE :
MANUFACTURER’S NAME & ADDRESS
CT OPERATED STATIC REV.NO.: CONTRACT NO. :
ENERGY METER DATE: MAIN-SUPPLIER :

Sl. Compo- Characteristics Class Quantum Reference Acceptance Format Of Agency


nents Type Of Remarks
No Of Check Document Norms Record
Check M C N
1 2 3 4 5 6 7 8 9 ** 10. 11.
Visual Check for
the following: Single Sampling AS per
AS per
• Legend Level II of IS Specification P V V Review of
Visual/ Specification
1 PCB Marking 2500 (PartI) Sheet for the IQC P V V records of
Major Elect- Sheet for the
• Masking (AQL=0.65) component Documents P V V the at the
rical component
Dimension 2 from each lot ----do---- V V V time of Final
Electrical Testing 2 from each lot ----do---- Inspection
Bare Board Testing 100% BBT OK
Single Sampling
Visual Check for As Per
Level II of IS
Damages and Specification I.Q.C. Review of
Visual/ 2500 (PartI)
2 Shunts twisting & Tinning Sheet for the Deptt. of IQC records of
Major Elect- (AQL=0.65) P V V
of wires component ----do---- Documents the at the
rical ----do----
Resistance Value ----do---- ----do---- time of Final
10% of Sample
Dimensions ----do---- Inspection
Qty.
Visual check for
Damages, Twisting,
Single Sampling AS per
Tinning of wire,
Level II of IS Specification I.Q.C.
Epoxy coating & Review of
Visual/ 2500 (PartI) Sheet for the Deptt. of
3 CTs Shielding IQC records of
Major Elect- (AQL=0.65) component ----do---- P V V
Electrical Tests: Documents the at the
rical ----do---- ----do---- ----do----
• Inductance time of Final
10% of Sample ----do----
• Resistance Inspection
Qty
• Output Voltage
Dimensions
Visual Check for
• Damage Single Sampling As per
• Colour Level II of IS Specification I.Q.C.
Review of
Electrical Test: Visual/ 2500 (PartI) Sheet for the Deptt. of
4 LED IQC records of
• Forward Voltage Major Elect- (AQL=0.65) component ----do---- P V V
Documents the at the
Drop rical ----do---- ----do---- ----do----
time of Final
• Reverse Voltage 10% of Sample ----do----
Inspection
Drop Qty
Dimensions

133
1 2 3 4 5 6 7 8 9 ** 10. 11.

134
Visual Check for
• Damage Single Sampling As per
• Colour Level II of IS Specification I.Q.C.
Review of
Electrical Test: Visual/ 2500 (PartI) Sheet for the Deptt. of
4 LED IQC records of
• Forward Voltage Major Elect- (AQL=0.65) component ----do---- P V V
Documents the at the
Drop rical ----do---- ----do---- ----do----
time of Final
• Reverse Voltage 10% of Sample ----do----
Inspection
Quality Control Manual

Drop Qty
Dimensions
Visual Single Sampling
As per
• Damage Level II of IS
Specification I.Q.C. Review of
Resis- • Coding Visual/ 2500 (PartI)
5 Sheet for the Deptt. of IQC records of
tance • Package Major Elect- (AQL=0.65) P V V
component ----do---- Documents the at the
Resistance value rical ----do----
----do---- ----do---- time of Final
Tolerance 10% of Sample
----do---- Inspection
Dimension Qty

Single Sampling
Visual As per
Level II of IS
• Damage Specification I.Q.C. Review of
Capac- Visual/ 2500 (PartI)
6 • Package Sheet for the Deptt. of IQC records of
itor Major Elect- (AQL=0.65) P V V
Capacitance value component ----do---- Documents the at the
rical ----do----
Tolerance ----do---- ----do---- time of Final
10% of Sample
Dimension ----do---- Inspection
Qty

Visual Check for


• Damage
Single Sampling
• Package As per
Level II of IS
• Marking Specification I.Q.C. Review of
Visual/ 2500 (PartI)
7 Diode Electrical Test: Sheet for the Deptt. of IQC records of
Major Elect- (AQL=0.65) P V V
• Forward Voltage component ----do---- Documents the at the
rical ---do----
Drop ----do---- ----do---- time of Final
10% of Sample
• Reverse Voltage ----do---- Inspection
Qty
Drop
Dimensions
1 2 3 4 5 6 7 8 9 ** 10. 11.
Visual Check for
• Damage
• Package Single Sampling
As per
• Marking Level II of IS
Specification As per Review of
Zener Electrical Test: 2500 (PartI)
8 Sheet for the Specification IQC records of
Diode • Forward Voltage Major (AQL=0.65) P V V
component Sheet for the Documents the at the
Drop ---do----
----do---- component time of Final
• Reverse Voltage 10% of Sample
----do---- Inspection
Drop Qty
• Zener Voltage
Dimensions

Visual Check for Single Sampling


As per
• Damage Level II of IS
Specification As per Review of
• Package Visual/ 2500 (PartI)
9 ICs Sheet for the Specification IQC records of
• Marking Major Elect- (AQL=0.65) P V V
component Sheet for the Documents the at the
Electrical Test: rical ---do----
----do---- component time of Final
• Functional 10% of Sample
----do---- Inspection
Dimensions Qty

Single Sampling
Visual Check for As per
Level II of IS
• Damage Specification As per Review of
Visual/ 2500 (PartI)
10 MOV • Marking Sheet for the Specification IQC records of
Major Elect- (AQL=0.65) P V V
Electrical Test: component Sheet for the Documents the at the
rical ---do----
• Functional ----do---- component time of Final
10% of Sample
Dimensions ----do---- Inspection
Qty
Single Sampling
Visual Check for As per
Level II of IS
• Damage Specification As per Review of
Visual/ 2500 (PartI)
Crystal • Package Sheet for the Specification IQC records of
11 Major Elect- (AQL=0.65) P V V
Electrical Test: component Sheet for the Documents the at the
rical ---do----
• Functional ----do---- component time of Final
10% of Sample
Dimensions ----do---- Inspection
Qty
Visual Check for
• Damage Single Sampling
As per
• No. of Digits Level II of IS
Specification
• Mounting Holes 2500 (Part-I) As per Review of
Stepper Visual/ Sheet for the
12 Electrical Test: (AQL=0.65) Specification IQC records of
Motor Major Elect- component P V V
• HV Test ---do---- Sheet for the Documents the at the
Counter rical ----do----
• Resistance 2 from each Lot component time of Final
----do----
• Functional 10% of Sample Inspection
----do----
Boiling Water Test Qty
Dimensions

135
Sl. Class Type Quantum Reference Acceptance Format of

136
Operations Characteristics Remarks
No of Of check Document Norms Record Agency
Check

Soldering
Solder bridging or
Review of
dry solder 100% check As per
PCB records of
Components and again 5 Specification QC
1. Inspection Major Visual Functionally P V V the at the
Quality Control Manual

Mounting nos. randomly Sheet for the Documents


OK time of Final
Polarity of selected daily component
Inspection
components by Q.C.
Functional Testing

100% check Reference Review of


As per
Counter and 5 nos. Sample & records of
Specification QC
2. & PCB Counter alignment Major Visual randomly Alignment P V V the at the
Sheet for the Documents
Assembly selected daily should be time of Final
component
by Q.C. proper Inspection

100% check Review of


Tightness of Reference As per
Assembled and 5 nos. records of
Connections Sample & Specification QC
3. Base Major Visual randomly P V V the at the
Terminal Block Work Sheet for the Documents
connection selected daily time of Final
Gasket Instructions component
by Q.C. Inspection
100% check
Name Plate Marking As per
Name and 5 nos. As per
Serial Number Specification QC
4. Plate Major Visual randomly NTPC P V V
punching and Sheet for the Documents
selected daily Specification
control component
by Q.C.
100% check Reference Review of
Name Plate position As per
Cover and 5 nos. Sample & records of
Cover fitment with Specification QC
5 Fixing Major Visual randomly Work P V V the at the
base Sheet for the Documents
selected daily Instructions time of Final
component
by Q.C. Inspection
Review of
Meter is calibrated As per
Meter records of
by solder shorting Elect- Specified Specification QC
6. Calibration Major 100% check P V V the at the
in phase as well as rical Standard Sheet for the Documents
time of Final
neutral element component
Inspection
Review of
10 Nos. As per
As per the As per records of
Temper Elect- samples Specification QC
7 requirements of Major NTPC P V V the at the
Test rical selected daily Sheet for the Documents
specification Specification time of Final
by Q.C. component
Inspection

100% check Should Review of


As per
Sealing and 5 nos. be proper records of
Specification QC
8 Packing Functional Testing of Major Visual randomly as per P V V the at the
Sheet for the Documents
Meter selected daily customer time of Final
component
by Q.C. requirement Inspection

137
Agency

138
Sl. Type of Quantum Reference Acceptance Format of
Operations Characteristics Class Remarks
No Check Of check Document Norms Record M C N

1 2 3 4 5 6 7 8 9 ** 10. 11.

Review of
Records
A.C. High 100% on each QC
Critical Electrical IS : 14697 IS : 14697 P V V of at the
Quality Control Manual

Voltage Test Meter Documents


time of Final
Inspection
100% on each QC
Insulation Test Critical Electrical IS : 14697 IS : 14697 P V V - do -
Routine Meter Documents
1
Test Test on limits 100% on each QC
Critical Electrical IS : 14697 IS : 14697 P V V - do -
of Errors Meter Documents
Test of Starting 100% on each QC
Critical Electrical IS : 14697 IS : 14697 P V V - do -
condition Meter Documents
Test of no load 100% on each QC
Critical Electrical IS : 14697 IS : 14697 P V V - do -
condition Meter Documents
Meter 100% on each QC
Critical Electrical IS : 14697 IS : 14697 P V V - do -
Constant Meter Documents

A. C. High Inspection
Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
Voltage Test Report
Inspection
Insulation Test Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
Report
Test on limits Inspection
Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
of Errors Report
Acceptance Test of Starting Inspection
2. Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
Test condition Report
Test of no load Inspection
Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
condition Report
Meter Inspection
Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
Constant Report
Test of
Inspection
repeatability of Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
Report
meter
Test of Power Inspection
Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w
Consumption Report
To be done
Test on limits Inspection
Critical Electrical As per IS : 14697 IS : 14697 IS : 14697 P w w after Vibration
of Errors Report
Test
Anti-Tamper As per NESCL Inspection
Critical Electrical IS : 14697 IS : 14697 P w w
Tests Tech. Specs. Report
Type Test
All Type Tests clearance
Electrical Inspection
3. Type Tests as per IS : Critical As per IS : 14697 IS : 14697 IS : 14697 V w w from NESCL
/ Mech Report
14697 Engineering
department

Legend:

M : Manufacturer
C : Contractor
N : NTPC Electric Supply Company Ltd.
IQC : Incoming Quality Control
P : Perform
V : Verify
W : Witness

139
MANUFACTURING QUALITY PLAN

140
PROJECT/ UTILITY :
MANUFACTURER’S NAME & PACKAGE :
ADDRESS ITEM: SINGLE PHASE QP NO.:
CONTRACT NO. :
WHOLE CURRENT REV.NO.:
ENERGY METER MAIN-SUPPLIER :
DATE:

Agency
Sl. Comp- Type Of Quantum Reference Acceptance Format Of Remarks
Characteristics Class
No onents Check Of Check Document Norms Record
M C N
Quality Control Manual

1 2 3 4 5 6 7 8 9 ** 10. 11.
Visual Check for the
AS per
following: Single Sampling
Specification AS per
• Legend Level II of IS 2500 P V V
Sheet for the Specification
1 PCB Marking Visual / (PartI) (AQL=0.65) P V V Review of records
Major component Sheet for the IQC Documents
• Masking Electrical 2 from each lot P V V of the at the time of
----do---- component
Dimension 2 from each lot V V V Final Inspection
----do----
Electrical Testing 100%
BBT OK
Bare Board Testing
Visual Check for Single Sampling As Per
Damages and Level II of IS 2500 Specification I.Q.C.
2 Shunts twisting & Tinning Visual / (PartI) (AQL=0.65) Sheet for the Deptt. of Review of records
Major IQC Documents P V V
of wires Electrical ----do---- component ----do---- of the at the time of
Resistance Value 10% of Sample ----do---- ----do---- Final Inspection
Dimensions Qty. ----do----

Visual check for


Damages, Twisting,
Tinning of wire, Single Sampling AS per
I.Q.C.
Epoxy coating & Level II of IS 2500 Specification
Deptt. of
3 CTs Shielding Visual / (PartI) (AQL=0.65) Sheet for the Review of records
Major ----do---- IQC Documents P V V
Electrical Tests: Electrical ----do---- component of the at the time of
----do----
• Inductance 10% of Sample ----do---- Final Inspection
• Resistance Qty ----do----
• Output Voltage
Dimensions

Visual Check for


• Damage As per
Single Sampling
• Colour Specification I.Q.C.
Level II of IS 2500
Electrical Test: Sheet for the Deptt. of
4 LED Visual / (PartI) (AQL=0.65) Review of records
• Forward Voltage Major component ----do---- IQC Documents P V V
Electrical ----do---- of the at the time of
Drop ----do---- ----do----
10% of Sample Final Inspection
• Reverse Voltage ----do----
Qty
Drop
Dimensions
1 2 3 4 5 6 7 8 9 ** 10. 11.

Visual
Single Sampling As per
• Damage
Level II of IS 2500 Specification I.Q.C.
Resis- • Coding
5 Visual / (PartI) (AQL=0.65) Sheet for the Deptt. of Review of records
tance • Package Major IQC Documents P V V
Electrical ----do---- component ----do---- of the at the time of
Resistance value
10% of Sample ----do---- ---do---- Final Inspection
Tolerance
Qty ----do----
Dimension
As per
Single Sampling
Visual Specification I.Q.C.
Level II of IS 2500
• Damage Sheet for the Deptt. of
(PartI) (AQL=0.65)
• Package component
Capa-
6 Visual / Review of records
citor Major ----do---- IQC Documents P V V
Capacitance value Electrical ----do---- of the at the time of
Tolerance ----do---- Final Inspection
10% of Sample
Dimension ----do----
Qty
----do----
As per
Visual Check for Specification I.Q.C.
• Damage Sheet for the Deptt. of
• Package Single Sampling component
• Marking Level II of IS 2500
7 Diode Electrical Test: Visual / (PartI) (AQL=0.65) Review of records
Major IQC Documents P V V
• Forward Voltage Electrical ---do---- of the at the time of
Drop 10% of Sample ----do---- Final Inspection
• Reverse Voltage Qty ----do----
Drop
Dimensions ----do----
----do----
Visual Check for
• Damage
• Package
Single Sampling As per
• Marking
Level II of IS 2500 Specification As per
Zener Electrical Test:
8 (PartI) (AQL=0.65) Sheet for the Specification Review of records
Diode • Forward Voltage Major IQC Documents P V V
---do---- component Sheet for the of the at the time of
Drop
10% of Sample ----do---- component Final Inspection
• Reverse Voltage
Qty ----do----
Drop
• Zener Voltage
Dimensions

Visual Check for


Single Sampling As per
• Damage
Level II of IS 2500 Specification As per
• Package
9 ICs Visual / (PartI) (AQL=0.65) Sheet for the Specification Review of records
• Marking Major IQC Documents P V V
Electrical ---do---- component Sheet for the of the at the time of
Electrical Test:
10% of Sample ----do---- component Final Inspection
• Functional
Qty ----do----
Dimensions

141
1 2 3 4 5 6 7 8 9 ** 10. 11.

142
Visual Check for Single Sampling As per
• Damage Level II of IS 2500 Specification As per
10 MOV • Marking Visual / (PartI) (AQL=0.65) Sheet for the Specification Review of records
Major IQC Documents P V V
Electrical Test: Electrical ---do---- component Sheet for the of the at the time of
• Functional 10% of Sample ----do---- component Final Inspection
Dimensions Qty ----do----
Visual Check for Single Sampling As per
• Damage Level II of IS 2500 Specification As per
Review of records
Crystal • Package Visual / (PartI) (AQL=0.65) Sheet for the Specification
11 Major IQC Documents P V V of the at the time of
Quality Control Manual

Electrical Test: Electrical ---do---- component Sheet for the


Final Inspection
• Functional 10% of Sample ----do---- component
Dimensions Qty ----do----
Visual Check for
• Damage Single Sampling
As per
• No. of Digits Level II of IS
Specification
• Mounting Holes 2500 (Part-I) As per
Stepper Sheet for the
12 Electrical Test: Visual / (AQL=0.65) Specification Review of records
Motor Major component IQC Documents P V V
• HV Test Electrical ---do---- Sheet for the of the at the time of
Counter ----do----
• Resistance 2 from each Lot component Final Inspection
----do----
• Functional 10% of Sample
----do----
Boiling Water Test Qty
Dimensions
Sl. Type Of Quantum Reference Acceptance Format Of
Opera-
No Characteristics Class Agency Remarks
tions Check Of Check Document Norms Record

Soldering
Solder bridging or
dry solder As per
PCB 100% check and
Components Specification Review of records
1. Inspe- Major Visual again 5 nos. Functionally QC Documents P V V
Mounting Sheet for the of the at the time of
ction randomly selected OK
Polarity of component Final Inspection
daily by Q.C.
components
Functional Testing

Reference
Counter As per
100% check and Sample &
& PCB Counter alignment Specification Review of records
2. Major Visual 5 nos. randomly Alignment QC Documents P V V
Ass Sheet for the of the at the time of
selected daily by should be
embly- component Final Inspection
Q.C. proper

Asse-
Tightness of Reference As per
mbled 100% check and Review of records
Connections Sample & Specification
3. Base Major Visual 5 nos. randomly QC Documents P V V of the at the time of
Terminal Block Work Sheet for the
conne- selected daily by Final Inspection
Gasket Instructions component
ction Q.C.

Name Plate
As per
Marking 100% check and
Name Specification
4. Serial Number Major Visual 5 nos. randomly As per NTPC QC Documents P V V
Plate Sheet for the
punching and selected daily by Specification
component
control Q.C.

Name Plate position Reference As per


100% check and
Cover Cover fitment with Sample & Specification Review of records
5 Major Visual 5 nos. randomly QC Documents P V V
Fixing base Work Sheet for the of the at the time of
selected daily by
Instructions component Final Inspection
Q.C.

Meter is calibrated
As per
Meter by solder shorting
Specification Review of records
6. Calib- in phase as well as Major Electrical Specified QC Documents P V V
100% check Sheet for the of the at the time of
ration neutral element Standard
component Final Inspection

As per
As per the 10 Nos. samples Review of records
Temper As per NTPC Specification
7 requirements of Major Electrical selected daily by QC Documents P V V of the at the time of
Test Specification Sheet for the
specification Q.C. Final Inspection
component

100% check and Should be As per


Sealing Review of records
5 nos. randomly proper as Specification
8 Packing Functional Testing Major Visual QC Documents P V V of the at the time of
selected daily by per customer Sheet for the
of Meter Final Inspection
Q.C. requirement component

143
Agency

144
Sl. Oper- Type Of Quantum Reference Acceptance Format Of
No ations Characteristics Class Remarks
Check Of Check Document Norms Record
M C N

1 2 3 4 5 6 7 8 9 ** 10. 11.
Review of Records
A.C. High Voltage 100% on each
Critical Electrical IS : 13779 IS : 13779 QC Documents P V V of at the time of Final
Test Meter
Inspection
100% on each
Quality Control Manual

Insulation Test Critical Electrical IS : 13779 IS : 13779 QC Documents P V V - do -


Meter
Routine Test on limits of 100% on each
1. Critical Electrical IS : 13779 IS : 13779 QC Documents P V V - do -
Test Errors Meter
Test of Starting 100% on each
Critical Electrical IS : 13779 IS : 13779 QC Documents P V V - do -
condition Meter
Test of no load 100% on each
Critical Electrical IS : 13779 IS : 13779 QC Documents P V V - do -
condition Meter
100% on each
Meter Constant Critical Electrical IS : 13779 IS : 13779 QC Documents P V V - do -
Meter
As per NESCL
A. C. High Voltage
Critical Electrical Tech. Specs./ IS: IS : 13779 IS : 13779 Inspection Report P w w
Test
13779
As per NESCL
Insulation Test Critical Electrical Tech. Specs./ IS: IS : 13779 IS : 13779 Inspection Report P w w
13779 The offered quantity
As per NESCL of meters shall be
Test on limits of
Critical Electrical Tech. Specs./ IS: IS : 13779 IS : 13779 Inspection Report P w w divided into sub-lots
Accept- Errors
13779 of 1000 meters each
2. ance
As per NESCL and sampling plan for
Test Test of Starting
Critical Electrical Tech. Specs./ IS: IS : 13779 IS : 13779 Inspection Report P w w each sub-lot of 1000
condition meters shall be as
13779
per IS: 13779
As per NESCL
Test of no load
Critical Electrical Tech. Specs./ IS: IS : 13779 IS : 13779 Inspection Report P w w
condition
13779
As per NESCL
Meter Constant Critical Electrical Tech. Specs./ IS: IS : 13779 IS : 13779 Inspection Report P w w
13779
1 2 3 4 5 6 7 8 9 ** 10. 11.
As per NESCL
Test of repeatability As per IS
Critical Electrical Tech. Specs./ IS: IS 13779:99 Inspection Report P w w
of meter 13779:99
13779 The offered quantity
As per NESCL of meters shall be
Test of Power As per IS
Critical Electrical Tech. Specs./ IS: IS 13779:99 Inspection Report P w w divided into sub-lots
Consumption 13779:99
13779 of 1000 meters each
As per NESCL and sampling plan for
Shock Test As per IS Inspection each sub-lot of 1000
Critical Mech Tech. Specs./ IS: IS 13010 P w w
(Acceptance) 13010 Report meters shall be as
13779
As per NESCL per IS: 13779
Vibration Test NESCL Tech. NESCL Tech. Inspection
Critical Mech Tech. Specs./ IS: P w w
(Acceptance) Specs. Specs. Report
13779
As per NESCL
Test on limits of To be done after
Critical Electrical Tech. Specs./ IS: IS : 13779 IS : 13779 Inspection Report P w w
Errors Vibration Test
13779

As per NESCL
Anti-Tamper Tests Critical Electrical IS : 13779 IS : 13779 Inspection Report P w w
Tech. Specs.

Type Test clearance


Type All Type Tests as Electrical As per IS As per IS from NESCL
3. Critical IS 13779:99 Inspection Report V w w
Tests per IS 13779 / Mech 13779:99 13779:99 Engineering
department

Legend:

M : Manufacturer
C : Contractor
N : NTPC Electric Supply Company Ltd.
IQC : Incoming Quality Control
P : Perform
V : Verify
W : Witness

145
Project/ UTILITY:

146
manufacturing Quality Plan
Manufacturer’s Name And PACKAGE:
Address : QP No.:
Item :11 kv a b Contract No.:
Rev. No.:
switch
Date: main-supplier:
Sl. Component Agency
Characte- Type of Quantum Reference Acceptance Format of Remarks
No & Class
ristics Check Of check Document Norms RecordS M C N
Operations
Quality Control Manual

1 2 3 4 5 6 7 8 9 10 11

Section : 1 Raw Materials

IS-191 IS-191 IS-191 Review Of Records At


Visual
Major Part-IV, Part-IV, Part-IV, Qc Record P V V The Time Of Final
Examination PH
IS-1897 IS-1897 IS-1897 Inspection

IS-191 IS-191 IS-191


Dimension Major PH Part-II Part-II Part-II Qc Record P V V ----DO---
IS-1897 IS-1897 IS-1897

Review of
Manufacturer
Tensile
Major ME IS-1608 IS-1608 IS-1608 Supplier TC V V V TC/Reputed lab TC at
Strength
the time of final
Copper
1. inspection
Flats
IS-191 IS-191 IS-191
Chemical
Major CH Part-IV Part-IV Part-IV Supplier TC V V V ---DO---
Composition
IS-1897 IS-1897 IS-1897

IS-191 IS-191 IS-191


Bend Test Major ME Part-IV Part-IV Part-IV Supplier Tc V V V ---DO---
IS-1897 IS-1897 IS-1897

IS-191 IS-191 IS-191


Resistivity /
Major E Part-IV Part-IV Part-IV Supplier Tc V V V ---DO---
Conductivity
IS-1897 IS-1897 IS-1897
1 2 3 4 5 6 7 8 9 10 11
Review Of Records At
Visual
Major PH IS-5082 IS-5082 IS-5082 Qc Record P V V The Time Of Final
Examination
Inspection
Dimension Major PH IS-3965 IS-3965 IS-3965 Qc Record P V V ---DO---
Review of Manufacturer
Tensile TC/Reputed lab TC at
Aluminium Major ME Supplier TC V V V
2. Strength IS-1608 IS-1608 IS-1608 the time of final
Flats inspection
Bend Test Major ME IS-5082 IS-5082 IS-5082 Supplier TC V V V ---DO---
Resistivity /
Major E IS-5082 IS-5082 IS-5082 Supplier TC V V V ---DO---
Conductivity
Chemical
Major CH IS-5082 IS-5082 IS-5082 Supplier TC V V V ---DO---
Composition
Review Of
Visual
Major PH IS-2062 IS-2062 IS-2062 Qc Record P V V Records At The Time
Examination
Of Final Inspection
IS-808, IS-808, IS-808,
IS-1730, IS-1730, IS-1730,
Dimension Major PH Qc Record P V V ---DO---
IS-1732, IS-1732, IS-1732,
IS-3954 IS-3954 IS-3954
Mild
Review of Manufacturer
3. steel
Tensile TC/Reputed lab TC at
sections Major ME IS-1608 IS-1608 IS-1608 Supplier TC V V V
Strength the
time of final inspection
Chemical
Major CH IS-2062 IS-2062 IS-2062 Supplier TC V V V ---DO---
Composition
Review Of
Bend Test Major ME IS-2062 IS-2062 IS-2062 Qc Record P V V Records At The Time
Of Final Inspection

147
1 2 3 4 5 6 7 8 9 10 11

148
Visual PLANT PLANT
PH 100% Qc Record P V V ---DO---
Examination Major STANDARD STANDARD

10
PLANT PLANT
Dimension Nos. Qc Record P V V
Major PH STANDARD STANDARD ---DO---
CONTACT per lot
4.
SPRIGS
Quality Control Manual

Functional PLANT PLANT


Major --DO-- Qc Record P V V
check PH STANDARD STANDARD ---DO---

Fitment/ PLANT PLANT


--DO-- Qc Record P V V ---DO---
Springs Major PH STANDARD STANDARD
IS- Review Of
Visual
Major PH 1367- IS-1367-III IS-1367-III Qc Record P V V Records At The
Examination
III Time Of Final Inspection
IS-
Dimension Major PH IS-1363 IS-1363 Qc Record P V V ---DO---
1363
Review of Manufacturer
IS-
TC/Reputed lab TC
Fastn- Wedge Test Major ME 1367- IS-1367-III IS-1367-III Supplier TC V V V
5. at the time of final
ers III
inspection
IS-
Hardness Major ME 1367- IS-1367-III IS-1367-III Supplier TC V V V ---DO---
III

IS-
SUPPLIER
Galvanizing Major CH 1367- IS-1367-XIII IS-1367-XIII V V V ---DO---
TC
XIII

IS- Review Of Records


Visual Major PH 2486- IS-2486- II IS-2486- II Qc Record P V V At The Time Of Final
II Inspection

IS-
6. GI pins Dimension Major PH 2486- IS-2486- II IS-2486- II Qc Record P V V ---DO---
II
Review of Manufacturer
Galvaniza- IS- TC /Reputed lab TC at
Major CH IS-4759 IS-4759 Supplier TC V V V
tion Checks 4759 the time of final
inspection
1 2 3 4 5 6 7 8 9 10 11
NGK Birla/ WSI/
Jayshree
IS-2544 IS-2544
Makes only. Review Of
Visual Major PH 100% IS-5350 IS-5350 Qc Record P V V
Records At The Time Of
IS-731 Is-731
Final
Inspection
IS-
Major
2544
Approved Approved
Dimension PH IS- Qc Record P V V ---DO---
Drgs. Drgs.
5350
IS-731
Review of Manufacturer
Major IS-
High Voltage IS-2544 IS-2544 TC/Reputed lab TC at
E 2544 Supplier TC V V V
Test IS-731 IS-731 the
IS-731
time of final inspection
Insula- IS-
7. Temperature Major IS-2544 IS-2544
tor E 2544 Supplier TC V V V -----DO----
Cycle IS-731 IS-731
IS-731
Mechanical
Major IS-
Strength/ IS-2544 IS-2544
ME 2544 Supplier TC V V V -----DO----
Failing load IS-731 IS-731
IS-731
Test
IS-
Puncture Major IS-2544 IS-2544
E 2544 Supplier TC V V V -----DO----
Test IS-731 IS-731
IS-731
IS-
Major IS-2544 IS-2544
Porosity Test PH 2544 Supplier TC V V V -----DO----
IS-731 IS-731
IS-731
IS-
Major
2544 IS-2544 IS-2544
Galvanizing
CH IS- IS-4759 IS-4759 Supplier TC V V V -----DO----
test
4759 IS-731 IS-731

149
IS-731
1 2 3 4 5 6 7 8 9 10 11

150
Chemical
8. Al. AlLoy Major CH IS-617 SI-617 IS-617 Supplier TC V V V ---DO---
Composition

IS-209
Chemical IS-209 IS-209, IS-
9.. Zinc Major CH IS- Supplier TC V V V ---DO---
Composition IS-13229 4759
13229
Quality Control Manual

Major Review Of Records


IS-
Visual PH IS-1239 IS-1239 Qc Record P V V At The Time Of Final
1239
Inspection

IS- Approved
Dimension Major PH IS-1239 Qc Record P V V -----DO----
1239 Drgs

Review of Manufacturer
Chemical IS- TC/Reputed lab TC
Major CH IS-1239 IS-1239 Supplier TC V V V
Analysis 1239 at the time of final
inspection

Tensile IS-
10. GI Tubes Major ME IS-1239 IS-1239 Supplier TC V V V -----DO----
Strength 1239

IS-
Elongation Major ME IS-1239 IS-1239 Supplier TC V V V -----DO----
1239

Review Of Records At
IS-
Bend Test Major ME IS-1239 IS-1239 P V V The Time Of Final
1239
Inspection
Review of Manufacturer
IS- TC /Reputed lab TC at
Galvanizing Major CH IS-1239 IS-1239 Supplier TC V V V
1239 the time of
final inspection
Sl. Component & Type of Quantum Reference Acceptance Format of Agency
Characteristics Class Remarks
No Operations Check Of check Document Norms RecordS M C N
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
SECTIION: 2 INPROCESS INSPECTION
Review Of Records
Visual QC
Major PH 100% -FQP -FQP P V V At The Time Of Final
Examination Record
Inspection
Welded/ Min. five
QC
FABRICATED Dimension Major PH sample -FQP -FQP P V V ----DO---
1. Record
M.S. per lot
componeNt
One
Fitment/ QC
Major PH sample -FQP -FQP P V V ----DO---
Assembly Record
per lot

Visual QC
Major PH 100% -FQP -FQP P V V ----DO---
Examination Record

Min. five
fabrication QC
Dimension Major PH sample -FQP -FQP P V V ---DO---
2. of copper Record
per lot
contacts
Fitment / One
PH QC P V V ----DO---
Assembly Major sample -FQP -FQP
Record
per lot

Visual QC
Major PH 100% IS-4759 IS-4759 P V V ----DO---
Examination Record
One
sample
QC
Appearance PH of each P V V ----DO---
Hot dip IS-2629 IS-2629 Record
3. Major compon-
galvanizing
ent per lot
QC
Uniformity Major CH -----DO--- IS-2633 IS-2633 P V V ----DO---
Record
CH QC
Mass of zinc Major -----DO---- IS-6745 IS-6745 P V V ----DO---
Record

151
Type Agency Remarks
Sl. Component & Quantum Reference Acceptance Format of

152
Characteristics Class of
No Operations Of check Document Norms RecordS M C N
Check
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Review Of
Visual QC Records At The
Major PH 100% IS-5561 IS-5561 P V V
Examination Record Time Of Final
Inspection
Quality Control Manual

One
Approve d Approved QC
Dimension Major PH sample P V V -----DO----
drags. Drgs. Record
per lot

Review of type test


Terminals Type Test from CPRI/NABL
4. Tensile Major ME Type test IS-5561 IS-5561 W V V
Connector Report approved lab on
similar connector.

Type Test
Resistance Major E IS-5561 W V V -----DO----
Type test IS-5561 Report

Temperature Type Test


Major E IS-5561 W V V -----DO----
Rise Type test IS-5561 Report

Short Time Type Test


Major E IS-5561 W V V -----DO----
Current test Type test IS-5561 Report

Review Of
Visual IS-3203 IS-3203 Inspection Records At
Major PH 100% SV W V V
Examination IS-6012 IS-6012 The Time of Final
Inspection
5. Electroplating
One
sample
Thickness of of each IS-3203 IS-3203
Major PH SV W V V ---DO---
plating comp IS-6012 IS-6012
onents
per lot
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Review Of Records
Visual QC
PH 100% -FQP -FQP P V V At The Time Of Final
Examination Major RECORD
Inspection
Approved/ Approved/
QC
Dimension 10% Floor Floor P V V
Major PH RECORD ---DO---
Drgs. Drgs.
Assemblies/
Subassem- Verification of Approved/ Approved/
6. QC
blies Major 10% Floor Floor P V V
components PH RECORD ---DO---
Drgs. Drgs.
Min. one
Functional sample QC
-FQP P V V
check Major PH per -FQP RECORD ---DO---
lot
Verification of
Packing Packing list
100% packing List at the
list QC
7. packing Visual Approved P V V time of
Major PH Approved RECORD
Drgs. final inspection &
Drgs.
review

153
Agency

154
Component Format
Sl. Type of Quantum Reference Acceptance
& Characteristics Class of Remarks
No Check Of check Document Norms
Operations RecordS M C N

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
SECTIION: 3 PRODUCT TESTING

All type tests IS-9920, IS-9920,


Quality Control Manual

Type Test Clearance


TYPE TEST as per relevant NESCL NESCL TYPE
Proto- from
1. – go ab IS & Major TTR Technical Technical TEST W W W
type REPORT NESCL Engineering
switch Technical specific- specific-
Department
Specifications ation ation
1) Power
Frequency
IS-9920, IS-9920,
Voltage
NESCL NESCL
routine Dry Test
Technical Technical Review Of Routine
test- 2) Routine QC
2. Major 100% specifi- specifi- P V V test reports during
go ab Measurement Checks RECORD
cation cation final Inspection
switch of Resistance
Approved Approved
of main circuit
Drgs Drgs
3)Operating
Test
IS-9920 IS-
Visual Test Report
Major Physical 100% /9921, 9920/9921, P W W
Examination
Part-I-IV Part-I-IV

Dimension Major Physical P W W


Approved Approved
Verification of Drgs. Drgs.
Major Physical P W W
component
Accept-
Operational
ance Major Physical P W W
3. check Sample
Tests-Goab
Switch Measurement as Test Report
of Resistance per IS:
Major Electrical P W W
on main 2500 IS-9920, IS-9920,
circuits Part-I-IV Part-I-IV
Power
Frequency
Major Electrical P W W
withstand
voltage test

SECTIION: 5 REMARKS

1. The MQP should be read in conjunction with NESCL specification and shall deem to include additional tests if any required as per contract.

In case of any contradiction between the manufacturer’s manufacturer FQP & NESCL FQP, this MQP and NESCL specification following precedence shall be followed:
a) NESCL specification
2.
b) This Manufacturing Quality Plan
c) Manufacturer’s FQP.

It is the responsibility of the manufacturer to ensure that this document is readily available at their works as well as at the works of their sub vendors in order to avoid any delay at the
3.
time of inspection.
4. In case of any tests being carried out at third party lab, such lab/facility should be NABL accredited / accepted by NESCL.
5. The raw material/bought out items should be procured from reputed sources.
The manufacturer shall maintain the proper co-relatio
6.
NESCL.
Any material rejected during power grid inspection shall be disposed off with the approval of NESCL. For destructive disposal NESCL may depute its representative for witnessing.
7. In case the material is to be returned to sub-vendor, all such items shall be indelibly marked (to prevent mixing) at the works of the manufacturer and offered to NESCL Inspector for
verification of marking.
8. Insulators shall be procured from M/S Birla NGK (JSI)/ India pottery only.

155
Doc. No.: Rev…… Cat…..

156
legeNd
M: Manufacturer/Sub-SUPPLIER
C: SUPPLIER/ Nominated Inspection Agency
Manufacturer/ Main-
(SUBJECT TO PRIOR
Sub-supplier supplier
APPROVAL OF NESCL), N: NESCL p: perform For
W: witness and NESCL
Quality Control Manual

V: verification. as appropriate, ,PH:PHYSICAL, USE


E:ELECTRICAL ME:MECHANICAL,CH:CHEMICAL
CHP: NESCL shall identified in colum “N” Reviewed Approved Approval
Signature
By By Seal
MANUFACTURING QUALITY PLAN
QP NO. VEL/
ITEM : 33 kV AND 11 KV VACCUM PROJECT/UTILITY:
NESCL/CG/01
MANUFACTURE’S NAME & ADDRESS: CIRCUIT BREAKERS (VCB)
REV. NO: PACKAGE :
DATE: CONTRACT NO:
MAIN-CONTRACTOR: M/s.
Sl. Component Characte- Type Of Quantum Reference Acceptance Format of
Class Agency Remarks
No & Operation ristics Check of Check Document norms Records
1 2 3 4 5 6 7 8 9 D 10 11
SECTION: 1 RAW MATERIAL M N C
Supplier
ISO W/I
Manufac- Review Of
WIQR03 CGL
turer’s / Manufacturer,
SPEC HR- Nescl Spec
Cgl S Test
Hot Rolled S2MS006 And Nescl
1. Finish Major Visual 5PCS/LOT Record P V V Records/
Sheets CR-S2MS005 Approved
On Supplier
(3.15mm)/ PLATES Drawing
Electr- Tc At The
1 Cold Rolled S2M007 IS
onic Inspection
Sheets 1079, 1S 513
System
(1.25mm Measur-
TO 3mm) 2. Dimension Major 5PCS/LOT DO DO DO P V V DO
ement
3. Bend Test Major Mechanical 1 PCS/LOT DO DO DO P V V DO
1 PCS/LOT
4.Chemical Major Chemical DO DO DO P V V DO
OF 10 Tons
Nescl Spec
Alloy Steel ISO W/I AND
10% PER And Nescl
Barsi/ Flats/ 1. Finish Major Visual CGL SPEC DO P V V DO
LOT Approved
Angles & S2MS 008
Drawing
2 Sections En
Measur- 5 NOS/
8, En 9, En 2. Dimension Major DO DO DO P V V DO
ement LOT
19a SAE
8620 3. Chemical Major Chemical 2 NO/LOT DO DO DO P V V DO
4. Tensile Major Mechanical 1NO/LOT DO DO DO P V V DO

157
ISO W/I

158
WIQR03 NESCL
CGL SPEC SPEC AND
10% PER
1. Finish Major Visual S2MSOO1 NESCL DO P V V DO
Copper/ LOT
3 AND 1S6134, APPROVED
Copper 1S 191 & IS DRAWING
Alloys, Flats 2826
Round
Sections Measur- 5 NOS/
2. Dimension Major DO DO DO P V V DO
ement LOT
3. Conduct- 2 NOS/
Quality Control Manual

Major Electrical DO DO DO P V V DO
ivity LOT
2 NOS/
4. Bend Test Major Mechanical DO DO DO P V V DO
LOT
5. Chemical Major Chemical 1 NO/LOT DO DO DO P V V DO
6. Tensile 1 NO/LOT
Test & Major Mechanical (LOT SIZE DO DO DO P V V DO
Elongation 1500 KG)
ISO W/I
NESCL
WIQR03
SPEC AND
10% PER CGL SPEC
1. Finish Major Visual NESCL DO P V V DO
LOT S2MS002
APPROVED
AND 1S5082
DRAWING
AND 1S 3965
Aluminium Measur- 5 NOS/
2. Dimension Major DO DO P V V DO
And ement LOT
4 Aluminium
Alloys Flats 3. Conduct- 2 NOS/
Major Electrical DO DO P V V DO
And Section ivity LOT
2 NOS/
4. Bend Test Major Mechanical DO DO P V V DO
LOT
5. Chemical Major Chemical 1 NO/LOT DO DO P V V DO
1 NO/LOT
6. Tensile
Major Mechanical (LOT SIZE DO DO P V V DO
Test
1000 KG)
CGL Drawing CGL
1. Defects &
Major Visual 10% LOT And Control Drawing And DO P V V DO
Finsih
Plan Control Plan
Castings/ Samples
5
Forgings Measur- Per Chart
2. Dimension Major DO DO P V V DO
ement – 3 Of
QCC09
3. Chemical Major Chemical 1 NO/LOT DO DO P V V DO
SECTION: 1 BOUGHT OUT COMPONENTS M C N
Supplier
Review Of
Manufa-
Manufa-
cturer’s
cturer’s Test
100% And CGL Drawing CGL /Cgl
Identified 1. Dimen- Measur- Records/
Major Chart 1 As And Control Drawing And Record P V V
Major sions ement Supplier Tc
Per QCC09 Plan Control Plan On
Compo- At The Time
Electr-
6 nents (Lost Of Final
onic
As Per Qcc Inspection
System
01 And NESCL
Qcc03) As
2. Chemical CGL Drawing SPEC and
Mentioned
(Where Major And Control NESCL Do P V V Do
In Resp.
Applicable) Plan Approved
Drawing
Drawing
Inspe-
CGL ction
SAMPLES
Drawing Record
1. Dimen- Measur- AS PER CGL
Major (Identified On P V V DO
sions ement CHART-3 DRAWING
Charecte- Electr-
Pressed OF QCC09
ristics) onic
7 Comp- System
onents

2. Surface
Major Visual D0 DO DO DO P V V DO
Finish

1. Dimen-
Measur-
sions Major D0 DO DO DO P V V DO
ement
Fabricated
8 Comp-
onents
2. Finish
Major Visual D0 DO DO DO P V V DO

159
Supplier

160
Manufac-
CGL turer’s
CGL
9 DRAWING /Cgl
1. Dimen- Measur- DRAWING
Major D0 AND Record P V V DO
sions ement AND NESCL
CONTROL On
SPEC
Springs PLAN Electr-
onic
System
Quality Control Manual

2. Surface
Major Visual D0 DO DO DO P V V DO
Finish
3. Load
Major Test D0 DO DO DO P V V DO
Values
Inspe-
NESCL ction
SPEC AND Record
1. Surface NESCL
Major Visual D0 NESCL On P V V DO
Finish SPEC
APPROVED Electr-
Hardware DRAWING onic
10
System
Measur-
2. Dimension Major D0 DO DO DO P V V DO
ement
IS 1363, IS
IS 1363, IS
3. Harness 1364, IS
1364, IS
(If Major Test D0 1367, 1S DO P V V DO
1367, IS
Applicable) 2389, 1S
2389, IS 2016
2016
NESCL
CGL SPEC and
1. Surface
Major Visual D0 DRAWING NESCL DO P V V DO
Finish
AND SPEC Approved
Expoy Drawing
Insulators Measur-
11 Bushings 2. Dimension Major D0 DO DO DO P V V DO
ement
And Pole
Units 3. Cantilever
Load (Is Major Mechanical D0 DO DO DO P V V DO
Specified)
4. Hv Test (If
Major Electrical D0 DO DO DO P V V DO
Specified)
1. Dimen- Measur-
Major D0 DO P V V DO
sions ement
12 Gaskets
2. Hardness
Major Test D0 DO DO DO P V V DO
Test
Supplier
B Sheet And Manufa-
NESCL
Manufa- cter’s /Cgl
SPEC and
1. Routine cturing Record
Major Electrical 100% NESCL P V V DO
Vaccum Test Instruction On
Approved
Interrupters Sheet Of Inprocess
13 Drawing
Make Cgl/ Cgl Test Card
Bel Fiv-02
2. Type/
Major Visual Sample DO DO DO P V V DO
Rating
3. Functional
Major Operational 100% DO DO DO P V V DO
Test
Supplier
Manufa-
Electrical NESCL cturer,S
Accessories SPEC and /Cgl
Relays, 1. Type/
Major Visual SAMPLE DO NESCL Record P V V DO
Meters, Rating
14 Approved On
Switches, Drawing Inprocess
Contrators Test Card
And Other Fiv-01
Fitments
2. Functional
Major Operational 100% DO DO DO P V V DO
Test

161
NESCL

162
SPEC and
1. Routine Supplier
Major Electrical 100% DO NESCL P V V DO
Test Tc
Approved
15 Ct/Pts Drawing
2. Frame
Major Visual 100% DO DO DO P V V DO
Size
3. Terminal
Major Visual 100% DO DO DO P V V DO
Quality Control Manual

Marking

Sample As NESCL
1. Dimen- Measur- NESCL
Major Per Chart-3 Approved DO P V V
sions ement SPEC
of QCC-O9 Drawing
16 Pvc Wires
2. Resist-
Major Electrical DO DO DO DO P V V DO
ance

3. Insulation Major Electrical DO DO DO DO

Supplier
1. Type/ Supplier
Major Visual 100% B Sheet/MI TC/B Sheet/
Rating Tc
17. MOTORS M.I P V V DO
2. Functional Measur-
Major 100% DO DO DO
Test ement
Section: 3.1 Inprocess Inspection & Testing (Feeder Shop) M C N
Review Of
Cnc
FIRST Manufa-
Punching NESCL Inspe-
PIECE NESCL cturer’s Test
Shearing, Approved ction
1. Dimen- Measur- RANDOM Approved Records/
18 Bending Major Drawing/ Record P V V
sions ement PIECE Drawing / Supplier Tc
Drilling CGL On Daily
LAST CGL Drawing At The Time
Welding Drawing Job Card
PIECE Of Final
Machining
Inspection
NESCL
AS PER NESCL
Finished Approved
1. Dimen- Measur- CHART-3 Approved
Comp- Major Drawing/ DO P V V DO
sions ement OF QCC- Drawing /
19 onents CGL
09 CGL Drawing
(Feeder Drawing
Shop) 2. Complet-
eness Of Major Visual D0 DO DO DO P V V DO
Oepration
1. Bath
CGL W.I Plant
Concen- Major Analysis Daily Once Register P V V DO
PTO-03 Standard
tration
Pretreat- 2. Temper- Temp.
ment Major Di DO DO DO P V V DO
ature Control
Process
20 Zinc
3. Coating Once In 6 CGL W.I Supplier
Phosph- Major Physical DO P V V DO
Weight Month PTO-015 Tc
ating (9
Tank)
4. Surface
Major Visual Daily Once DO DO DO P V V DO
Finish

Cgl Material Shade To


Spec And Match With
W.I Pto-16 Std Panel
1. Shade Major Visual DAILY Register P V V DO
And Pto-17 Dft Min 40
Powder Approved Microns/
21 Drawing Approved
Coating
DAILY
2. Dry Film Measur- SAMPLE
Major Do Do Do P V V DO
Thickness ement AS PER
CHART-03
Review Of
Manufac-
ISO Work turer’s Test
Breaker
1. Assembly Visual/ Instruction As Per Work Records/
Major 100% Test Card P V V
Checks Mechanical (W/I) W/I- Instructions Supplier Tc
FIV-02
WIQV-01 At The Time
Of Final
Inspection
22. Breaker
ISO Work
2. Coil/ Mecha-
Instruction
Mechanism Major nical/ 100% DO DO P V V DO
(W/I) W/I-
Setting Electrical
WIQV-02
ISO Work
3. Operation Instruction
Major Electrical 100% DO do p V V DO
Testing (W/I) W/I –
WIQV-06

163
ISO Work

164
Breaker
1. Assembly Visual/ Instruction As Per Work
Major 100% Test Card P V V DO
Checks Mechanical (W/I) W/I – Instuctions
FIV-02
WIQV-01
ISO Work
2. Coil/
Mechanical/ Instruction
23. Breaker Mechanism Major 100% DO DO P V V DO
Electrical (W/I) W/I
Setting
–WIQV-02
Quality Control Manual

ISO Work
3. Operation Instruction
Major Electrical 100% DO DO P V V DO
Testing (W/I) W/I-
WIQV-06
Section : 3.2 Inprocess Inspection & Testing (Assembly Shop)
PANEL
As Per Work
TEST
Inprocess 1. Assembly Major Visual 100% W;I-WIQV-03 Instruction P V V DO
CARD
24 Inspection And Bom/Mi
FIV-01
(Panel)
2. Bom/M.I
Major Visual 100% BOM/MI DO P V V DO
Checks
Section: 4 Final Inspection And Testing M C N
1. Power
Frequency
Test
Voltage (Dry) Major Electrical 100% P V V
Report
Test On The
Main Circuit
2. Voltage
Test On Review Of
Control & Major Electrical 100% DO P V V Manufa-
As Per Is As Per Is
Routine Auxiliary cturer’s Test
13118-91 13118-91
25 Testing Of Circuits Records/Tc
And Nescl And Nescl
Vcb 3. Measure At The Time
Specification Specification
Ment Of Fo Final
Resistance Major Electrical 100% DO P V V Inspection
Of Main
Circuit
4. Mecha-
Nical
Major Electrical 100% DO P V V
Operating
Test
1.Verification
Of Terminal Test
Major Electrical 100% P V V
Markings & Report
Polarity
2. Power
Frequency
(Dry)
Withstand Major Electrical 100% DO P V V
Tests On Review Of
Primary As per As per Manufa-
Routine Windings IS 3156 IS 3156 cturer’s Test
Tests For
26 (PART-1) 92 (PART-1) 92 Records/Tc
Voltage 3. Power
and NESCL and NESCL At The Time
Transformer Frequency
Specification Specification Fo Final
(Dry)
Inspection
Withstand Major Electrical 100% DO P V V
Tests On
Secondary
Windings
4.Determi-
nation Of
Errors For Major Electrical 100% DO P V V
Accuracy
Class

165
1.Verification

166
Of Terminal TEST
Major Electrical 100% P V V
Markings & REPORT
Polarity
2. Power
Frequency
(Dry)
Withstand Major Electrical 100% DO P V V
Tests On
Primary
Quality Control Manual

Windings Review Of
AS PER AS PER Manufac-
Routine 3. Power
IS 2705 IS 2705 turer’s Test
Tests For Frequency
27 (PART-1) 92 (PART-1) 92 Records/Tc
Current (Dry)
and NESCL and NESCL At The Time
Transformer Withstand Major Electrical 100% DO P V V
Specification Specification Fo Final
Tests On
Inspection
Secondary
Windings
4. Over
Voltage Inter Major Electrical 100% P V V
Turn Test
5. Determi-
nation Of
Errors For Major Electrical 100% DO P V V
Accuracy
Class
All Type AS PER AS PER Type Test
Test As Per IS: 13118 IS: 13118 Clearance
Type Test Type Test
28 Is: 13118 & Major Electrical Prototype & NESCL & NESCL V V V From Nescl
For Vcb Report
Nescl Tech. TECH. TECH. Engineering
Spec. SPEC. SPEC. Dept.
AS PER AS PER Type Test
All Type Test
IS: 3156 IS: 3156 Clearance
Type Test As Per Is: Type Test
29 Major Electrical Prototype & NESCL & NESCL V V V From Nescl
For Pt 3156 & Nescl Report
TECH. TECH. Engineering
Tech. Spec.
SPEC. SPEC. Dept.
AS PER AS PER Type Test
All Type Test
IS: 2705 IS: 2705 Clearance
Type Test As Per Is: Type Test
30 Major Electrical Prototype & NESCL & NESCL V V V From Nescl
For Ct 2705 & Nescl Report
TECH. TECH. Engineering
Tech. Spec.
SPEC. SPEC. Dept.
MANUFACTURING QUALITY PLAN
ITEM: 33 kV CUR- Qp No: PROJECT/UTILITY:
RENT TRANSFORM-
Manufacture’s Name & Address: Rev.No: PACKAGE:
ER
Date: CONTRACT NO:
SUB-SYSTEM:
MAIN-CONTRACTOR:
Compo-
Sl. Type Of Quantum Reference Acceptance Format of
nent & Characteristics Class Agency Remarks
No Check of Check Document Norms Records
Operation
1 2 3 4 5 6 7 8 9 D * 10 11
Section: 1 Raw Materials M C N
Plant Verification Of Record /
Standard IS 13778 VCS/ Supplier Tc At The Time
1. Visual Major Visual 5% P V V
Qai/01 Pt-1 QA/02R Of Final Inspection By
Sec-2 Nescl Inspector
1 SAM-
Measure- IS 13778
2.Diameter Major PLE PER Do DO P V V DO
ment Pt-1 &2
LOT
Supper Random SUPPLI-
1 MTR
Enamal Supplier Sample Test- ER TC /
1 3.Resistance Major Electrical EACH P V V DO
Copper Tc ing As Per Is VCS LAB
SIZE
Wire 13778 Pt -5 REPORT
1 SAM-
Supplier IS 13778
4.B.D.V Major Electrical PLE PER DO P V V DO
Tc Pt-5
LOT
Mechani- Supplier IS 13778
5.Elongation Major DO DO P V V DO
cal Tc Pt-3
6.Continuity Of Supplier IS 13778
Major Electrical DO DO P V V DO
Enamel Cover Tc Pt-5
D.C.C Covering To
(Double Be Uniform
5% RAN- Qai / 01 VCS/
2 Cotton 1.Visual Major Visual With Suffi- P V V DO
DOM Sec-1 QA/02R
Cover ) cient Insula-
Copper tion

167
Number

168
Of Strands Supplier
1 SAM-
2. Cross Sec- Measure- Qai / 01 Multiplied By TC / VCS
Major PLE PER P V V DO
tion ment Sec-2 Cross Sec- Lab Re-
LOT
tion Of Each port
Strand
Suppli-
3. Resistance Major Electrical DO IS 4800 DO P V V DO
er Tc
Quality Control Manual

99% MIN
4.Purity Of
Major Chemical DO Do / NESCL DO P V V DO
Copper
SPEC
AS PER
Measure- Qai/01 VCS/
1. Dimension Major 5% NESCL P V V DO
ment Sec-3 QA/02R
3 Crgo Coils SPEC
UNIFOR-
2. Visual Major Visual 100% Do DO P V V DO
MITY
Measure- 10% PER Qai/01 NESCL
1.Dimension Major DO P V V DO
ment LOT Sec-3 SPEC
Torroidal 100% UNIFOR-
4 2. Visual Major Visual Do DO P V V DO
Core PER LOT MITY
3. Ampere Turn 10% PER
Major Electrical Do 0.35 AT/cm DO P V V DO
Test LOT
VERIFICATION OF RE-
UN-
CORD / SUPPLIER TC
5% PER Qai/01 BLEACHED VCS/
1. Visual Major Visual P V V AT THE TIME OF FINAL
LOT Sec-4 KRAFT QA/02R
INSPECTION BY NESCL
PULP
INSPECTOR
1 SAM-
Measure- NESCL
2. Thickness Major PLE PER Do DO P V V DO
ment SPEC
Insulat- LOT
5 ing Kraft SUPPLI-
Paper 3. Electric ER TC /
Major Electrical DO Do 7 KV/mm P V V DO
Strength VCS LAB
REPORT
Mechani- Vcs/ 660-800 Kg/
4. Density Major DO DO P V V DO
cal Ms/04 m3
MD 95 &
5. Tensile Mechani-
Major DO Do CMD 40 Nm/ DO P V V DO
Strength cal
gm
5% PER Qai/01 FREE FROM VCS/
1.Visual Major Visual P V V DO
LOT Sec-4 DAMAGE QA/02R
SUPPLI-
1 SAM- AS PER
Measure- ER TC /
2. Dimensions Major PLE PER Do NESCL APP P V V DO
ment VCS LAB
Insulating LOT DWG
REPORT
6 Creepe
Paper 3. Electric Vcs/
Major Electrical DO 1 KV/mm DO P V V DO
Strength Ms/06
“MD 90% TO
Mechani- 110%
4.Elongation Major DO Do DO P V V DO
cal CMD 3% TO
5%”
1 SAM-
Qai/01 FREE FROM VCS/
1.Visual Major Visual PLE PER P V V DO
Sec-4 DAMAGE QA/02R
LOT
Measure- Vcs/ 50 +/- 3 MI-
2.Dimensions Major DO DO P V V DO
ment Ms/08 CRONS
Poly
Ethylene SUPPLI-
7 3.Electric 5 KV FOR 50 ER TC /
Terepha- Major Electrical DO Do P V V DO
late Film Strength MICRONS VCS LAB
REPORT
“MD 1732
4.Tensile Mechani- KG/sq.cm
Major DO Do DO P V V DO
Strength cal CMD 1710
KG/sq.cm”
SUPPLI-
1 SAM- BLACK
Vcs/ ER TC /
1.Visual Major Visual PLE PER FREE FROM P V V DO
Ms/07 VCS LAB
LOT DAMAGE
REPORT
Measure- 0.45 mm TO VCS/
2.Dimensions Major DO Do P V V DO
Semicon- ment 0.55 mm QA/02R
8 ducting SUPPLI-
Paper 0.65 gm/cc
Mechani- ER TC /
3.Density Major DO Do TO 0.85gm/ P V V DO
cal VCS LAB
cc
REPORT
160 MICRO
4.Conductivity Major Electrical DO Do SIEMENS/ DO P V V DO
cm

169
SUPPLI-

170
1 SAM-
No Sign Of ER TC /
1. Visual Major Visual PLE PER Vcs/Ms/09 P V V DO
Oxidation VCS LAB
LOT
REPORT
Aluminium Measure- 30 MICRONS VCS/
9 2. Thickness Major DO Do P V V DO
Foil ment +/- 3 QA/02R
SUPPLI-
ER TC /
3.Purity Major Chemical DO Do 99% MIN P V V DO
Quality Control Manual

VCS LAB
REPORT
1 SAM- IS 1576 /
Qai/01 VCS/
Press 1.Visual Major Visual PLE PER Free From P V V DO
Sec-4 QA/02R
Board / LOT Damage
10
Letheroid IS 1576
Sheet Measure-
2.Dimensions Major DO Do Nominal DO P V V DO
ment
Thickness
IS 335 / Oil
Shell Be
SUPPLI- Verification Of Record /
1 SAM- Clear Trans-
Supplier ER TC / Supplier Tc At The Time
1. Appearance Major Visual PLE PER parent And P V V
Tc / Is 335 VCS LAB Of Final Inspection By
LOT Free From
REPORT Nescl Inspector
Suspenede
Particals
Supplier
2.Density Major Physical DO 0.89gms/CC DO P V V DO
Tc / Is 335
Supplier
3.Viscosity Major Physical DO 27CST DO P V V DO
Trans- Tc / Is 336
11 4.Interfacial Supplier
former Oil Major Physical DO .04n/m DO P V V DO
Tension Tc / Is 337
Supplier
5.Flash Point Major Physical DO 1400C DO P V V DO
Tc / Is 338
Supplier MINUS 6
6.Pour Point Major Physical DO DO P V V DO
Tc / Is 339 O C
“0.03mg
Supplier
Major Chemical DO KOH/gm DO P V V DO
Tc / Is 340
NIL”
8.Corrosive Supplier NON COR-
Major Electrical DO DO P V V DO
Sulphur Tc / Is 341 ROSIVE
9.Electric
Strength Un- Qai/01 “30KV rms VCS/
Major Elctrical DO P V V DO
treated New Oil Sec-06 60KV rms” QA/02R
/Treated Oil
SUPPLI-
10.Tan Delta At Supplier ER TC /
Major Elctrical DO 0.002 P V V DO
900c Tc / Is 341 VCS LAB
REPORT
“11.Specific “35 X 10 ^ 12
Resistance Supplier Ω-cm
Major Elctrical DO DO P V V DO
At 900c Tc / Is 341 1500 X 10 ^
At 27oc” 12 Ω-cm”
12.Oxidation
Stability
Supplier 0.04 mg/
Neutralization Major Chemical DO DO P V V DO
Tc / Is 341 KOH/ gm
Value Total
Sludge
13.Ageing
Characteristics
Specific Resis-
tance
VERIFICATION OF RE-
SUPPLI-
CORD / SUPPLIER TC
Supplier 0.2 X 10 ^ 12 ER TC /
A)At 900c Major Elctrical DO P V V AT THE TIME OF FINAL
Tc / Is 341 Ω-cm VCS LAB
INSPECTION BY NESCL
REPORT
INSPECTOR
Supplier 2.5 X 10 ^12
B) At 270c Major Elctrical DO DO P V V DO
Tc / Is 342 Ω-cm
C) Tan Delta At Supplier
Major Elctrical DO 0.2 DO P V V DO
900c Tc / Is 343
Supplier 0.05 mg/
D) Total Acidity Major Chemical DO DO P V V DO
Tc / Is 344 KOH/gm
Supplier
E) Total Sludge Major Chemical DO 0.05% DO P V V DO
Tc / Is 345
14.Presence
Supplier
Of Oxidation Major Chemical DO NIL DO P V V DO
Tc / Is 346
Inhibitor
15. Water Con- Supplier
Major Chemical DO 50ppm DO P V V DO

171
tent Max Tc / Is 347
Verification Of Record /

172
Qa/01 VCS/ Supplier Tc At The Time
1 . Visual Major Visual 100% IS5621 P V V
Sec - 7 QA/02R Of Final Inspection By
Nescl Inspector
IS 5621 /
IS2099 /
Measure- Supplier
2 . Dimension Major 5 %/LOT NESCL AP- DO P V V DO
ment Tc
Bushings PROVED
DRW
Quality Control Manual

( Nescl
12
Approved SUPPLI-
Make) 3 .Routine ER TC /
Major Electrical DO Do IS 5621 P V V DO
Electrical Test VCS LAB
REPORT
NO DYE
4 . Porosity Major Physical DO Do PENTRITA- DO P V V DO
TION
5 . Temp Cycle NO CRACK
Major Physical DO Do DO P V V DO
Test AFTER TEST
Qai/01 FREE FROM VCS/
1. Visual Major Visual 10% P V V DO
Sec-5 DAMAGE QA/02R
AS PER
Measure-
2. Dimensions Major 5 % /LOT Do DRAWING / DO P V V DO
ment
SIZE
SUPPLI-
70 =/-5 ER TC /
3. Hardness Major Physical DO Vcs/Ms/13 P V V DO
13 Gaskets SHORE A VCS LAB
REPORT
“4. Ageing Test
7 Days In T/F
Oil
10 %
A ) Change In Major Physical 2 % / LOT Do DO P V V DO
Weight Max
B ) Change In
Hardness”
10% / Qai/01 FREE FROM
1.Visual Major Visual VS P V V DO
LOT Sec-9 DAMAGE
NESCL AP-
Measure-
2.Dimensions Major DO Do PROVED DO P V V DO
ment
14 Tanks DRW
SUPPLI-
NO LEAK AT
ER TC /
3.Leak Test Major Physical 100% Vcs/Ms/11 1.5 KG/sq.cm P V V DO
VCS LAB
FOR 15
REPORT
Nescl FREE FROM VCS/
1.Visual Major Visual 10% /LOT P V V DO
App.Dwg DAMAGE QA/02R
Primary
15 NESCL AP-
Terminals Measure-
2.Dimensions Major 5% / LOT Do PROVED DO P V V DO
ment
DRW
10% / FREE FROM VCS/
1.Visual Major Visual Vcs/Ms/14 P V V DO
LOT DAMAGE QA/02R
NESCL AP-
Measure-
2.Dimensions Major 5% / LOT Do PROVED DO P V V DO
Sec.Ter- ment
16 DRW
minals
3.Insulation Qai/01
Major Electrical 2% / LOT 2 M OHMS DO P V V DO
Resistance Sec-8
4.Dielectric 5KV rms / 1
Major Electrical DO Do DO P V V DO
Test MINUTE
10% / Nescl FREE FROM VCS/
1.Visual Major Visual P V V DO
Chimney LOT App.Dwg DAMAGE QA/02R
17
Pipe Measure-
2.Dimensions Major 5% / LOT Do PARTS DWG DO P V V DO
ment
10% / Nescl FREE FROM VCS/
1.Visual Major Visual P V V DO
Porcelain LOT App.Dwg DAMAGE QA/02R
18
Collar Measure-
2.Dimensions Major 5% / LOT Do PARTS DWG DO P V V DO
ment
Bom /
10% / FREE FROM VCS/
1.Visual Major Visual Nescl P V V DO
LOT DAMAGE QA/02R
19 Hardware Spec
Measure- AS PER
2.Dimensions Major 5% / LOT Do DO P V V DO
ment NESCL DWG

173
FREE FROM VCS/

174
1. Visual Major Visual 1% / LOT Vcs/Ps/11 P V V DO
DAMAGE QA/02R
20 Painting
Measure- 40 MIC-
2.Dimensions Major 1% / LOT Do DO P V V DO
ment CRONS MIN
FREE FROM VCS/
1.Visual Major Visual 1% / LOT Do P V V DO
DAMAGE QA/02R
SUPPLI-
Measure- 85 MI- ER TC /
2.Thickness Major 1% / LOT Do P V V DO
Quality Control Manual

Galvaniz- ment CRONS VCS LAB


21
ing REPORT
COATING
3.Pivot Ham- Mechani- SHOULD
Major 1% / LOT Do DO P V V DO
mer Test cal NOT PEEL
OFF
Section: 2 In-Process
Verification Of Record /
1.Basic Insula- Pl/01 FREE FROM VCS/ PR / Supplier Tc At The Time
Major Visual 100% P V V
Second- tion Sec-1 DAMAGE 08R Of Final Inspection By
22 ary Wind- Nescl Inspector
ing AVOID
2.Overlapping Pl/01
Major Visual 100% OVER LAP- DO P V V Do
Conductor Sec-2
PING
Stage 1 Testing
Verification Of Record /
1.Ratio & Qai/01
AS PER IS VCS/ Supplier Tc At The Time
Phase Angle Major Electrical 100% Sec-10 / P V V
2705 QA/04R Of Final Inspection By
Errors Is 2705
Nescl Inspector
Protection 2.Resistance Major Electrical 100% Do DO DO P V V DO
23 Measurement
Core
3.Exciting Cur-
Major Electrical 100% Do DO DO P V V DO
rent Measurent
4.% Composite
Major Electrical 100% Do DO DO P V V DO
Error
Metering Ratio & Phase
24 Major Electrical 100% Do DO DO P V V DO
Core Angle Error
1.Resistance
Major Electrical 100% Do DO DO P V V DO
Measurement
2.Turns Ratio Major Electrical 100% Do DO DO P V V DO
25 P.S Core 3.Vk Measure-
Major Electrical 100% Do DO DO P V V DO
ment
4.Magnetizing
Major Electrical 100% Do DO DO P V V DO
Current
1.Chimney Qai/01 NESCL VCS/PR/
Bunching Position Major Visual 100% P V V DO
Sec-11 SPEC 08R
26 & Chim-
ney Fixing 2.Tightness Of NESCL
Major Electrical 100% Do DO P V V DO
Chimney SPEC
Stage 2 Testing P V V DO
Qai/01
Sec-11 AS PER IS VCS/
1.Polarity Major Electrical 100% P V V DO
Protection And Is 2705 QA/04R
27 Core & 2705
Metering 2.Ratio &
Phase Angle Major Electrical 100% Do DO DO P V V DO
Errors
1.Polarity Major Electrical 100% Do DO DO P V V DO
28 P.S Core
Turns Ratio Major Electrical 100% Do DO DO P V V DO
Qai/01 VCS/
1.Dimension Major Electrical 100% DO P V V DO
Sec-12 PR/08R
29 Taping
2.Tightness Of
Major Electrical 100% Do DO DO P V V DO
Taping
1.Cross Sec- Measure- Qai/01 NESCL
Major 5% DO P V V DO
tion ment Sec-13 SPEC
Primary Measure-
30 2.No Of Turns Major 100% Do DO DO P V V DO
Winding ment
Qai/01
3.Rigidity Major Visual 5% DO DO P V V DO
Sec-14

175
1.Temp.Mea- EVERY VCS/

176
Major Physical Do DO P V V DO
surement HOUR PR/010R
2.Vacuum EVERY
Major Physical Do DO DO P V V DO
Drying & Measurment HOUR
31 Impregna- 1 SAM-
tion 3.Filtered Oil
Major Electrical PLE PER Do DO DO P V V DO
Bdv Check
LOT
4.Oil Soaking
Major Physical 100% Do DO DO P V V DO
Quality Control Manual

Time
1.Primary Con- Qai/01 VCS/
Major Visual 100% DO P V V DO
nection Sec-15 PR/08R
2.Secondary
Major Visual 100% Do DO DO P V V DO
Main As- Connection
32
sembly 3.Locking Ar-
Major Visual 100% Do DO DO P V V DO
rangements
4.Securing Of
Major Visual 100% Do DO DO P V V DO
Active Part
Section: 3 Final Inspection
1. Verification
Qai/01
Of Terminal AS PER IS VCS/
Critical Electrical 100% Sec-18 & √ P W W
Marking And 2705 QA/05F
Is 2705
Polarity
2. Power
Frequency
Dry Withstand Critical Electrical 100% Do DO DO √ P W W
Tests On Pri-
mary Windings
3.Power
Routine
33 Frequency
Test
Dry Withstand
Critical Electrical 100% Do DO DO √ P W W
Tests On Sec-
ondary Wind-
ings
4. Over Voltage
Critical Electrical 100% Do DO DO √ P W W
Interturn Test
5 Partial Dis-
charge Mea-
Critical Electrical 100% Do DO DO √ P W W
surement (If
Applicable)
6 Ratio &
Phase Angle Critical Electrical 100% Do DO DO √ P W W
Error
Additional Test
As Per Nescl
Technical
Specifications
7) Measure-
ment Of Ca- Critical Electrical 100% Do DO DO √ W W W
pacitance
8) Oil Leakage
Test (Process
Critical Electrical 100% Do DO DO √ W W W
To Be Mutually
Agreed)
9) Measure-
ment Of Tan
Delta At 0.3, Critical Electrical 100% Do DO DO √ W W W
0.7, 1.0 & 1.1
Um
1.Short-Time 1 SAM- Qai/01 & AS PER IS VCS/
Critical Electrical √ W V V
Current Test PLE Is-2705 2705 PR/008R
2.Temperature 1 SAM-
Critical Electrical Do DO DO √ W V V
Rise Test PLE
3.Lightning Im-
1 SAM-
pulse Voltage Critical Electrical Do DO DO √ W V V
PLE
Withstand Test
4.High Volt-
age Power
1 SAM-
Frequency Wet Critical Electrical Do DO DO √ W V V
Type PLE
39 Withstand Volt-
Tests* age Test
5.Determin-
ation Of Errors
And Other
Characteristics
According To 1 SAM-
Critical Electrical Do DO DO √ W V V
The Require- PLE
ment Of The
Appro-priate
Designation Of
Accuracy Class

177
Qai/01 VCS/

178
1.Visual Check Critical Visual 100% DO √ P V V
Sec-20 PR/008R
2.Nuts &
Washer For Critical Visual 100% Do DO DO √ P V V
Earth Bolts
3.Earthing
Critical Visual 100% Do DO DO √ P V V
Symbol
4.Oil Level In
Critical Visual 100% Do DO DO P V V
Quality Control Manual


38 Finishing Gauge
5.Primary Ter-
Critical Visual 100% Do DO DO √ P V V
minal Markings
6.Oil Leaks Critical Visual 100% Do DO DO √ P V V
7.Terminal
Critical Visual 100% Do DO DO √ P V V
Markings
8.Name Plate
& Connection Critical Visual 100% Do DO DO √ P V V
Diagram
*-All Type Tests To Be Carried Out As Per Nescl Specification, Contract Agreement And As Per Minutes Of The Meeting Between Nescl And Vel Ap-
proval Of Type Tests By Engineering Department Of Nescl Or Waival Thereof To Be Shown At The Time Final Inspection To Enable Nescl Issue Mdcc.
√ - Record Identified’√’ “”Tick Mark”” Shall Be Essentially Included By Supplier In Qa Documentations.
√ - Record Identified’√’ “Tick Mark” Shall Be Essentially Included By Supplier In Qa Documentations.
M= Manufacturer
P= Performed By P.S= Plant Standard N= Customer (NESCL)
V= Verified By C = Contactor
W= Witness Of Test Signature Of The Contractor SIGNATURE OF THE MANUFACTURER
Manufacturing Quality Plan
Item : 33 kV Potential QP NO: PROJECT/UTILITY:
MANUFACTURE’S NAME & AD-
Transformers REV.NO:R0 PACKAGE:
DRESS:
DATE: CONTRACT NO:
Sub-System:
MAIN-CONTRACTOR:
Compo- Accep-
Sl. Characteris- Quantum Reference Format of
nent & Class Type Of Check tance Agency Remarks
No tics of Check Document Records
Operation Norms
1 2 3 4 5 6 7 8 9 D * 10 11
SECTION: 1 RAW MATERIALS M C N
Verification Of Record /
Qai/01 IS 13778 VCS/ Supplier Tc At The Time
1. Visual Major Visual 5% P V V
Sec-2 Pt-1 QA/02R Of Final Inspection By
Nescl Inspector
1 PER IS 13778
2.Diam-eter Major Measurement Do DO P V V Do
LOT Pt-1 &2
SUPPLI-
1 MTR
3.Resi- Suppiler IS 13778 ER TC /
Major Electrical EACH P V V Do
S.E Cop- stance Tc Pt -5 VCS LAB
1 SIZE
per Wire REPORT
1 SAM-
Suppiler IS 13778
4.B.D.V Major Electrical PLE PER DO P V V Do
Tc Pt-5
LOT
Suppiler IS 13778
5.Elong-ation Major Mechanical DO DO P V V Do
Tc Pt-3
6.Conti-nuity
Suppiler IS 13778
Of Enamel Major Electrical DO DO P V V Do
Tc Pt-5
Cover
AS PER
Qai/01 VCS/
1. Dimension Major Measurement 5% NESCL P V V Do
Sec-3 QA/02R
2 Crgo Coils SPEC
UNIFOR-
2. Visual Major Visual 100% Do DO P V V Do
MITY

179
UNBLEA-

180
5% PER Qai/01 CHED VCS/
1. Visual Major Visual LOT Sec-4 KRAFT QA/02R P V V Do
PULP
1 SAM- NESCL
2. Thickness Major Measurement PLE PER Do DO P V V Do
SPEC
LOT
Insulat- SUPPLI-
3 ing Kraft 3. Electric ER TC /
Paper Major Electrical DO Do 7 KV/mm P V V Do
Strength VCS LAB
Quality Control Manual

REPORT

4. Density Major Mechanical DO Vcs/Ms/04 660-800 DO P V V Do


Kg/m3
MD 95 &
5. Tensile Major Mechanical DO Do CMD 40 DO P V V Do
Strength Nm/gm
FREE
5% PER Qai/01 VCS/
1.Visual Major Visual FROM P V V Do
LOT Sec-4 QA/02R
DAMAGE
SUPPLI-
1 SAM- AS PER
2. Dimen- ER TC /
Major Measurement PLE PER Do NESCL P V V Do
Insulating sions VCS LAB
LOT SPEC
4 Creepe REPORT
Paper 3. Electric Major Electrical DO Vcs/Ms/06 1 KV/mm DO P V V Do
Strength
“MD 90%
TO 110%
4.Elongation Major Mechanical DO Do DO P V V Do
CMD 3%
TO 5%”
1 SAM- FREE
Qai/01 VCS/
1.Visual Major Visual PLE PER FROM P V V Do
Sec-4 QA/02R
LOT DAMAGE
2.Dimen- +/- 3
Major Measurement DO Vcs/Ms/08 50 P V V Do
sions MICRONS DO
Poly SUPPLI-
Ethylene 3.Electric 5 KV FOR ER TC /
5 Major Electrical DO Do 50 MI- P V V Do
Terepha- Strength VCS LAB
late Film CRONS REPORT
“MD 1732
KG/sq.cm
4.Tensile Major Mechanical DO Do CMD DO P V V Do
Strength 1710 KG/
sq.cm”
Verification Of Record /
1 SAM- Is 1576
Qai/01 VCS/ Supplier Tc At The Time
Press 1.Visual Major Visual PLE PER Free From P V V
Sec-4 QA/02R Of Final Inspection By
Board/ LOT Damage
6 Nescl Inspector
Letheroid
Sheet Is 1576
2.Dimen-
Major Measurement DO Do Nominal DO P V V Do
sions
Thickness
Oil Shell
Be Clear
Transpar- SUPPLI-
1 SAM-
1. Appear- Supplier ent And ER TC /
Major Visual PLE PER P V V Do
ance Tc / Is 335 Free From VCS LAB
LOT
Sus- REPORT
penede
Particals
Supplier 0.89gms/
2.Density Major Physical DO DO P V V Do
Tc / Is 335 CC
Supplier
3.Viscosity Major Physical DO 27 CST DO P V V Do
Tc / Is 335
4.Interfacial Supplier
Major Physical DO 0.04n/m DO P V V Do
Tension Tc / Is 335
Supplier
5.Flash Point Major Physical DO 1400C DO P V V Do
Tc / Is 335
Trans-
7 Supplier MINUS 6
former Oil 6.Pour Point Major Physical DO DO P V V Do
Tc / Is 335 O C
7.Neutral- “0.03mg
Supplier
ization Value Major Chemical DO KOH/gm DO P V V Do
Tc / Is 335
Total Acidity NIL”
NON
8.Corrosive Supplier
Major Electrical DO CORRO- DO P V V Do
Sulphur Tc / Is 335
SIVE
9.Electric
“30KV
Strength Un- Is 335 &
rms VCS/
treated New Major Elctrical DO Qai/01 P V V Do
60KV QA/02R
Oil /Treated Sec-06
rms”
Oil
SUPPLI-
10.Tan Delta Supplier ER TC /
Major Elctrical DO 0.002 P V V Do
At 900c Tc / Is 335 VCS LAB
REPORT

181
“35 X 10 ^

182
“11.Specific
12 Ω-cm
Resistance Supplier
Major Elctrical DO 1500 X DO P V V Do
At 900c Tc / Is 335
10 ^ 12
At 27oc”
Ω-cm”
12.Oxidation
Stability
Supplier 0.04 mg/
Neutraliza- Major Chemical DO DO P V V Do
Tc / Is 335 KOH/ gm
tion Value
Quality Control Manual

Total Sludge
13.Ageing
Characteris-
tics
Specific Re-
sistance
SUPPLI- Verification Of Record /
Supplier 0.2 X 10 ^ ER TC / Supplier Tc At The Time
A)At 900c Major Elctrical DO P V V
Tc / Is 335 12 Ω-cm VCS LAB Of Final Inspection By
REPORT Nescl Inspector
Supplier 2.5 X 10
B) At 270c Major Elctrical DO DO P V V Do
Tc / Is 335 ^12 Ω-cm
C) Tan Delta Supplier
Major Elctrical DO 0.2 DO P V V Do
At 900c Tc / Is 335
D) Total Acid- Supplier 0.05 mg/
Major Chemical DO DO P V V Do
ity Tc / Is 335 KOH/gm
E) Total Supplier
Major Chemical DO 0.05% DO P V V Do
Sludge Tc / Is 335
14.Presence
Supplier
Of Oxidation Major Chemical DO NIL DO P V V Do
Tc / Is 335
Inhibitor
15. Water Supplier
Major Chemical DO 50ppm DO P V V Do
Content Max Tc / Is 335
Verification Of Record /
Qa/01 VCS/ Supplier Tc At The Time
1 . Visual Major Visual 100% IS5621 P V V
Sec - 7 QA/02R Of Final Inspection By
Nescl Inspector
Supplier NESCL
2 . Dimen- Tc / Is AP-
Major Measurement 5 %/LOT DO P V V Do
sion 5621 / PROVED
Is2099 DRW
Bushings
SUPPLI-
( Nescl 3 .Routine
8 ER TC /
Approved Electrical Major Electrical DO Do IS 5621 P V V Do
VCS LAB
Make) Test
REPORT
NO DYE
4 . Porosity Major Physical DO Do PENTRI- DO P V V Do
TATION
NO
5 . Temp CRACK
Major Physical DO Do DO P V V Do
Cycle Test AFTER
TEST
FREE
Qai/01 VCS/
1. Visual Major Visual 10% FROM P V V Do
Sec-5 QA/02R
DAMAGE
AS PER
2. Dimen- DRAW-
Major Measurement 5 % /LOT Do DO P V V Do
sions ING /
SIZE
SUPPLI-
70 +/-5 ER TC /
9 Gaskets 3. Hardness Major Physical DO Vcs/Ms/13 P V V Do
SHORE A VCS LAB
REPORT
“4. Ageing
Test 7 Days
In T/F Oil
A ) Change “10 %
Major Physical 2 % / LOT Do DO P V V Do
In Weight “
Max
B ) Change
In Hardness”

183
FREE

184
10% / Qai/01
1.Visual Major Visual FROM VS P V V Do
LOT Sec-9
DAMAGE
NESCL
2.Dime- AP-
Major Measurement DO Do DO P V V Do
10 Tanks nsions PROVED
DRW
NO LEAK SUPPLI-
Quality Control Manual

AT 1.5 ER TC /
3.Leak Test Major Physical 100% Vcs/Ms/11 P V V Do
KG/sq.cm VCS LAB
FOR 15 REPORT
FREE
Nescl VCS/
1.Visual Major Visual 10% /LOT FROM P V V Do
App.Dwg QA/02R
DAMAGE
Primary
11 NESCL
Terminals
2.Dime- AP-
Major Measurement 5% / LOT Do DO P V V Do
nsions PROVED
DRW
FREE
10% / VCS/
1.Visual Major Visual Vcs/Ms/14 FROM P V V Do
LOT QA/02R
DAMAGE
NESCL
2.Dime- AP-
Sec.Ter- Major Measurement 5% / LOT Do DO P V V Do
12 nsions PROVED
minals DRW
3.Insulation Qai/01 2M
Major Electrical 2% / LOT DO P V V Do
Resistance Sec-8 OHMS
4.Dielectric 5KV rms /
Major Electrical DO Do DO P V V Do
Test 1 MINUTE
Bom / FREE
10% / VCS/
1.Visual Major Visual Nescl FROM P V V Do
LOT QA/02R
Spec DAMAGE
13 Hardware
AS PER
2.Dime-
Major Measurement 5% / LOT Do NESCL DO P V V Do
nsions
DWG
FREE
VCS/
1. Visual Major Visual 1% / LOT Vcs/Ps/11 FROM P V V Do
QA/02R
DAMAGE
14 Painting
40 MIC-
2.Dimen-
Major Measurement 1% / LOT Do CRONS DO P V V Do
sions
MIN
Free From VCS/
1.Visual Major Visual 1% / LOT Do P V V Do
Damage QA/02R
SUPPLI-
85 MI- ER TC /
2.Thickness Major Measurement 1% / LOT Do P V V Do
Galvaniz- CRONS VCS LAB
15
ing REPORT
Coating
3.Pivot Ham- Should
Major Mechanical 1% / LOT Do DO P V V Do
mer Test Not Peel
Off
Section: 2 In-Process
Verification Of Record /
Pl/02
1.Winding Free From VCS/ PR / Supplier Tc At The Time
Major Measurement 5% Sec-1 P V V
Width Damage 09R Of Final Inspection By
To 3
Nescl Inspector
L.V & H.V 2.Over Lap- Pl/02 Avoid
16
Winding ping Con- Major Visual 100% Sec-1 Over Lap- DO P V V Do
ductor To 3 ping
Pl/02
3.Interlayer NESCL
Major Visual 100% Sec-1 DO P V V Do
Insulation SPEC
To 3
1.Paper
Pl / 02 NESCL VCS/
Width & Major Electrical 10% P V V Do
Sec-4 SPEC PR/09R
Length
Cutting , 2.Overlap
17 Folding & Folding Of Major Electrical 100% Do DO DO P V V Do
Hv Taping Paper
3.Finished
Coil Dimen- Major Electrical 100% Do DO DO P V V Do
sion

185
1.Core Limb Pl/02 AS PER

186
Major Visual 100% DO P V V Do
Insulation Sec-5 & 6 IS 2705
Core &
2.Hv-Lv
18 Coil As- Major Visual 100% Do DO DO P V V Do
Insulation
sembly
3.Polarity
Major Visual 100% Do DO DO P V V Do
Check
Ratio & Qai/01
Stage AS PER VCS/
19 Phase Angle Major Electrical 100% Sec-16 & P V V Do
Testing IS 3156 QA/04R
Quality Control Manual

Errors Is 3156
1.Temp.Mea- EVERY Pl/01 Sec- VCS/
Major Physical DO P V V Do
surement HOUR 06 PR/010R
2.Vacuum EVERY
Major Physical Do DO DO P V V Do
Drying & Measurment HOUR
20 Impregna- 1 SAM-
tion 3.Filtered Oil
Major Electrical PLE PER Do DO DO P V V Do
Bdv Check
LOT
4.Oil Soak-
Major Physical 100% Do DO DO P V V Do
ing Time
1.Primary Pl/01 Sec- VCS/
Major Visual 100% DO P V V Do
Connection 06 PR/09R
2.Secondary
Major Visual 100% Do DO DO P V V Do
Connection
Main As-
21 3.Locking Ar-
sembly Major Visual 100% Do DO DO P V V Do
rangements
4.Securing
Of Active Major Visual 100% Do DO DO P V V Do
Part
Section: 3 Final Inspection
AS PER
NESCL
1.Visual Criti- Qai/01 VCS/
Visual 100% APP. √ P V V
Check cal Sec-20 PR/009R
DRAW-
ING
22 Finishing
2.Nuts &
Criti-
Washer For Visual 100% Do DO DO √ P V V
cal
Earth Bolts
3.Earthing Criti-
Visual 100% Do DO DO √ P V V
Symbol cal
4.Oil Level In Criti-
Visual 100% Do DO DO √ P V V
Gauge cal
5.Primary
Criti-
Terminal Visual 100% Do DO DO √ P V V
cal
Markings
Criti-
6.Oil Leaks Visual 100% Do DO DO √ P V V
cal
7.Terminal Criti-
Visual 100% Do DO DO √ P V V
Markings cal
8.Name
Plate & Criti-
Visual 100% Do DO DO √ P V V
Connection cal
Diagram
1. Verifi- AS PER
cation Of NESCL
Qai/01 VCS/
Terminal Major Visual 100% APP. √ P W W
Sec-17 QA/05F
Marking And DRAW-
Polarity ING
2. Power
Frequency
Qai/01
Dry With- Criti- AS PER VCS/
Electrical 100% Sec-19 & √ P W W
stand Tests cal IS 3156 QA/05F
Is 3156
On Primary
Windings
Routine 3.Power Fre-
21
Test quency Dry
Withstand Criti-
Electrical 100% Do DO DO √ P W W
Tests On cal
Secondary
Windings
4 Partial Dis-
charge Mea- Criti-
Electrical 100% Do DO DO √ P W W
surement (If cal
Applicable)
5 Ratio &
Criti-
Phase Angle Electrical 100% Do DO DO √ P W W
cal
Error

187
Section: 4 Type Test

188
1.Temper- Qai/01
Criti- AS PER AS PER VCS/
ature Rise Electrical Sec-20 & √ W V V
cal IS; 3156 IS 3156 PR/009R
Test Is 3156
2.Lightning
Impulse Volt- Criti- AS PER
Electrical Do DO DO √ W V V
age With- cal IS; 3156
stand Test
Quality Control Manual

3.High Volt-
age Power
Frequency Criti- AS PER
Electrical Do DO DO √ W V V
Wet With- cal IS; 3156
stand Volt-
23 Type Test age Test
4.Determi-
nation Of
Errors And
Other Char-
acteristics
According To Criti- AS PER
Electrical Do DO DO √ W V V
The Require- cal IS; 3156
ment Of The
Appropriate
Designation
Of Accuracy
Class
*-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and VEL Ap-
proval of type tests by Engineering department of NESCL or waival thereof to be shown at the time final inspection to enable NESCL issue MDCC.
√ - Record identified’√’ “”tick mark”” shall be essentially included by supplier in QA Documentations.
√ - Record Identified’√’ “Tick Mark” Shall Be Essentially Included By Supplier In Qa Documentations.
P.S= Plant Standard M= Manufacturer
P= Performed By A.D.S= Approved Data Sheet N= Customer (NESCL)
V= Verified By M/I=Minor C = Contactor
W= Witness Of Test Signature Of The Contractor
SIGNATURE OF THE MANUFACTURER
STANDARD MANUFACTURING QUALITY PLAN
PROJECT/UTILITY:
ITEM: BUS POST QP NO:
INSULATORS
MANUFACTUER’S NAME & ADDRESS: UPTO 33 kV REV.NO: PACKAGE:
DATE: CONTRACT NO:
SUB-SYSTEM:
PAGE:….OF….. MAIN-CONTRACTOR:
Compo-
Sl. Type of Quantum Reference Format of
nent & Characteristics Class Acceptance Norms Agency Remarks
No Check of Check Document Records
operation
1 2 3 4 5 6 7 8 9 ** 10 11
SECTION: RAW MATERIALS INSPECTION M C N
0.01% in White/off White,
IRM/CD/ Record review during
a) Inspection Major Visual the total deep cream colour QC Report V V V
TP/2 final inspection
wt in raw form
b) Residue 4% Max. The
retained on 300 Major Test Do residue shall be free QC Report P V V Do
mesh (BSS) from iron impurities
white to cream, free
c) Fired colour Major Visual Do QC Report V V V Do
from black specks.
“d) Chemical
“Supplier test certifi-
analysis
China cate approx
1 Sampling 30-40% Supplier
clays Al2 03 T/C review during final
Major Test Once in 40-55% TC/ QC P V V
Sio2 inspection
250 MT <4% lab/TPL
Fe2 03
<2%
Tio2
16-19%”
LOI at 1220oc”
Supplier
e) Dry shrink- Record review during
Major Test Do 6% Max TC/ QC P V V
age final inspection
lab/TPL
Supplier
f) Total shrink-
Major Test Do 18% Max TC/ QC P V V Do
age
lab/TPL
0.01% in
IRM/CD/ white to deep Record review during
a) Inspection Major Visual the total QC Report V V V
TP/2 cream/ yellow colour final inspection
wt
2 Ball clays
b) Residue < 5% The residue
retained on 240 Major Test Do shall be free from QC Report P V V Do
mesh iron impurities

189
White/off white to

190
c) fired colour Major Visual Do cream/Buff free from QC Report V V V Do
impurities.
“d) Chemical “Supplier test certifi-
analysis cate approx
Al2 03 >25% Supplier
Once in T/C review during final
Sio2 Major Test 50-60% TC/ QC P V V
250 MT inspection
Fe2 03 < 3% lab/TPL
Tio2 < 3%
Quality Control Manual

LOI at 1220oc” < 13%”


Supplier
e) Dry shrink- Record review during
Major Test Do 6% Max TC/ QC P V V
age final inspection
lab/TPL
Supplier
f) Total shrink- Record review during
Major Test Do 18% Max TC/ QC P V V
age final inspection
lab/TPL
0.01% in
IRM/CD/ White to off White Record review during
a) Inspection Major Visual the total QC Report V V V
TP/1 raw colour final inspection
wt
< 3%Max The
b) Residue residue shall be free
retained on 240 Major Test Do from iron particles QC Report P V V Do
mesh (BSS) and magnetic impu-
rities
Off white to White
Quartz c) fired colour Major Visual Do QC Report V V V Do
3 free from impurities
Powder
d) Sintering Major Visual Do Nil, No vitrification QC Report V V V Do
“Supplier test certifi-
cate approx
“e) Chemical
analysis Sampling Supplier
98% Min T/C review during final
SiO2 Major Test Once in TC/ QC P V V
0.25% Max. inspection
Fe2 O3 250 MT lab/TPL
0.5% Max
LOI at 1000oc”

0.01% in
IRM/CD/ White to light pink Record review during
a) Inspection Major Visual the total QC Report V V V
TP/1 colour final inspection
wt
< 3% Max The
b) Residue residue shall be free
retained on 240 Major Test Do from iron particles QC Report P V V Do
mesh and magnetic impu-
rities
Grayish/off white to
Feldspar c) fired colour Major Visual Do QC Report V V V Do
4 white
powder
d) Firing behav- Vitirified mass free
Major Test Do QC Report P V V Do
ior from impurities
“e) Chemical “Suppliertest certifi-
analysis cate approx
K2O+Na2O 13% Min Supplier
Once in T/C review during final
K2O Major Test 11% Min. TC/ QC P V V
250 MT inspection
Na2O 3.5% Max lab/TPL
Fe2O3 0.2% Max
LOI at 1000OC” 0.5% Max”
500
gms/MT IRM/CD/ Record review during
a) Inspection Major Visual Dark brown colour QC Report V V V
or part TP/1 final inspection
thereof
b) Residue
retained on 300 Major Test Do 0.5% Max QC Report P V V Do
5 Iron oxide mesh
Block/Greyish black
c) Fired colour Major Visual Do QC Report V V V Do
free from impurities
“d) Chemical
“Supplier test certifi- Supplier
analysis Once in 1 T/C review during final
Major Test cate approx TC/ QC P V V
Fe2O3 content MT inspection
85% Min “ lab/TPL

500
Dark Grey to black
gms/MT IRM/CD/ Record review during
a) Inspection Major Visual colour free from QC Report V V V
Manga- or part TP/1 final inspection
impurities
6 nese di- thereof
oxide b) Residue
retained on 300 Major Test Do 0.5% Max QC Report P V V Do
mesh

191
Black/ balckish vio-

192
c) Fired colour Major Visual Do let free from impuri- QC Report V V V Do
ties
“d) Chemical
Supplier
analysis Once in Supplier Test certifi- T/C review during final
Major Test TC/ QC P V V
MnO2 content 10 MT cate 85% Min inspection
lab/TPL

500
gms/MT IRM/CD/ Record review during
Quality Control Manual

a) Inspection Major Visual Bottle Green colour QC Report V V V


or part TP/1 final inspection
thereof
b) Residue
retained on 300 Major Test Do 0.5% Max QC Report P V V Do
Chromium mesh
7
oxide
Dark Green free
c) Fired colour Major Visual Do QC Report V V V Do
from impurities
“d) Chemical
Supplier
analysis Once in Supplier Test certifi- T/C review during final
Major Test TC/ QC P V V
Cr2O3 content 10 MT cate 85% Min inspection
lab/TPL

500
White to cream raw
gms/MT IRM/CD/ Record review during
a) Inspection Major Visual colour. Free from QC Report V V V
or part TP/1 final inspection
impurities
thereof
b) Residue
Calcite retained on 300 Major Test Do 3% Max QC Report P V V Do
8 mesh
powder
c) Fired colour Major Visual Do Light greenish QC Report V V V Do
“d) Chemical
Supplier
analysis Once in Supplier Test certifi- T/C review during final
Major Test TC/ QC P V V
CaO content 10 MT cate 50% Min inspection
lab/TPL

SECTION: ASSEMBLY MATERIALS INSPECTION M C N
0.01% “IS: 12269

of total IRM/CD/ Record review during
a) Inspection Major Visual No lumpiness/solidi- QC Report V V V
quantity TP/3 final inspection
9 Cement fication.”
received “
b) Compressive QC lab/ T/C review during final
Major Test Do 380 Kg/cm2 P V V
strength TPL inspection
Each
QC lab/
c) Expansion Major Test consign- 0.8% Max P V V Do
TPL
ment
SECTION: METAL PARTS INSPECTION M C N
No sharp / rough Record review during
a) Inspection Major Visual 100% QC Report V V V
edges. final inspection
“Lot
sample
size
size
(nos)
Mea-
(nos)
Lead b) Dimension Major sure- As per drawing QC Report P V V Do
11 1-500
Thimble ment
4
501-1000
6
1001+
10”
“As per
c) Gauge “As per IS:2486
Major Visual Do IS:2486 QC Report P V V Do
Checking part-II”
part-II”
SECTION: IN-PROCESS INSPECTION M C N
Pale white to cream
Each IP/CD/ Record review during
a) Inspection Major Visual colour with no visual QC Report V V V
charge TP/1 final inspection
impurities
Wet grind- b) Residue
ing of retained on 300 Major Test Do < 30 grms/Ltrs QC Report P V V Do
12
ceramic mesh
body “<10 Microns-Min
c) Particle size Once in 70%
Major Test QC Report P V V Do
Analysis week < 30 Microns-Min
97%”
Slip’s Litre Daily IP/CD/
13 Major Test 1.40-1.50 Kg/litre QC Report P V V Do
Weight once TP/1
Twice in IP/CD/
a) Moisture % Major Test 16.5-19% QC Report P V V Do
Pug mill’s a shift TP/1
14
clay blank b) De airing Min. 700mm of Hg
Major Test Do QC Report P V V Do
checking vaccum

193
During Residue re-

194
Each
15 glaze tained on 300 Major Test Max. 2% QC Report P V V Do
charge
preparation mesh
a) Linear Once in a
Properties Major Test Max. 2% QC Report P V V Do
shrinkage day
16 of unfired
porcelain Once in
b) Dry MOR Major Test 30 Kgs/cm2 Min QC Report P V V Do
week
a) Making cav- Once in a
Major Test As per drawing QC Report P V V Do
Quality Control Manual

ity check shift


Mea-
b) Finishing
Major sure- Do As per drawing QC Report P V V Do
17 Shaping dimension
ment
c) Moisture % 8 to 12% ( depend-
Once in a
before entry Major Test ing upon climate QC Report P V V Do
day
into dryer condition)
a) Hot rooms Once in a
Major Visual Ambient-85oC QC Report V V V Do
temperature day
18 Drying 3 sam-
b) moisture
Major Test ples per 0.8% Max. QC Report P V V Do
content
day
Unglazed 750 Kgs/
Once in 3
Major Test cm2 Min Glazed 850 QC Report P V V Do
month
gs/cm2 Min
a) Linear Once in a “ Record review during
Major Test QC Report P V V
shrinkage day < 14%” final inspection
4 pieces
Properties from
of fired every
19 As per IS: As per IS: 731 &
porcelain b) porosity Major Test unloaded QC Report P V V Do
731 5300
Fired MOR car of
Tunnel
Kiln
Daily
c) Bulk density Major Test 2.38 Min QC Report P V V Do
once
d) Water ab- Daily
Major Test 0.2% Max QC Report P V V Do
sorption once
Rose pink slip
a) Inspection Major Visual 100% colour slurry with no QC Report V V V Do
visual impurities
Glazing
3 sam-
20 (Brown
b) Moissture % Major Test ples per 2-3% Max QC Report P V V Do
glaze)
day
Twice in
c) Sp.gravity Major Test 1.4-1.45 QC Report P V V
a day.
Temperra-
ture during
1220-1230oC de-
20 firing of Major Visual Hourly QC Report V V V Do
pending on cycle
green
wares
a) Inspection Major Visual 100% As per IS:2544 QC Report V V V Do
Mea- As per NESCL ap-
b) Dimension & 3 Nos/
Major sure- proved specified QC Report P V V Do
weight day
ment drawings
Sorting of As per
21 fired insu- NESCL
lator approved
Mea-
specified
c) Marking Major sure- 100% QC Report P V V Do
drawings/
ment
NESCL
Tech.
Specs.
a) Inspection Major Visual 100% No broken planks QC Report V V V Do
“Lot
sample
size
size
Packing (nos)
23 (wooden) Mea-
(nos) As per Approved
crate b) Dimension Major sure- QC Report P V V Do
1-500 Drawing
ment
4
501-1000
6
1001+
10”

195
SECTION: FINAL INSPECTION M C N

196
Mea-
a) Dimension As per As per IS:
Major sure- As per IS: 2544 QC Report P W W CHP
checking IS: 2544 2544
ment
b) Temperature As per As per IS:
Major Test As per IS: 2544 QC Report P W W CHP
cycle test IS: 2544 2544
c) Mechanical As per As per IS:
Major Test As per IS: 2544 QC Report P W W CHP
strength test IS: 2544 2544
Quality Control Manual

Accep-
24 As per As per IS:
tance Tests d) Porosity test Major Test As per IS: 2544 QC Report P W W CHP
IS: 2544 2544
e) Puncture As per As per IS:
Major Test As per IS: 2544 QC Report P W W CHP
Test IS: 2544 2544
f) Galvanising As per As per IS:
Major Test As per IS: 2544 QC Report P W W CHP
Test IS: 2544 2544
a) Visual Ex- As per IS:
Major Test 100% As per IS: 2544 QC Report P V V
amination 2544
b) Electrical As per IS:
Major Test 100% As per IS: 2544 QC Report P V V
Routine Tests 2544
25
Tests c) Mechanical As per IS:
Major Test 100% As per IS: 2544 QC Report P V V
tests 2544
All type test as
Type Test Clearance
per IS: 2544 & As per IS: Type Test
26 Type Tests* Major Test Sample As per IS: 2544 V V V from NESCL Engineer-
NESCL Tech. 2544 Certificate
ing Department
Specs.
-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and main con-
tractor. Approval of type tests by Engineering department of NESCL or waival thereof to be shown at the time final inspection to enable NESCL issue
MDCC.
√ - Record identified’√’ “”tick mark”” shall be essentially included by supplier in QA Documentations.
LEGEND : M - MANUFACTURER V - VERIFICATION
C - CONTRACTOR W - WITNESSING
N - CUSTOMER QC-QUALITY CONTROL
P - PERFORM TPL-THIRD PARTY LAB

SIGNATURE OF THE CONTRACTOR SIGNATURE OF THE MANUFACTURER


STANDARD MANUFACTURING QUALITY PLAN
PROJECT/UTILITY:
ITEM: 11 kV DISC QP NO:
MANUFACTURE’S NAME & ADDRESS: INSULATORS REV.NO: PACKAGE:
DATE: CONTRACT NO:
SUB-SYSTEM:
MAIN-CONTRACTOR:
Compo-
Sl. Type of Quantum Reference Format of
nent & Characteristics Class Acceptance Norms Agency Remarks
No Check of Check Document Records
operation
1 2 3 4 5 6 7 8 9 ** 10 11
SECTION:1 RAW MATERIAL INSPECTION M C N
SECTION: 1.1 RAW MATERIAL FOR BODY
1 Kg/20
a) Inspection / Record review dur-
Major Visual MT part S 1201 White QC Report V V V
colour ing final inspection
thereof
2% Max. the residue
b) Residue
shall be free iron
retained on 200 Major Test Do S 1201 QC Report P V V Do
particles and magnetic
mesh
impurities
c) fired colour Major Visual Do S 1201 White QC Report V V V Do
Quartz Should not stick to
1 d) Sintering/
Powder Major Visual Do S 1201 the container and no QC Report V V V Do
fired behavior
specks
“e) Chemical
“Vendor’s test certifi-
analysis
Sampling cate
Supplier
Once in 3 T/C review during
Major Test S 1201 TC/ QC P V V
month/ 300 98% Min final inspection
SiO2 lab/TPL
MT 0.25% Max.
Fe2 O3
1% Max”
LOI at 1000oc”
1 Kg/20
a) Inspection / Off White or pink Record review dur-
Major Visual MT part S 1201 QC Report V V V
colour colour ing final inspection
thereof
2% Max. the residue
b) Residue
Feldspar shall be free iron
2 retained on 200 Major Test Do S 1201 QC Report P V V Do
powder particles and magnetic
mesh
impurities
Translucent (glossy
c) fired behav-
Major Visual Do S 1201 white) and low impuri- QC Report V V V Do
ior/Sintering
ties

197
1 2 3 4 5 6 7 8 9 ** 10 11

198
“d) Chemical
“Vendor’s test certifi-
analysis
cate
Sampling
11% Min Supplier
K2O+Na2O Once in T/C review during
Major Test S 1201 8% Min. TC/ QC P V V
K2O 3 month/ final inspection
3.5% Max lab/TPL
Na2O 300MT
1% Max
Fe2O3
1.5% Max”
LOI at 1000OC”
Quality Control Manual

1 Kg/20
Record review dur-
a) Inspection Major Visual MT or part S 1201 cream/ pink QC Report V V V
ing final inspection
thereof
3% Max. the residue
b) Residue
shall be free iron
retained on 200 Major Test Do S 1201 QC Report P V V Do
particles and magnetic
mesh
impurities
c) Fired colour Major Visual Do S 1201 Snow white/ white QC Report V V V Do
China d) Dry shrink-
3 Major Test Do S 1201 7% Max QC Report P V V Do
clays age
e) Total shrink-
Major Test Do S 1201 16% Max QC Report P V V Do
age
“f) Chemical Vendor’s test certifi-
analysis cate
Once in Supplier
Al2 03 30% Min T/C review during
Major Test 3 month/ S 1201 TC/ QC P V V
Fe2 03 5% Max final inspection
300MT lab/TPL
Tio2 2% Max
LOI at 1000oc” 18% Max
1 Kg/20
a) Inspection/ Record review dur-
Major Visual MT or part S 1201 Dull white/ black QC Report P V V
colour ing final inspection
thereof
3% Max. the residue
b) Residue
shall be free iron
retained on 200 Major Test Do S 1201 QC Report P V V Do
particles and magnetic
mesh
4 Ball clay impurities
Pale cream/dull cream
c) Fired colour Major Visual Do S 1201 QC Report V V V Do
or light grey/white
d) Dry shrink-
Major Test Do S 1201 7% Max QC Report P V V Do
age
e) Total shrink-
Major Test Do S 1201 18% Max QC Report P V V Do
age
1 2 3 4 5 6 7 8 9 ** 10 11
“f) Chemical Vendor’s test certifi-
analysis cate
Once in Supplier
Tio2 3% Min T/C review during
Major Test 3 month/ S 1201 TC/ QC P V V
Al2 03 25% Max final inspection
300MT lab/TPL
Fe2 03 2% Max
LOI at 1000oc” 13% Max
SECTION: 1.2 RAW MATERIAL FOR GLAZE
1 Kg/05
a) Inspection/ Record review dur-
Major Visual MT or part S 1201 Red coloured powder QC Report V V V
colour ing final inspection
thereof
b) Residue
retained on 200 Major Test Do S 1201 2% Max QC Report P V V Do
mesh
5 Iron oxide c) Fired colour
Should match with the
of 1% iron oxide
Major Visual Do S 1201 standard reference QC Report V V V Do
in feldspar
sample
powder
“d) Chemical Sampling
“Vendor’s test certifi- Supplier
analysis Once in T/C review during
Major Test S 1201 cate approx TC/ QC P V V
Fe2O3 content 6 month/ final inspection
82% Min “ lab/TPL
“ 10 MT
1 Kg/05
a) Inspection/ “Black coloured Record review dur-
Major Visual MT or part S 1201 QC Report V V V
colour powder “ ing final inspection
thereof
b) Residue
retained on 200 Major Test Do S 1201 10% Max QC Report P V V Do
mesh
Manga-
6 nese di- c) Fired colour
Should match with the
oxide of 2% manga-
Major Visual Do S 1201 standard reference QC Report V V V Do
nese dioxide in
sample
feldspar powder
“d) Chemical Sampling
“Vendor’s test certifi- Supplier
analysis Once in T/C review during
Major Test S 1201 cate TC/ QC P V V
MnO2 content 6 month/ final inspection
78% Min “ lab/TPL
“ 10 MT

199
1 2 3 4 5 6 7 8 9 ** 10 11

200
1 Kg/05
a) Inspection/ “Green coloured Record review dur-
Major Visual MT or part S 1201 QC Report V V V
colour powder “ ing final inspection
thereof
b) Residue
retained on 200 Major Test Do S 1201 2% Max QC Report P V V Do
mesh
Chromium c) Fired colour
7 Should match with the
oxide of 3% chro-
Quality Control Manual

Major Visual Do S 1201 standard reference QC Report V V V Do


mium oxide in
sample
feldspar powder
“d) Chemical Sampling
“Vendor’s test certifi- Supplier
analysis Once in T/C review during
Major Test S 1201 cate TC/ QC P V V
Cr2O3 content 6 month/ final inspection
90% Min “ lab/TPL
“ 10 MT
1 Kg/05
a) Inspection/ Record review dur-
Major Visual MT or part S 1201 Off or dull white QC Report V V V
colour ing final inspection
thereof
5% Max of the residue
b) Residue
shall be free from iron
retained on 200 Major Test Do S 1201 QC Report P V V Do
particles and magnetic
mesh
impurities
Calcite Fired character- Free from ferrous/fer-
8 Major Visual Do S 1201 QC Report V V V Do
powder istic ric impurities
“d) Chemical
analysis “Vendor’s test certifi-
Sampling
cate Supplier
Once in T/C review during
CaO Major Test S 1201 40% Min TC/ QC P V V
6 month/ final inspection
Fe2O3 0.5% Max lab/TPL
10 MT
SiO2 5% Max”

0.01%
of total “IS 12269 Record review dur-
9 Cement a) Inspection Major Visual No lumpiness QC Report V V V
quantity S 1003” ing final inspection
received
b) Compressive “IS 12269
Major Test Do 380 Kg/cm2 Min QC Report P V V Do
strength S 1004”
Supplier
c) Expansion “IS 12269
Major Test Do 0.8% Max TC/ QC P V V Do
(Autoclave) S 1005”
lab/TPL
1 2 3 4 5 6 7 8 9 ** 10 11
5Nos/ 5000 Record review dur-
10 Cork sheet a) Thickness Major Visual S 1003 1-2mm QC Report V V V
Nos ing final inspection
b) specific grav-
Major Test Do S 1003 0.2±0.1 QC Report P V V Do
ity
SECTION:3 METAL PARTS INSPECTION M C N
a) Inspection
Record review dur-
(Black & Galva- Major Visual 100% S 1201 No sharp edges QC Report V V V
ing final inspection
nizing stage)
b) Gauge “Record review
checking (black during final inspec-
Major Test 100% S 1201 As per IS:2486 part-II QC Report P V V
& Galvanizing tion &
stage) T/C review”
“Lot
sample
c) Dimension (
1-1000 Record review dur-
black & Galva- Major Test S 1201 As per Drawing QC Report P V V
5 ing final inspection
nizing stage)
1000+
10”
“Lot
d) Mechanical sample
Ball Pin &
11 failing load test 1-1000
Tongue Pin Major Test S 1201 As per Drawing QC Report P V V Do
( black & Galva- 3
nizing stage) 1000+
5”
e) Yield
strength, Ten-
T/C review during
sile Strength & Major Test Do S 1201 NESCL spec. QC Report P V V
final inspection
% Elongation
on test bar
f) Hardness Major Test Do S 1201 Do QC Report P V V Do
“Lot
sample
1-10000 Record review dur-
g) Galvanizing Major Test S 1201 As per IS:2633 QC Report P V V
3 ing final inspection
1000+
5”

201
1 2 3 4 5 6 7 8 9 ** 10 11

202
“h) Chemical “Vendor’s test certifi-
Analysis cate
Carbon 0.15-0.45 Supplier
Each con- T/C review during
Manganese Major Test S 1201 0.6-1.00 TC/ QC P V V
signment final inspection
Silicon 0.05-0.35 lab/TPL
Sulphur 0.60 Max
Phosphorous” 0.06 Max “
Quality Control Manual

Supplier
i) Heat Treat-
Major Test 100% S 1201 Time & Temp chart TC/ QC P V V Do
ment
lab/TPL
Supplier
j) M.P.I Major Test 100% S 1201 NESCL spec. TC/ QC P V V Do
lab/TPL
a) Inspection
Record review dur-
(Black & Galva- Major Visual 100% S 1201 No blow Holes QC Report V V V
ing final inspection
nizing stage)
b) Gauge
checking (black
Major Test 100% S 1201 As per IS:2486 part-II QC Report P V V Do
& Galvanizing
stage)
“Lot
sample
c) Dimension ( Mea-
1-1000
black & Galva- Major sure- S 1201 As per Drawing QC Report P V V Do
M.C.I. Cap 5
nizing stage) ment
12 (Socket/ 1000+
Clevis) 10”
“Lot
d) Mechanical sample
failing load test 1-1000
Major Test S 1201 As per Drawing QC Report P V V Do
( black & Galva- 3
nizing stage) 1000+
5”
e) Galvanizing Major Test Do S 1201 As per IS:2633 QC Report P V V Do
f) Tensile
T/C review during
Strength on test Major Test Do S 1201 350 N/mm2 Min QC Report P V V
final inspection
bar
1 2 3 4 5 6 7 8 9 ** 10 11
“Lot
sample
g) 0.2% Proof
1-1000
stress on test Major Test S 1201 200 N/mm2 Min QC Report P V V Do
3
bar
1000+
5”
h) Elongation
Major Test Do S 1201 10% Min QC Report P V V Do
on test bar
i) Hardness Major Test Do S 1201 150 BHN Max QC Report P V V Do
“Vendor’s T/C as per
“j) Chemical
Each con- BM 350 Gr. Of
Analysis Major Test S 1201 QC Report P V V Do
signment IS 14329
Phosphorous”
0.12% max”
k) M.P.L Major Test 100% S 1201 NESCL spec. QC Report P V V Do
Supplier
l) Micro Struc-
Major Test 1 No/Lot S 1201 Do TC/ QC P V V Do
ture
lab/TPL
Record review dur-
a) Inspection Major Visual 100% S 1201 No sharp edges QC Report V V V
ing final inspection
“Lot
sample
Mea-
1-1000
b) Dimension Major sure- S 1201 As per Drawing QC Report P V V Do
3
Security ment
1000+
13 Clip (W/R 5”
Clip)
c) Chemical Supplier
Each con- Vendor’s T/C as per T/C review during
Analysis Major Test S 1201 TC/ QC P V V
signment IS:7814 Gr.I final inspection
i) Phosphorous lab/TPL
Supplier
ii) Stainless Vendor’s T/C as per
Major Test Do S 1201 TC/ QC P V V Do
W/R clip AISI 304
lab/TPL
“Lot
sample
Cotter Pin a) mechanical 1-1000 Record review dur-
Major Test S 1201 As per Drawing QC Report P V V
14 (for T& C failing load test 3 ing final inspection
Cap) 1000+
5”
b) Galvanizing Major Test Do S 1201 As per IS:2633 QC Report P V V Do

203
1 2 3 4 5 6 7 8 9 ** 10 11

204
Brass split Chemical Vendor’s T/C as per T/C review during
Major Test Do S 1201 QC Report P V V
15 Pin ( for Tic Analysis IS:410 CuZn3OGrI final inspection
Cap)
SECTION: 4 IN PROCESS INSPECTION M C N
Off White to cream
Each Record review dur-
a) Inspection Major Visual colour with no visual QC Report V V V
Wet grind- charge ing final inspection
impurities
Quality Control Manual

ing of
16 b) Residue
ceramic
retained on 200 Major Test Do S 1003 0.2% Max. QC Report P V V Do
body
mesh
c) Litre Weight Major Test Do S 1003 1350-1450 QC Report P V V Do
Glaze a) Residue
Each
17 Prepara- retained on 300 Major Test S 1003 0.4% Max. QC Report P V V Do
charge
tion mesh
b) Litre Weight Major Test Do S 1003 1500-1650 QC Report P V V Do
Pug mill’s a) De airing Every 30 Min. 700mm of Hg Record review dur-
18 Major Test S 1003 QC Report P V V
clay blank checking Mins vacuum ing final inspection
Sampling
Record review dur-
a) Dry MOR Major Test Once in 3 S 1003 28 Kgs/cm2 Min QC Report P V V
Properties ing final inspection
month
19 of unfired
porcelain Sampling
b) Linear
Major Test Once in S 1003 Max. 14% QC Report P V V Do
shrinkage
month
a) Making Mea-
Once in As per Record review dur-
cavity check ( Major sure- As per Drawing QC Report P V V
every shift Drawing ing final inspection
Dimension) ment
Mea-
20 Shaping b) Finishing
Major sure- Do Do Do QC Report P V V Do
dimension
ment
8% before entry into
c) Moisture Major Test Once daily S 1003 QC Report P V V Do
drier
a) Hot rooms Once in a Record review dur-
Major Visual S 1003 50-80oC QC Report V V V
temperature day ing final inspection
21 Drying
b) moisture 3 samples
Major Test S 1003 1.5% Max QC Report P V V Do
content per day
1 2 3 4 5 6 7 8 9 ** 10 11
“Unglazed 750 kg/cm2
Sampling
Min Record review dur-
a) Fired M.O.R Major Test Once in 3 S 1003 QC Report P V V
glazed 850 kg/cm2 ing final inspection
month
Min”
All cars
of every
Properties
shuttle kiln
22 of fired As per
b) porosity Major Test & any one As per IS:731 QC Report P V V Do
porcelain IS:731
unloaded
car of tun-
nel kiln
c) Bulk density/
daily &
Water absorp- Major Test S 1003 2.38 Min / 0.2% QC Report P V V Do
each kiln
tion
Light buff colour slurry
Record review dur-
a) Inspection Major Visual 100% with no visual impuri- QC Report V V V
Glazing ing final inspection
ties
23 (Brown
b) Sp.gravity Major Test Every hour S 1003 1.49-1.51 QC Report P V V Do
glaze)
3 samples
c) Moisture % Major Test S 1003 2.5% Max QC Report P V V Do
per day
Tempera-
ture during
24 firing of Major Visual Every hour S 1003 As per firing Graph QC Report V V V Do
green
wares
a) Inspection Major Visual 100% Ref.sample As per IS:731 QC Report V V V Do
Sorting of
25 fired insu- Mea- As per NESCL ap-
lator b) Dimension Major sure- 5 Nos/day S 1003 proved specified draw- QC Report P V V Do
ment ings
Routine
electri-
cal Test
AS per IS “As per IS:731
26 on Shell Major Test 100% QC Report P V V Do
731 For 5 Minutes”
( Power
frequency
test)

205
1 2 3 4 5 6 7 8 9 ** 10 11

206
Hydraulic
proof load
27 test on shell Major Test 100% NESCL NESCL spec QC Report P V V Do
(if appli- spec
cable)
Routine AS per IS “As per IS:731
Major Test 100% QC Report P V V Do
electrical 731 For 5 Minutes”
(power
frequency) a) Routine Me- Major Test 100% AS per IS 40% of rated Ems for 5 QC Report P V V Do
Quality Control Manual

& Mechani- chanical test 732 minutes


28 cal Routine
Mechani-
cal Test on b) Routine Elec- Major Test 100% AS per IS “As per IS:731 QC Report P V V Do
Assembled trical test 733 For 5 Minutes”
insulators
a) Inspection Major Visual 100% S 1201 No broken planks QC Report V V V Do
“Lot
Packing sample
29 1-1000
Crate b) Dimension Major Test S 1201 S 1201 QC Report P V V Do
5
1000+
10”
SECTION:5 FINAL INSPECTION M C N
Mea-
a) Dimension As per As per
Major sure- As per IS:731 QC Report P W W CHP
checking IS:731 IS:731
ment
b) Temperature As per As per
Major Test As per IS:731 QC Report P W W CHP
cycle test IS:731 IS:731
Acceptance As per As per
c) Puncture Test Major Test As per IS:731 QC Report P W W CHP
test on IS:731 IS:731
30 assembled d) Galvanizing As per As per
insulators Major Test As per IS:2633 QC Report P W W CHP
test IS:731 IS:2633
e) Electrome- As per As per
chanical failing Major Test As per IS:731 QC Report P W W CHP
IS:731 IS:731
load test
As per As per
f) Porosity test Major Test As per IS:731 QC Report P W W CHP
IS:731 IS:731
a) Visual Exami- As per
Major Test 100% As per IS:731 QC Report P V V
nation IS:731
Routine b) Electrical As per
31 Major Test 100% As per IS:731 QC Report P V V
Tests Tests IS:731
c) Mechanical Major Test 100% As per As per IS:731 QC Report P V V
tests IS:731
a) Visual Ex- Visu- As per IS: As per IS:
Major As per IS: 731 TPL W W W CHP
amination ally 731 731
Mea-
b) Verification of As per IS: As per IS:
Major sure- As per IS: 731 TPL W W W CHP
Dimensions 731 731
ment
c) Visible dis- As per IS: As per IS:
Major Test As per IS: 731 TPL W W W CHP
charge test 731 731
d) Impulse with-
As per IS: As per IS:
stand voltage Major Test As per IS: 731 TPL W W W CHP
731 731
test
e) Wet power
frequency with- As per IS: As per IS:
Major Test As per IS: 731 TPL W W W CHP
stand voltage 731 731
test
f) Temperature As per IS: As per IS:
32 Type Test * cycle test Major Test As per IS: 731 TPL W W W CHP
731 731
As per IS: As per IS:
g) Puncture test Major Test As per IS: 731 TPL W W W CHP
731 731
As per As per
h) Porosity test Major Test As per IS:731 TPL W W W CHP
IS:731 IS:731
i) Galvanizing As per IS: As per IS:
Major Test As per IS: 731 TPL W W W CHP
test 731 731
J) Electro-me-
As per IS: As per IS:
chanical failing Major Test As per IS: 731 TPL W W W CHP
731 731
load test
k) Thermal
Mechanical As per IS: As per IS:
Major Test As per IS: 731 TPL W W W CHP
Performance 731 731
Tests

“*-All type tests to be carried out as per NESCL specification, Contract Agreement and as per minutes of the meeting between NESCL and main con-
tractor. Approval of type tests by Engineering department of NESCL or waival thereof to be shown at the time final inspection to enable NESCL issue
MDCC.
√ - Record identified’√’ “”tick mark”” shall be essentially included by supplier in QA Documentations.

207
STANDARD MANUFACTURING QUALITY PLAN

208
PROJECT/UTILITY:
ITEM: PIN INSU- QP NO:
LATORS UPTO
MANUFACTUER’S NAME & ADDRESS: 33 kV REV.NO: PACKAGE:
DATE: CONTRACT NO:
SUB-SYSTEM:
PAGE:….OF….. MAIN-CONTRACTOR:
Compo-
Sl. Type of Quantum Reference Format of
nent & Characteristics Class Acceptance Norms Agency Remarks
No Check of Check Document Records
Quality Control Manual

operation
1 2 3 4 5 6 7 8 9 ** 10 11
SECTION: RAW MATERIALS INSPECTION M C N
0.01% in White/off White, deep
IRM/CD/ Record review during
a) Inspection Major Visual the total cream colour in raw QC Report V V V
TP/2 final inspection
wt form
b) Residue 4% Max. The residue
retained on 300 Major Test Do shall be free from iron QC Report P V V Do
mesh (BSS) impurities
white to cream, free
c) Fired colour Major Visual Do QC Report V V V Do
from black specks.
“d) Chemical
“Supplier test certifi-
analysis
China cate approx
1 Sampling 30-40% Supplier
clays Al2 03 T/C review during
Major Test Once in 40-55% TC/ QC P V V
Sio2 final inspection
250 MT <4% lab/TPL
Fe2 03
<2%
Tio2
16-19%”
LOI at 1220oc”
Supplier
Record review during
e) Dry shrinkage Major Test Do 6% Max TC/ QC P V V
final inspection
lab/TPL
Supplier
f) Total shrinkage Major Test Do 18% Max TC/ QC P V V Do
lab/TPL
0.01% in
IRM/CD/ white to deep cream/ Record review during
a) Inspection Major Visual the total QC Report V V V
TP/2 yellow colour final inspection
wt
2 Ball clays
b) Residue < 5% The residue
retained on 240 Major Test Do shall be free from iron QC Report P V V Do
mesh impurities
1 2 3 4 5 6 7 8 9 ** 10 11
White/off white to
c) fired colour Major Visual Do cream/Buff free from QC Report V V V Do
impurities.
“d) Chemical “Supplier test certifi-
analysis cate approx
Al2 03 >25% Supplier
Once in T/C review during
Sio2 Major Test 50-60% TC/ QC P V V
250 MT final inspection
Fe2 03 < 3% lab/TPL
Tio2 < 3%
LOI at 1220oc” < 13%”
Supplier
Record review during
e) Dry shrinkage Major Test Do 6% Max TC/ QC P V V
final inspection
lab/TPL
Supplier
Record review during
f) Total shrinkage Major Test Do 18% Max TC/ QC P V V
final inspection
lab/TPL
0.01% in
IRM/CD/ White to off White raw Record review during
a) Inspection Major Visual the total QC Report V V V
TP/1 colour final inspection
wt
< 3%Max The residue
b) Residue
shall be free from iron
retained on 240 Major Test Do QC Report P V V Do
particles and magnetic
mesh (BSS)
impurities
Off white to White free
c) fired colour Major Visual Do QC Report V V V Do
Quartz from impurities
3
Powder d) Sintering Major Visual Do Nil, No vitrification QC Report V V V Do
“Supplier test certifi-
cate approx
“e) Chemical
analysis Sampling Supplier
98% Min T/C review during
SiO2 Major Test Once in TC/ QC P V V
0.25% Max. final inspection
Fe2 O3 250 MT lab/TPL
0.5% Max
LOI at 1000oc”

209
1 2 3 4 5 6 7 8 9 ** 10 11

210
0.01% in
IRM/CD/ White to light pink Record review during
a) Inspection Major Visual the total QC Report V V V
TP/1 colour final inspection
wt
< 3% Max The
b) Residue
residue shall be free
retained on 240 Major Test Do QC Report P V V Do
from iron particles and
mesh
magnetic impurities
Grayish/off white to
Quality Control Manual

c) fired colour Major Visual Do QC Report V V V Do


Feldspar white
4
powder Vitirified mass free
d) Firing behavior Major Test Do QC Report P V V Do
from impurities
“e) Chemical “Suppliertest certificate
analysis approx
K2O+Na2O 13% Min Supplier
Once in T/C review during
K2O Major Test 11% Min. TC/ QC P V V
250 MT final inspection
Na2O 3.5% Max lab/TPL
Fe2O3 0.2% Max
LOI at 1000OC” 0.5% Max”
500
gms/MT IRM/CD/ Record review during
a) Inspection Major Visual Dark brown colour QC Report V V V
or part TP/1 final inspection
thereof
b) Residue
retained on 300 Major Test Do 0.5% Max QC Report P V V Do
Iron mesh
5
oxide
Block/Greyish black
c) Fired colour Major Visual Do QC Report V V V Do
free from impurities
“d) Chemical
“Supplier test certifi- Supplier
analysis Once in 1 T/C review during
Major Test cate approx TC/ QC P V V
Fe2O3 content MT final inspection
85% Min “ lab/TPL

500
Dark Grey to black
gms/MT IRM/CD/ Record review during
a) Inspection Major Visual colour free from impu- QC Report V V V
or part TP/1 final inspection
rities
Man- thereof
6 ganese b) Residue
di-oxide retained on 300 Major Test Do 0.5% Max QC Report P V V Do
mesh
Black/ balckish violet
c) Fired colour Major Visual Do QC Report V V V Do
free from impurities
1 2 3 4 5 6 7 8 9 ** 10 11
“d) Chemical
Supplier
analysis Once in Supplier Test certifi- T/C review during
Major Test TC/ QC P V V
MnO2 content 10 MT cate 85% Min final inspection
lab/TPL

500
gms/MT IRM/CD/ Record review during
a) Inspection Major Visual Bottle Green colour QC Report V V V
or part TP/1 final inspection
thereof
b) Residue
retained on 300 Major Test Do 0.5% Max QC Report P V V Do
Chromi- mesh
7
um oxide
Dark Green free from
c) Fired colour Major Visual Do QC Report V V V Do
impurities
“d) Chemical
Supplier
analysis Once in Supplier Test certifi- T/C review during
Major Test TC/ QC P V V
Cr2O3 content 10 MT cate 85% Min final inspection
lab/TPL

500
White to cream raw
gms/MT IRM/CD/ Record review during
a) Inspection Major Visual colour. Free from im- QC Report V V V
or part TP/1 final inspection
purities
thereof
b) Residue
Calcite retained on 300 Major Test Do 3% Max QC Report P V V Do
8 mesh
powder
c) Fired colour Major Visual Do Light greenish QC Report V V V Do
“d) Chemical
Supplier
analysis Once in Supplier Test certifi- T/C review during
Major Test TC/ QC P V V
CaO content 10 MT cate 50% Min final inspection
lab/TPL

SECTION: ASSEMBLY MATERIALS INSPECTION M C N
0.01% “IS: 12269

of total IRM/CD/ QC Re- Record review during
a) Inspection Major Visual No lumpiness/solidifi- V V V
quantity TP/3 port final inspection
cation.”
received “
9 Cement b) Compressive QC lab/ T/C review during
Major Test Do 380 Kg/cm2 P V V
strength TPL final inspection
Each
QC lab/
c) Expansion Major Test consign- 0.8% Max P V V Do
TPL
ment

211
1 2 3 4 5 6 7 8 9 ** 10 11

212
SECTION: METAL PARTS INSPECTION M C N
Lead No sharp / rough Record review during
11 a) Inspection Major Visual 100% QC Report V V V
Thimble edges. final inspection
“Lot
sample
size
size
Quality Control Manual

(nos)
Mea-
(nos)
b) Dimension Major