Quality & Testing Department

Guided By:
Mrs. B. PANDYA
Mr. A. SINGH
Department Interface
 Functions
• Regulation of the quality of raw materials,
packing materials (wooden drum), In process
checks and Final testing of finished cables.
• Handling customer Inspections & preparation
of inspection reports and documents.
• Hold all non-conforming products prior to
dispatch.
• Maintains BIS License.
 Standards
For 1.1 kv LT power & control cables, we have
following BIS License:

• IS-1554/Part-1/1988 (For PVC Insulated cables)

• IS-7098/Part-1/1988 (For XLPE Insulated

cables)
• IS-694/1990 (For House Wiring cables)
 Quality Assurance Plan
• Quality is assured at every stage of cable
manufacturing.
Raw Material Testing
 Inprocess Testing
PURPOSE:
• To inspect & Test in process products as per QAP , hold all non conforming
products & release in process products for further production .
• Cost saving.
Cont..
 Final Testing
PURPOSE:
• To ensure that the final products confirm to the prescribed
standards &/or customers specifications
• To hold all non confirming finished products prior to dispatch.

TESTS COVERED:

• Routine Test
• Type Test
• Acceptance Test
• Optional Test
 Routine Test
These type of tests made by the manufacturers on all finish cable
lengths to demonstrate the integrity of cable.

• Conductor Resistance Test :- This describes the energy losses due to

current flow through the cable and therefore has an important role in
determining cable temperature.

• High Voltage Test (at room temperature):- The insulation material in

a cable is used to isolate the conductors from one another and from
ground as well as provide the necessary mech. Strength. It is necessary
that an evaluation of the condition of the insulation be met by imposing
a higher voltage stress for a short duration.
 Type Test
• Tests required to be made before supply on a general commercial basis a
type of cable in order to demonstrate the satisfactory performance
characteristics to meet the intended application.
 Acceptance Test
Tests carried out on samples taken from a lot for the purpose
acceptance of the lot.

• Conductor Resistance Test,

• Annealing Test (For Copper),
• Tensile Strength Test (For Aluminium),
• Wrapping Test (For Aluminium),
• Tests for Thickness of Insulation and Sheath,
• Hot Set Tests For Insulation,
• Tensile Strength and elongation at break test for Insulation & O.S

• High Voltage Test at room temperature

• Insulation Resistance (Volume Resistivity) Test
 Optional Test

Special Tests to be carried out, when required, by agreement

between the Purchaser & Supplier.

• Cold Impact Tests for outer sheath (IS:5831/1984 and part 21 of

IS:10810) shall constitute the optional Test.
• Cold bend Tests for outer sheath (IS:5831/1984 and part 20 of
IS:10810) shall constitute the optional Test.
 Tests
SWEDISH CHIMNEY TEST :-
To assess the ability of the electric cable to resist ignition and to prevent fire
from spreading.

SIGNIFICANCE :-
A cable is considered flame retardant if it is tested ,is ignited but extinguishes
again when the external heat supply ceases and the spread of the fire does not
exceed the given maximum value.

REQUIREMENTS :-
The length of the test specimen shall be 850 mm in a finished condition.
Burning time of ethanol in min. , t = K + D / 5
where K = 1 for c/s area <= 2.5 sq.mm
K = 2 for c/s area > 2.5 sq.mm
D = external dia. Of test specimen
Quantity of ethanol = 20 * t ml

THE UNBURNT PART OF THE SPECIMEN SHOULD BE ATLEAST

300 mm FROM THE TOP.
Engineering Services
Department

GUIDED BY:
Mr. P.N. SINGH
Mr. A. PATIL
 Functions Of Department
• Periodic Maintenance of every machine on the shop
floor.
• Attending Breakdowns
• Making job orders, indents & preserving maintenance
records.
• Maintenance of Electrical Sub – Station, Utilities.
• Development Activities to improve the Plant
Productivity.
 Preventive Maintenance
• Yearly preventive maintenance schedule is prepared for
all machines.
• As per yearly schedule, monthly preventive schedule is
made.
• As per the schedule & availability of machine,
Department attends to the machines & undertakes
activities listed in PM checklist.
• Necessary machine modifications are done in
consultation with respective HOD’s.
• Records of inspections carried out by external agencies
are maintained in Engineering Department.
 Breakdown Maintenance
• In case of any machine breakdown, the concerned dept.
informs the Engineering Dept.
• The Dept. analyzes the nature of breakdown & takes
necessary action.
• The required spare parts are taken from the stores.
• Incase the spare parts are not available, the Dept. prepares
the Indent & forward it to the materials Dept.
• At the same time if possible the Dept. provide the
temporary arrangement to start the machine.
• Necessary entries regarding the breakdown are made in
Log book.
 Utilities
• HOT WATER GENERATOR • COMPRESSOR
 OUT PUT : 400000  IR1(100 Psi)
KCAL/HR  IR2(125 Psi)
 MAX. TEMP. :1400C  IR3(125Psi)
 ELGI(250 Psi)
 FUEL :HSD

• WATER CHILLING PLANT • DG SETS

 COMPRESSOR  750 KVA
 320 KVA
CAPACITY 32 KW
 TOTAL CAPACITY 40
TR • FORK LIFT &
HYDRA
Hot Water Generator
 Constructional Features
• It consists of two concentric helical coils which are
concentric with inner and outer jacket.
• The inner coil forms the combustion chamber; the annular
space between the two coils is used as a second pass for
flue gas while space between outer coil and inner jacket is
used as third pass for flue gases.
• The space between the two jackets is used for passing the
air required for the combustion.
• Water is pumped and passed through outer coil & then it
enters the inner coil at the rear end and then comes out.
During this , water is heated by flue gases.
• It is a fully automatic, forced circulation, coil type, water
tube, three pass, oil fired type Hot Water Generator.
 Fuel Modulation
• Fuel modulation takes place as per the hot water temp.
which is sensed by temp. transmitter.
• Depending on the HW temp. the transmitter gives
proportional current o/p which is given as i/p to a PID
controller which in turn controls the blower.
• The blower receives signal to increase or decrease fuel
o/p by perfectly matching positions of fuel metering
valve & air damper till desired hot water generator is
stabilized.
• Whole operating sequence is controlled by the sequence
controller to which a flame sensor is also connected.
 Operating Control Procedure
• Ensure water tank is fully leveled before start.
• Ensure that there is no leakage of HSD/Waste oil.
• Set the temperature of water to which is required to
be maintained.
• Check all the safety valves and NRV’s.
• Ensure all the switches are in operating position.
• Ensure hot water pipelines are fully insulated.
• Ensure the hot water operation is auto-cut when
temperature is maintained.
 Diesel Generator
• 12 Cylinder - Kirloskar Cummins DG
• Capacity : 750 KVA , Rpm: 1500 (max)
660 v , 50 hz , 1000 A
• Cooling: Water cooled through Cooling Tower –
Forced Draft
• Heat Exchanger: Shell & Tube Type
• Lubrication: oil ( oil sump-165 liters)
• Consumption: Diesel (3 units/litre)
• Self excited AVR used
• Miscellaneous: Vibration Damper, Turbocharger
 Work Instruction

Ensure
• water circulation pump
• proper battery connection
• optimum engine oil level
• diesel line valve in open condition
• switch in idle position
• proper coolant water level
• proper water level in cooling tank
DG Set Troubleshooting
1- 90 mm , 400 A 27- CAPACITOR, 250 A
2- 42 ARM ,200 A 28- DT ,250 A
1-
3- LIGHTING .200 A 29- FURNACE, 32 B, 250 A
4- 6+1 ,200 A 30- 120 mm, 400A
5- DG ROOM ,400 A 31- HEAVY REW 3 , 250 A
6- 80 mm, 200 A 32- 61 B, 400 A
7- STRIP REW, 200A 33- 42 B NEW, 250 A
8- LIGHTING, 200 A 34- 6+1 TUB, 250 A
9- 72 B ARM, 200A
10- 24 B,200 A
11- 3+1, 200 A
12- TEST HOUSE, HWG, 200A
13- 4+1, 200 A
14- 37 B, 200 A
15- 19 B,WATER PUMP, 200 A
16- CAPACITOR, 200 A
17- 11 DIE RBD, 800 A
18- 150 mm, 600A
19- 9 DIE Al, 400 A
20- 9 DIE CU, 630 A
21- CAPACITOR,250 A
22- 150 mm MIXTURE, 250 A
23- EOT CRANE 15T, 250 A
24- 17 DIE CU, 250 A
25- CHILLING, 250 A
26- 60 mm, 250 A