MQP - 1.pdf

KEC INTERNA TIONAL LTD., JABA LPUR ,SECTIONREV NCl,

..••.•...•.•."~-~"" "-<1, ""' ..,,~.~.<.~•..•_-}-'V_HH_ •.•..;... '!~_q ttl·::>

r------,-, 1~'P.7,-.-~rH.I ii. 1 ~~;(~;~~~;'.~ • I1.1. I, SHWCH}RAL STEEL I

I(ANGLE SECTiONS &. IPLATES) I

I

i.i.r PHYSICALPROPERTIES

Test forStrength

ultimate Tensile lone sample for 50 1\1Tor I!S 2067 Grade ';'2 s r,)."', .,In',;;/f', n." ' !. part thereof as per IS I ""-',~_~-,".-'Pu D.

2062 E350

(a)

(b 1- Test tor Yield Stress for 50 r<l1'T or is 2062 Gradei Onepart thereof as pe~ ~S2062 E350I

( c ) II Test

( d) I Bend TC;t

lS 2062 GradeE250A/BRlBO

2062 EJ50

2062 £350Pieces at room temp.shall - withstandbending through 1800

To an internal dia notgreater forDia ~25 mm ".21for Dia > 25mm-3t ,with both side

QA,(KEC)

~~.!.Pi

(KEC:)

QPM/QA/20

OJ

Steef as per IS 2062 tob:-:::procured from main

l.e. SAIL,Tiseo, Hsee),

or Re- IRoBers main 1

producers and CESC Iapproved sources. For lre-rollers specificapproval ofCESC is tobe ensured if requiredas per contract forDirect Purchase.

i facturers, Certif-icates.

Verification of Manu-Test

Verification of r,,1anu-facturers TestCertif-icates.

Verification of Manu ..facturers TestCertif-icates,

_~__J

KEC INTERNATIONAL L TD.,JABALPUR SECTlONc REV,NO. 01QPM/QAl20

rSI-:Nc;, -, Comp{;;~ntlOperati;n and rSampling P!a~~~ith ba;T~ I

L ~_J~__?~~~~!i~n_of Test 1 J_~__a~ce~tancenormsRemarks

----.------r------~--------cracking.

1.1.2

Same as 1.1.3 ±..1.5mm

1.1.4 DIMENSIONALCHECKS INCLUDINGROOT Rl\DIUS

CHEMICALCOMPOSITION

One sample for 50 MT or IS 2062part thereof as per IS2062

1.1.3 VISUAL CHECKS FOR IS 2500 - Level - II AQL IS 2062 Material toSURFACE FINISH -1.5 as per table - 1 i be free from surface!

enclosed. : flaws.lamination, fOU- I'

gh ! Jagged Edge andimp-erfect edges,cracks, rounded apex,deep roll marks, pipyand any harmfuldefects.

Same as 1.1.3. IS 808

1.15 TOLERANCE FOR LEG ! Same as I. j .3LENGTH OF ANGLES ;

- IS 1852

( a ) EQUAL ANGLES

Upto 45 mm Leg Length

Verification of Manu-facturers TestCertif-icates.

MainProduc-ersWorkslQA(KEC)IThi-rdPartyIndepe-ndentLab.

RY(KEC)

Record Review (Rem-oval of minor surfacedefects as per is 2062012t!5e-7

RY Record Review(KEC)


RY(KEC)

Record Review

KEC INTERNATIONAL LTD.,JABALPURc SECTION

REV. NO.

QPM/QAl20

01

rTirLE:'-----_.,--,--_._--

PLAN

( b ) lJNEQUAL ANGLES :

Same as 1.L3

± 2.0 % of LegLengthDifference betweenthe leg length ofequal angles shall belimited to 75% oftotal tolerance (plus& minus) specifiedon the leg length.

± 1.5 mm

+ 2.0mm/-L5mm

IS 1852,± 1°

RY RecordReview(KEC)




1.1.7 CAMBER(i) For flange less than Same as 1.1.3 IS 1852, Max 0.02% RY Record Review

lOOmm of length. (KEC)

(ii) For flange 100 mm and Same as 1.1.3 Max. 0.2% of length RY Record Reviewabove (KEC)

(ir) > 45 to 100 lnm!Length

for One sample tor 20 MT IS 1852. IS 808Per section or part thereof - Uoto Irnm thick .r, "i,?/i U~ •..tLU -- It.... ..!- "" ()

> 3 mm thick+5%,-3%over weightsspecified in IS 808.

QA(KEC)

Record Review

(iii) > 100 rnm Leg Length Same as 1.1.3

Short Leg Length

Long Leg Length

1.1.6 OUTOFSQUARENBSS Sameas1.L3

1.1.8 Weight ToleranceAngle Sections

QA Record Review(KEC)

KEC INTERNA TlONAL LTD.,JABALPUR SECTION QPM{QN20Ire REV. NO. 01

MANUFACTURING QUALITY PLAN REV. DATE 13.08.2010

CUSTOMER-CESC SHEET NO. Page 4 of 22

! TITLE: MANUFACTURING QUALITY PLAN

Component/Operation and Sampling Plan with basis Reference DocumentDescription of Test & acceptance norms

Remarks

Verification of Manu-facturers Test Certif-icates.

1.1.10 Thickness Tolerance tor Same as 1.1.3 IS 2062, IS 8500 RY Record ReviewPlates IS 1730, IS 1852. (KEC)

< 8 mm thick+ 12.5 %,- 5.0 %8 mmto 12 mm+ 7.5 %, - 5.0 %Over 12 mm ± 5.0 %

1.2 ZINC (To be procuredfrom HZL or Imported )

1.2.1 CHEMICAL One sample for 50 MT or IS 209 - 99.95 %, KECI Verification of Manu-COMPOSITION as per CESC's Third facturers Test· Certif-

specification which ever is party icates.less. Indepe-

ndentOne sample every month IS 209 - 98.50 % Lab.from Bath.

I.3 LEAD (To be procuredfrom HZL or Imported)

QA Verification of Manu-(KEC) facturers Test Certif-

icates.

1.3.1 CHEMICALCOMPOSITION

IA RAW MATERIALS(IMPORTED)

IA.l STRUCTURAL STEEL

IA.1. PHYSICAL1 PROPERTIES

(a) Test for Ultimate TensileStrength

One sample for 100 MT IS 3717Grade: As per P.O.

KECIThird partyIndepe-ndentLab.

One sample for 20 MT BSEN 10025per section per lot or partthereof , one sample for40MT/sec/cast/or partthere of as per BSEN10025

KEC INTERNA TlOHAL LTD.,JABALPUR SECTION QPM/QAf20

I[e REV.NO. 01


CUSTOMER-CESC SHEETNO. Page'S of22

I TITLE: MANUFACTURING QUALITY PLAN

ComponentlOperation and Sampling Plan with basis Reference DocumentDescription of Test & acceptance norms

Remarks

(b) Test for Yield Stress

One sample for 50 MT or JIS G 3]01part thereof as per JIS G3101One sample for 40 MT or DIN 17100part thereof as per DIN ASTM- A361 A36M17100 / ASTM - A36 I A572/A572M-Gr.50A572One sample tor 20 MT. BSEN 10025per section per lot or partthereof , one sample for40MT/seclcastlor partthere of as per BSEN10025

One sample for 50 MT or JIS G 3101part thereof as per JIS G3101

One sample for 40 MT or DIN J 7100 __part thereof as per DIN ASTM - A36/A36M17100 I ASTM - A 361 A A 572fA572M572

One sample for 20 MT BSEN J 0025per section per lot or partthereof , one sample for40MT/seclcastlor partthere of as per BSEN10025

QA Verification of Manu-(KEC) facturers Test Certif-

icates.

QA(KEC)

QA(KEC)

\\

( c ) Percentage ElongationTest

( d ) Bend Test

One sample for SOMT or JIS G 3101part thereof as perJIS G3101One sample for 40 MT or DIN 17100part thereof as per DIN ASTM - A36/A36M17100 I ASTM-A 36 / A A.572/A572M572One sampJe for 20 MT or Not required for steelpart thereof as per DIN as per BSEN 1002517100

DIN 11100One sample for 40 MT or Bend Test 180"


Verification of Manu-facturers TestCertificates.

APPROVED~. STAMP HERE

KEC INTERNA nOHAL LTD.,JABALPUR SBCTlON QPMIQAI~()Ire REV. NO. 01MANUFACTURING QUALITY PLAN REV. DATE 13.08.2010

CUSTOMER-CESC SHEET NO. Page 6 of22



NOTE: For Acceptance Norms refer Table -2 for Chemical Properties and Table -3for Mechanical Properties.

part thereof as per ASTMand KEC Specification.

ASTM-A6/6MGrade A36/A36MBend Test - 1800

Grade A572/A572MBend Test - 1800

Remarks

IA.1. VISUAL CHECKS IS 2500 LEVEL - II, BSEN 10025 / lIS G RY Record Review.3 AQL - 1.5 as per Table- 31011 ASTM A6 / (KEC)

1 enclosed. DIN 17100

IA.I. DIMENSIONAL IS 2500 LEVEL -II, BSEN 10056-1 , JIS RY Record Review.4 CHECKS AQL - 1.5 as per Table- G 3101/ ASTM A6 / (KEC)

(Including Root Radius) I enclosed. DIN 1028 &1029

(e) Minimum Charpy 'V'Notch Impact TestFor BSEN t0025 GradeS 355 10

One sample for 50 MT orpart thereof as per JIS G3101

-,-_.

JIS G 3101Sample shall with-stand bending throu-gh 1800 to an intern-al dia. Not> 2t withboth sides parallelwith out cracking.


ird partyIndepe-ndentLab.QA /ThirdPartyLab./Manuf-acturerT.C.


IAJ. CHEMICAL2 COMPOSITION

IA.1. TOLERANCES FOR

BSEN 10025 for KECIThOne. sample for 20 MTper section per lot or partthereof , one sample for40MT/sec/cast/or partthere of as per BSEN10025One sample for 40 MT orpart thereof as per BSEN100251 JIS G 31011 DIN

·171001 ASTM-A36!A572.

acceptable norms,please refer Table -3, enclosed.

BSEN 10025JIS G 3101 ! DIN17100/ ASTM -AJ.6I A572.

RY Record ReviewIS 2500 LEVEL - II, BS 10056-2

~/APPROVED~<D; .,:.~ STAMP HERE

II I'

KEC IHTERHA TlOHAL LTD.,JABALPUR SECTION QPM/OAl20Ire REV.NO. 01





Remarks

5 LEG LENGTH AQL - 1.5 as per Table - Leg Length up to (KEC)I enclosed. "50mm,

±Imm

> 50 to::: 100 mm+1-2 mm

> 100 to::: 150 mm+/-3 mm

> ISO mm to 200mm+1-4mm

RY Record ReviewJISG3192 (KEC)Leg Length<50mm± 1.5 mm

50 to < 100 mm±2mm

100 to < 200 mm±3mm

200 mm and more±4mm RY

(KEC) Record ReviewASTM-A6

Leg Length up to50mm±lmm

>/= 50 mmto</=75 mm±2mm

>75 mm to < 100 mm

+ 31-2mm

>/= 100 mm to</= 150 mm±3mm

f\

~

&,~ I~I~YAPPROVED IO':~\. STAMP HERE..~ •...

((If ~~ . 3(~~'i~tDEORI ~}j ~ .~ h" •

KEC INTERNA TlONAL LTD.,JABALPUR SECTION QPM/QN20Ire REV.NO. 01MANUFACTURING QUALITY PLAN REV. DATE 13.08.2010

CUSTOMER-CESC SHEET NO. Page 8 of 22



Remarks

Over 150 mm+ 5/-3 mm

IA.1. OUT OF SQUARENESS IS 2500 LEVEL - n, BSEN 10056-21 RY· Record Review6 AQL - 1.5 as per Table- 1ISG3192 (KEC)

1 enclosed.J[S G 3192Up to 2.5% of flangeASTM-A6+ 1'.1,,0

BSEN 10056-2Leg Length'::;100 "'±Imm Record ReviewAbove 100 up to 150± I.5mm> 150 upto 200 mm±2mm

lA.l. CAMBER IS.2500 LEVEL -II, BSEN 10056 -2/ RY7 AQL - 1.5 as per Table- J[S G 3[92 (KEC) Record Review

1 enclosed.BSEN 10056-2Leg Length< 150 mm -0.4% of Length>150 to ':::;200- 0.2%

of Length> 200 mm - 0.1%

of LengthJISG 31920.3% of LengthASTM-A6Leg Length<75mm - 0.4%

of Length>/=75 mm - 0.2%

of Length

bI~~~

,~..4::¥."r~~,APPROV ., . ~ ~ ..•.,. STAMP HERE

/',e./ .~~) ,(Cl"~,{";/ .. ~ \~{- .~. ~I ,DeOR S}

KEC INTERNA TIONAL LTD.,JABALPUR SECTION QPM/QAl20Ire REV.NO. 01





Remarks

IA.1. WEIGHT TOLERANCE One sample for 20 MT8 FOR ANGLE SECTIONS per lot or part there of.

lA.I.9

THICKNESSTOLERANCE FORANGLE SECTIONS

IS 2500 LEVEL - II,AQL - 1.5 as per Table-1 enclosed.

RY(KEC) Record Review

BSEN 10056-2! JIS QAG 3101 ! JIS G 3192 (KEC) Record Review

BS 10056-2::;:4 mmthick- ±6%>4 mmthick- +/- 4.0%JIS G 3192< 10 mmthick- ± 5%10 mm thick & above- ±4%

ASTM- A6 - ± 2.5%

BSEN 10056-2 / JISG 3192IJIS G 3101

BSEN 10056-2.::; 5 mm thick- ±O.5 mm

> 5 to.::; 10 mm- ±0.75 mm

> 10 to'::; 15 mm- ± 1.0 mm

> I5mm - ± 1.20mm

ASTM-A6<5mm thick - ±0.2mm>5 - IOmm - +O.3mm

\ \\v.,APPROVED BY~~~, STAMP HERE

KEC INTERNA TlONAL LTD.,JABALPUR SECTION QPM/QN20lEe REV.NO. D}MANUFACTURING QUALITY PLAN REV. DATE 13.08.2010



Component/Operation and Sampling Plan with basis Reference DocumentDescription of Test & acceptance norms.

Remarks

>10mmthick-± O.4mm

JIS G 3192For Leg Length up to130mm < 6.3 mmthick ±O.6mm

:::6.3 to < 10 mm±0.7mm

::: 10 to < 16mm±O.8mm

~ 16mm - ± 1.0nim

For Leg Length morethan 130 mm

<6.3mm±0.7mm -

~ 6.3 to < IO mm±O.8mm

~lOto<16mm± 1.0mm

~ 16to < 25 mm±1.2mm

~25 mm - ±1.5mm

INPROCESS IS 802 PartII (KEC)INSPECTION IS 1215 & Approved

DrawingS/ShopFABRICATION OF SketchesTOWER PARTSStraightening 100% RY

(KEC)

KEC INTERNA nONAL LTD.,JABALPUR SECTION QPM/QAJ20Ire REV.NO. 01


CUSTOMER·CESC SHEET NO. Page 11 of22



Remarks

2.0

(ii) For 17.5 mm dia hole

Cropping (Cutting) Ist piece and subsequentlyany piece before soth andsoon.

( a ) Stamping

( b ) Punching/Drilling

( c ) Edge Security Same as 2.0 ( b )(i) For 13.5 mm dia hole

( d ) Drilling & Punching Hole Same as 2.0 ( b )to Hole Distance

Same as 2.0 (b)

Same as 2.0 ( b )

Length tolerance ± 2mm. The cut surfaceto be clean, reasonab-le square & free fromdistortion.

Letter Size8x16 mm or 8xl4 mm

Punching to be clonefor the thickness upto 12 mm. Drillingto be done forthickness more than12mm. Holes nearbend to be Punched IDrilled after bending.Hole should beperpendicular tosurface & differencein dia on both sidesof "flange should notbe more than 0.8 mm

Sheared 20 mm Min.. Rolled 16 mm Min.

Sheared 23 mm Min.Rolled 20 mm Min.



Tolerance cumulativeand between concee-utive hole shall bewithin ± 2 mm and ±1 mm respectively. '.

FAB Record Review(KEC)

FAB(KEC)

FAB(KEC)

FAR(KEC)

FAB(KECTL)

FAB(KEC)

Record Review

Record Review

Record Review

Record Review

Record Review

Record Review

(Hi) For 21.5 mm dia hole

(iv) For 2S/2S.Smm diahole

\'

APPROVED BY.-'l"': "....." STAMP HERE

KEC INTERNA TIONAL LTO.,JA BAL PUR SECTION QPMJQA/20Ire REV.NO. 01





Remarks

(e) Gauge Distance Same as 2.0 ( b ) :!:Imm FAB Record Review( Back Mark) (KEC)

(f) Notching, Same as 2.0 ( b ) + 5 mm on specified .FAB Record ReviewFlange Cut, length of cut operat- (KEC)Comer Cut, ion by Shearing uptoBevel Cut 12 mm thick, and by

gas cutting for mater-ial above 12mm thick

(g) Heel Grinding Same as 2.0 ( b ) After grinding the FAB Record Reviewthickness on heel (KEC)should be equal ormore than the thickn-ess of the memberwith + 2 mm and -0mm tolerance.

(h) Bending 100% Pieces -IS 802 Part II FAB Record ReviewIS 1215, Drawing (KEC)

(i) HT Section/Plates All sections and allangles to be hot bend

(ii) MS Sections Process Cold Bend:Upto 75x6 - upto 10°,Upto 100x8 - upto 5°

All other angle sect-ions and bend angleshall be hot bend.

(Hi) MS Plates Cold Bend - upto 12mm thick (MS) upto15° angle. Greaterbend & other thickn-ess shall be hot bend.

( i ) Welding Same as 2.0 ( b ) As per KEC FAB Record ReviewApproved Welding (KEC)Procedure & WeldingQualification.

1 i\

k~' ~~yAPPROVED BY/?!;;'~, STAMP HERE 155U

v;:.y , '''''

KEC INTERNA TlONAL LTD.,JABALPUR SECTION OPM/OAl20Ire REV.NO. 01



ITITLE:. MANUFACTURING QUALITY PLAN


Remarks

(k) Proto (Model Assembly One structure of each typeas per requirement of theCESC)

(j) Final InspectionFabricated Parts

3. GALVANIZING

3.1 PROCESS CONTROL

of As per Sampling PlanQPM/QAl26

All parameters froin(a) to (k) above arechecked and recordsmaintained beforereleasing the materi-als for galvanizing.

KEC ApprovedStructural Drawings,Bill of Materials,Tower to beassembled andchecked for dimens-ions, angle, size. Bythis, to verify interch-ange ability ofmembers, etc.

(a) Degreasing in DEOIL One sample dailysolution

Pointage of 10%solution 9 ±3 ML

Temperature ofdegreaser- Room to 60 °c

(b) Pickling

(i) Acid Content One sample daily IS 262950 - 210 GmsILtr.

(ii) Iron Content Om: sample daily IS 2629120 GmslLtr.Max.

(Hi) Density One sample daily 12 to 30 Beaume

(c) Rinsing One sample daily IS 2629PH value to be betw-


QA(KECTL)

R&D(KEC)

QA(KEC)


f\

Record Review

Record Review

Record Review

Record Review

Record Review

Record Review

~APPROVED B~NAT~ STAMP HERE

KEC INTERNA TlOHAL LTD.,JABALPUR SECTlON QPM/QA/20In:c REV. NO. 01MANUFACTURING QUALITY PLAN REV. DATE 13.08.2010


ITITLE: MANUFACTURING QUALITY PLAN


Remarks

een 5 and 6

(d) Pre-Fluxing in ZnCl2 and One sample daily IS 2629 QA Record ReviewNH4CI Solution (KEC)

~.

(i) Iron content 50 Gm/Ltr. Max.

(ii) Density in Be 36 to 44 Beo

(Hi) Ph Value 2 to 3

(iv) Temperature Room to se-e

(e) Stripping One sample daily QA Record Review(KEC)

Density in Beo 17 to 45 Beaume

Iron Content 25 GmslLtr. Max.

(f) Pre-heating Once in a day IS 2629 QA Record Review120°C to 150°C (KEC)

-Hot Chamber Temp.(2300 to 3300 C)

3.2 DIPPING (GALV.)

(a) Zinc bath temperature Once in a day. IS 2629 QA Record Reviewcontinuous recording by 4400 e to 4750 e (KEC)graph or manual. Hourly - Galvanizing Work-recording and verifi- jug Temperaturecation by Temperature ( 4450 to 4650 C )Meter.

(b) Immersion time and IS 2629 GPwithdrawal time Article to be immers- (KEC)

ed till reaction takesplace which is indio--

KEC INTERNA TlONAL LTD.,JABALPUR SECTION QI'M/QAl20Ire REV. NO. 01

MANUFACTURING QUALITY PLAN REV. DATE l3.08.2010


I TITLE: MANUFACTURINGQUALITY PLAN


Remarks

( c ) Quenching andDichromating in runningwater .lDeoxident

3.3 GALVANIZINGCHECKING·

Once daily.

( a ) Visual Checking 100 %

(c) Weight of Zinc Coating

( b) Thickness of Zinc Coat- Eight Samples per Shifting

GP Record Review(KEC)

IS 2629Surface to be freefrom defects like bare1 black spots (exceptwhen small andsuitable for patch-ing) heavy ash & fluxinclusion, lumps,pimples, runs, etc.

KEC Record ReviewIS 2629 / IS47591 (QA)BS729Material <5mm thick65 Microns minaverage.Smm thick & above86 Microns min

ated by stoppage ofbubbling withdrawalto be controlled, sothat zinc drainsfreely.

IS 2629Strength of solutionsto be maintainedBetween 0.2% to 1%Sodium Dichromate.Or as per supplierrecommendation

averageASTM A 123 ;::s3.2mm- 65 Microns

(Average)>3.2 to 6.4 mm - 85Microns (Average):

>6.4 mm-IOOMicrons (Average)

IS 2629 !IS 4759 !IS 6745 !BS 729

QA(KEC) Visual Check

colour matching.by

Three Samples per Shift QA Record Review(KEC)

"

~. ~~APPROVEDB~~~~ STAMP HERE

MQP - 1.pdf

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rnm leg length

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