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MANUFACTURING QUALITY PLAN Manufacturer’s Details Customer : POWERGRID Vendor’s Code : Item : Galvanized Tower Structures / Parts Q.P.No. : Rev. No. : Date : Valid From : Valid Upto : INSTRUCTIONS FOR CODE ALLOCATION Code 1 Indicates place where testing is planned to be performed i.e. Inspection location Code 2 Indicates who has to perform the tests i.e. Testing Agency A At Equipment Manufacturer's works (Fabricator) J The Equipment Manufacturer B At Component Manufacturer's works (Re- roller) K The Component Manufacturer C At Authorized Distributor's place L The Third Party D At Independent Lab M The Turnkey Contractor E At Turn Key Contractor's location F Not specified Code 3 Indicates who shall witness the tests i.e. Witnessing Agency Code 4 Review of Test Reports/Certificates P Component Manufacturer itself W By Equipment manufacturer during raw material / bought out component inspection Q Component Manufacturer and Equipment Manufacturer X By Contractor during product/process inspection R Component Manufacturer, Equipment Manufacturer and Contractor Y By POWERGRID during product/process inspection S Equipment Manufacturer itself Z By Contractor and/or POWERGRID during product/process inspection T Equipment Manufacturer and Contractor U Equipment Manufacturer, Contractor and POWERGRID V Third Party itself Page of 55 1
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Page 1: Sample Smqp Final-1

MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

INSTRUCTIONS FOR CODE ALLOCATION

Code 1 Indicates place where testing is planned to be performed i.e. Inspection location

Code 2 Indicates who has to perform the tests i.e. Testing Agency

A At Equipment Manufacturer's works (Fabricator)J The Equipment

Manufacturer 

B At Component Manufacturer's works (Re-roller)K The Component

Manufacturer 

C At Authorized Distributor's place L The Third Party  

D At Independent Lab M The Turnkey Contractor  

E At Turn Key Contractor's location    

F Not specified                               

Code 3 Indicates who shall witness the tests i.e. Witnessing Agency

Code 4 Review of Test Reports/Certificates

       

P Component Manufacturer itselfW By Equipment manufacturer during raw material / bought out component

inspectionQ Component Manufacturer and Equipment Manufacturer X By Contractor during product/process inspection  R Component Manufacturer, Equipment Manufacturer and

ContractorY By POWERGRID during product/process inspection  

S Equipment Manufacturer itself Z By Contractor and/or POWERGRID during product/process inspection

T Equipment Manufacturer and Contractor    

U Equipment Manufacturer, Contractor and POWERGRID    

V Third Party itself    

                           Code 5 Whether specific approval of sub-vendor / Component

make is envisaged?Code 6 Whether test records required to be submitted after final inspection

for issuance of CIP/MICCE Envisaged Y Yes  

N Not Envisaged     N No                

Page of 42 1

Page 2: Sample Smqp Final-1

MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

NOTES/GENERAL REQUIREMENTS TO BE CHECKED/ENSURED

I. IMPORTING OF RAW MATERIAL ,STELL ANGLE SECTIONS AND BILLETS

(1) The manufacturer may approach Power Grid for giving clearances of Imported Billets or imported angle sections, based on review of an un-priced copy of purchase order AND DULY SINGNED CONTRACT AGREMENT and manufacturers test certificate AS PER BSEN- 10024 DOCUMENT TYPE- 3.2 , ALONG WITH THIRD PATY INSPECTION REPORT (BVQI.LLOYDS,ETC), before shipment, to avoid discrepancy detection at later stage. Filled in information as per format at Annexure-I, shall be submitted to concerned Inspection office of POWERGRID.

2- THE DOCUMENT LIKE BILL OF LANDING, PACKING LIST. Country of origin certificate, ETC AFTER RECIEPT OF MATERIAL shall be submitted.

3 For imported angle sections THIRD PARTY INSPECTION IS MANDATORY(not required for billets). IT SHOULD BE RECORDED IN PURCHASE ORDER.

4. The suitability of hot dip galvanization as per BSEN-10025- 1-2004 clause-7.4.3 ,class -3, shall be intimated to producer of steel. If the POWERGRID technical specification specifies the grade of steel as Fe-490/490B or equivalent, then the equivalsnt grade of steel( keeping chemical and impact properties same) applicable is S-355 JO. Hence order may please be placed for this grade for high tensile steel and S-275 –JO for mild steel

5 For IMPORTED ANGLE sections EMBLUM OF MANUFACTURER IS MANDATORY .Othervise, THE REFUSAL OF THE PARTY IN WRITING SHOULD BE PRODUCED and FOOL PROOF SYSTEM OF IDENTIFICATION OF MATERIAL LIKE SOURCE, MILD STEEL AND HIGH TENSILE STEEL, GRADE, etc SHOULD BE INFORMED

6. IF THE SPECIFICATION OF THE MATERIAL IS OTHER THAN BSEN SPECIFICATION, THEN THE EQUIVALENT NATIONAL STANDARDS OF ORIGIN COUNTRY SHALL BE SUBMITTED FOR APPROVAL PRIOR TO PLACEMENT of THE ORDER.

7- IF THE ORDER IS NOT PLACED DIRECTLY ON THE MANUFACTURERER ,Then THE COPY OF THE DULY SINGNED UNPRICED COPY of Purchase ORDER AND the CONTRACT PLACED BY INTERMEDIATORY, SHALL BE SUBMITTED TO ENSURE THAT ALL THE REQUIRMENT OF POWERGRID CONTRACT/ TLT MANUFACTURER PURSHASE ORDER Have BEEN INTIMATED TO PRODUCER OF THE STEEL

8. In every specification there is provision of finalization of lower limit on mutual agreement. So while placing the order other than BSEN-10025 -2004 relevant specifications may please be examined and deviation in physical, chemical and any specific

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Page 3: Sample Smqp Final-1

MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

requirement in technical specification may be intimated to producer of steel and may be agreed mutually. In this case, no material shall be produced prior to the mutual agreement date.

9. TLT manufacturer shall ensure that no non - moving stock, second grade material shall be purchased or imported and also the it shall be non alloy prime grade material as defined in BSEN- 10020

10- It is observed that various international steel makers are having the on line system of viewing the test certificate, traceability , raw material used , heat no, etc. If possible the access to this system may please be given to POWERGRID so that the same can be viewed

11- In various test certificate the various comments and details are given in the language of origin country.Hence it shall be ensured that the English translation of the same shall be provided for reviewing the test certificate

12- In test certificate the heat-vise chemical composition of ladle analysis is to be recorded not product chemical composition . If inspection is done by third party then the heat wise chemical composition of product shall be recorded .

II. Material procurement from Indian Re rollers.

In case Steel sections are purchased from the main producers or directly from the re-rollers, the following conditions shall be fulfilled:-

(A) The Rerollers have to be approved by POWERGRID .Tower manufacturer’s shall ensure that the Materials bear the identification marks of the re-rollers ie. ‘PG00” embossing for MS ,PHT00 embossing for HT(E350 GRADE) and SHPHT embossing FOR SS-540 GRADE re-rolled section. . PG 00 MEANS YEAR OF MANUFACTURE

(B) Copy of MQP shall be available at re-roller’s works.

© THE GRADED RAW MATERIAL FOR ROLLIG MILD STEELas per IS 2830, shall be procured FROM APROVED PRIMARY STEEL PRODUCERS AND FOR HIGH TENSILE STEEL,it shall be JSP-355 OF JINDAL, TISTEN -50 OF TISCO, SAIL TOWER GRADE VI OF SAIL and JSP-540 FOR ROLLING JIS-SS-540 OR E-400 . UNDER IS-2062 billets/ SEMIS to be procured from the Billet producer like SAIL, RINL, TISCO, IISCO, SISCON and Jindal .For other parties POWERGRID’s approvals will have to be obtained. For any new grade of high tensile steel other than mentioned above,specific approval of grade from POWERGRID is required.

(D) TLT contractor Shall offer the Steel sections rolled out of indigenous / imported billets at re-roller’s works for Inspection to POWERGRID and inform at least one week before proposed inspection date. The rolled angle section shall be duly co-related with corresponding billets.

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(E) REROLLER shall ENSURE THE CHEMICAL TESTING of INCOMING RAW MATERIAL,SEMIES AND IF ANY LOT IS NOT AS PER TDC( FOR HIGH TENSILE) OR IS-2830 (FOR MILD STEEL) , THEN THE SAME SHALL BE REPORTED TO PRIME PRODUCERS with COPY marked TO POWERGRID . COPY OF THE QUALITY COMPLAINTS SHALL BE KEPT IN RECORDS FOR REVIEW

(F) ANY LOT OF PRIME PRODUCERS WHICH IS UNDER QUALITY COMPLAINT SHALL NOT BE USED. IF it is used the same shall have the permission of POWERGRID . Permission will be granted by POWERGRID based on the merit of the case if requested by prime producer of steel.

III. Inspection of angle sections at Black stage of Tower structures irrespective of specific contract, can be followed as

Detailed hereunder.

A) TLT manufacturer will inspect the material as per P.O, P.O length, and P.O requirement and issue the MICC to the re roller as per enclosed format.Accordingly inspection call will be raised on IMS and the unique MICC NO shall be mentioned in the inspection call .The MICC shall become the part of POWERGRID CIP at re rollers works. And inspection of material will be done as per relevant specification as applicable in the contract .

B) The material test certificate and invoice of raw material semies shall be in the name of concern re-rollers

C) In the case of conversion route, all the test certificate shall be issued in the name of TLT manufacturer and the concerned re- roller shall be consignee of the material

D) The hot rolled angles shall be dispatched to the works of the TLT manufacturer directly .If any change in the place of fabrication is planned the same shall be with the approval of POWERGRID. The re -roller shall mention TLT manufacturers MICC NO/POWERGRID CIP NO in the invoice

E) If any material is rejected during inwards testing at TLT manufacturer works,then the same shall be intimated to POWERGRID and relevant CIP may please be amended .

F) The presence of micro- alloying elements is a must for high tensile steel . Material produced under IS - 2830 with

minimum 0.5 % Mn shall be used for rolling MS sections.

G) Inspection call for angle sections at black stage at re-roller’s work, shall be raised against any one of the ongoing Contracts.

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(H) TLT contractor shall maintain a separate register indicating splitting and swapping of material between different Projects awarded to same contractor, which can be reviewed by Powergrid inspection engineer. Separate register for each

Contractor is to be maintained if the fabricator is executing jobs for different contractors

(I) All section shall be offered for inspection as per relevant standard at the re-roller’s works. The grade ofThe billets should be suitably selected to meet the raw material requirements.

Colour code for black section shall be as below;IS 2062 E250 : GreenIS 2062 E350 : WhiteBSEN10025 355JO : YellowBSEN10025 355JR : Pink( not required)BSEN10025 275JO : GreyBSEN10025 -275 JR : Blue

IV. FABRICATION OF TOWER PARTS AND FINAL INSPECTION:

(1) TLT contractor shall maintain “operator card” for each work (operation) station per shift and maintain it till the materials offered, inspected and cleared which can be verified at the time of inspection.

(2) IF during the process of manufacturing of the lot any re-work due to fabrication defects / any lot are rejected during fabrication process,quality check/ issue of wrong grade raw material for fabrication, then the same shall be informed at the time of inspection to POWERGRID inspectors and the lot which has been rejected by TLT manufacturer will be disposed off only after inspection of replacement lot.

( 3)- Process inspection shall be started with the venders having ERP system in place and proper correlation from raw material to the finished gavanised tower parts may please be shown . The raw material correlation statement from material inward ,issue, completion of fabrication , & galvanizing and handing over to yard has to be given on soft copies and original route sheets has to be preserved if it is required the same can also be varifed w.r.t soft copies data till completion of inspection.

(4) Welding procedure and Welder’s performance qualification approval by POWERGRID is required in case welding is involved at any stage of fabrication/erection.

(5) All bent pieces shall be checked at the process of bending by a bend gauge made as per bend ratio/degree shown in the sketch of the item/mark no. On the stand one piece is thoroughly checked with bend gauge and all other pieces are checked by comparison method and pieces are cleared for further process. If the holes are to be made near the bend line the same shall be done after bending.

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

( 6) All the concerned calibration certificates for testing machines/measuring equipments shall be made available for review at the time of final inspection.

(7) ALL Grades of steel used and the standards to which they conform shall be as approved by Power Grid Engineering for the specific contract and shall be indicated in approved Drawings/ BOM/offer list at the time of inspection.

( 8) Steel plates below 6 mm used for packing plates/Packing washers shall be as per POWERGRID specification/ approved drawings by Engineering Department.Steel produced as per IS 1079 1994 (Grade-O) are also acceptable.However if below 6 mm thickness plates are used as load bearing plates, gusset, splices etc. same shall confirm to IS 2062 or equivalent standard. If possible grade _O plates should be recorded in BOM

(9) In approved BOM along with grade of steel used and section summary the operation involved in manufacturing should also be mentioned.

(10) TLT contractor shall maintain proper co-relation of test certificate with respect to the material from raw material stage to Finished material stage.

(11) At the time of offering of galvanized tower parts for final inspection ,a stament showing details of rawmaterial CIPs from which raw materials are consumed ,sectionvise consumption quantity,previous quantity available in each CIP,and balace quantity available for next fabrication,etc shall be submitted for verification.

(12) Inspection will be based on actual quantity of galvanized bunduled production. For ensuring this readiness of material print out of the bundled production/galvanized production of the lot under offer has to be taken from ERP / mother system in presence of POWERGRID inspector prior to commencement of inspection . And the same shall be treated as offer list of material for inspection. In this offer list various operation of manufacturing such as cutting notching ,punching, heel grinding shall be there such as C/P/HG/S ETC

(13) Stripping off galvanizing of rejected material shall be done before re-galvanizing in case of rejection is due to galvanizing Testing / defects. POWERGRID INSPECTOR MAY witness the striping process and galvanization process

14 ) TLT contractor shall dispose off entire section rejected in physical testing by gas cutting or by machine cutting from any end of rejected mark number IN PRESENCE OF POWERGRID INSPECTORS AND SHALL SUBMIT THE PHOTOCOPY OF EXCISE INVOICE AND

RELEVANT PAPERS FOR RECORD. And a duplicate record of the same shall be maintained at the works of TLT manufacturer

15 ) In case of any contradiction between Technical Specification / Approved Drawing and MQP, the details mentioned in The Technical Specification / Approved Drawing shall be final

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Page 7: Sample Smqp Final-1

MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

16 ) TLT contractor should progressively align their Quality System and sub-vendors Quality System to the requirements of ISO 9000 series Quality Standards and in due course of time should get their quality system certified to ISO 9001. The quality Manual should also be submitted to POWERGRID.

17) - TLT MANUFACTURER WILL TAKE SUFFICIENT PRECAUTION THAT ANY OF THE TOWER PARTS OF TESTed TOWER SHALL NOT BE USED IN FABRICATED LOT. - And all test tower mark no will have prefix- T- easy identification

18- During proto assembly if any mild steel angles have been used in place of high tensile steel or angles of non approved source or raw material then the same shall be destroyed after completion of proto inspection. And the same shall be recorded in proto inspection report And proto assembly towers shall be offered separately not in combination with production lot/ batches

19 ) The Universal-testing machine shall have valid calibration certificate Issued by NABL accredited testing agency only

(20) After completion of the a project supplies, a combined statement of raw material cip qty, actual quantity lifted ,actual quantity consumed , qty diverted to other projects and balance if any shall be intimated to POWERGRID. before final MICC of the relevant contract

(21) Before starting the supplies under any new contract, use of major quantity from old stock without verification and consent of POWERGRID is not permitted but this condition is not applicable to stock of plates, randomly used section in small quantity

(22) During the testing of the material if any mild steel section is giving the high tensile steel mechanical properties, then chemical composition of the sample has to be checked to verify the grade of steel .

(23) If high tensile steel is used in place of mild steel then it shall be reported before commencement of inspection so that it can be verified

(24) Before commencement of inspection it shall be informed that that in which mark no rework or rectification (EXCLUDING Galvanization) has been done. If any lot has been rejected during in house quality check then the rejected lot shall be kept till the completion of inspection and if required the same can verified during the inspection.

(25) During final galvanizing test (mass of zinc coating) , test samples has to be tested for dimension also.in case of doubt the unit weight test shall be done. If test samples are found not confirming the lot will be checked and if it is found to be intentional negative rolling , then lot will be rejected.

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(26) The chemical composition of the material for which raw material inspection has not been done by POWERGRID (including imported) has to be done at the time of final inspection of finished galvanized tower parts to establish the correlation with raw material statement .

(27) For HT steel, requirement of micro-alloys elements shall be as follows:

Ladle Analysis: Vanadium 0.025% min, Niobium 0.015% min. or Vanadium + Niobium + Titanium = 0.025% min. However, the sum or individual shall not exceed 0.25% as per IS2062. Product Analysis: A tolerance of 0.005% from Laddle analysis

( 28) Pieces of light sections to be wire bundled & of heavy sections to be supplied loose. Stacking to have proper ventilation and kept inclined. Damage to galvanization coating to be avoided while handling. TLT MANUFACTUTER to ensure sequential supplies and other details as per POWERGRID Technical Specification

(29) Prior approval of POWERGRID is required to be taken for any activity or process that is out-sourced.

(30) Any addition/ change in Vendor/ Design/ Process shall call for review by POWERGRID and change in MQP, if necessary.

(31) POWERGRID may review the effective implementation of the Process during Product/ Process inspection. In case any violations in process or process parameters are observed, then the reasons along with corrective and preventive measures shall be conveyed to POWERGRID within 2 weeks.

(32) After galvanized tower parts inspection, it may also be ensured that all the material inspected and cleared for dispatch shall be dispatched within 15 days and same shall be intimated to Power grid In the format provided in the CIP .

(33) At the time of claiming the MICC, original copy CIP received for bolts and nuts and accessories may be submitted with all enclosure

V. INSPECTION OF BOLTS AND NUTS:

(1) Bolts & nuts, Step Bolts & Nuts and other bought out items are to be procured from Power Grid approved sources and CIP at sub-vendor’s works. If material is tested in third party lab. sample identification no and its correlation with the lot shall be there and in chemical analysis all the element present during spectro test should be reported in the test certificate. Graded raw material IS 1875: 1991

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

as per requirement of product shall be procured. THE chemical testing samples has to be preserved by third party lab incase of level –II items. If required POWERGRID may verify the same prior to issuance if CIP.

(2) IN THE RAW MATERIAL OF BOLTS AND NUTS,Elements not specified in Table 1 OF IS 2004 shall not be added to the steel, except when agreed to, and shall not exceed the following limits: AS PER CLUASE NO-7.3 OF IS-2004

(3) Constitutent Percent- Nickel 0.30, Chromium 0.30,Copper 0.25 , Molybdenum 0.05,Vanadium 0.05,Tin 0.05,Boron 0.000 3 Trace elements (Cr + Ni + MO) when added together shall not exceed 0.050 percent. Percent copper + 1O x (Percent tin) shall not exceed0.050 percent

(4) If any new party is approved for level _II items, at least ten initial inspection visits by POWERGRID is a must .After that vender can be allowed to dispatch the material for level II items based on no rejection during initial six month period .

(5) All forging items used for transmission line towers to be procured as per IS -2004 and condition of chemical composition as per clause no- may also be complied with .and in chemical anylsis all the elements present may be reported

(6) Any change IN PRODUCTION CAPACITY may be intimated to POWERGRID .

(Can attach more than one page)A. Raw Material Inspection (Indigenous) – At Re-Roller’s Work

Sr. No.

Components/ Operation

& Description

of Test

Type of Check

Quantum of Check / Sampling with basis

Reference

document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

1. RAW MATERIALS

E

1.1 Structural Steel (Angle Sections, Plates and sheets)

Steel to be procured fromPower Grid approved Sources. For re-rollers specific approval of Power Grid is to be ensured/ CIP for every lot at re-roller’s works.

1.1.1

MechanicalProperties

Page of 42 9

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(a) Test For Ultimate Tensile Strength

2 - Samples per Cast/Heat *

IS - 1608 As per IS 2062 Table-2

CIP B K U Z - Y CIP at Reroller’s works

*In case proper heat/cast number is not established,then 2 samples per section per 100 mt

a. Raw Material Inspection (Indigenous)

Sr. No.

Components/ Operation

& Description

of Test

Type of Check

Quantum of Check / Sampling with basis

Reference document

for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(b) Test For Yield Stress

2 - Samples per Cast/Heat. *

IS - 1608

As per IS 2062 Table-2

CIP B K U Z - Y CIP at Reroller’s works

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(c) Percentage Elongation Test

2 - Samples per Cast/Heat. *

IS - 1608 As per IS 2062 Table-2

CIP B K U Z - Y CIP at Reroller’s works

a. Raw Material Inspection (Indigenous)

Sr. No.

Components/ Operation

& Description

of Test

Type of Check

Quantum of Check / Sampling with basis

Reference

document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(d) Bend Test

2 - Samples per Cast/Heat. *

IS 1599 As per IS 2062 Table-2

CIP B K U Z - Y CIP at Reroller’s works

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

A. Raw Material Inspection (Indigenous)

Sr. No.

Components/ Operation

& Description

of Test

Type of Check

Quantum of Check / Sampling with basis

Reference document

for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(e) V ’notch Impact

One sample per cast/heat for ‘HT’

IS 1757 for Impact

As per IS 2062 Table-2

CIP B K U Z - Y CIP at Reroller’s works

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

test material. Applicable only for Grade E350 and E410as per IS 2062

Testing

1.1.2

Chemical Composition

Chemical Analysis

2 - Samples per Cast/HeatChemical analysis for each lot / heat . *

IS 2062/ Power Grid Specn./

As per IS 2062 Table-1Elements C, Mn, P, S, Si, Ni, Cr, Mo, Cu, AI, N and micro alloying elements as V / Nb / Ti and any other element specified by applicable product specifications for the applicable grade, class and type.

For permitted variations in product analysis relevant standard to be referred.

CIP B/D

K/L

U/V

Z - Y CIP at Reroller’s works

1.1.3

VisualInspection

Visual 5 samples/section

.

IS 2062/Power Grid specn.

(Removal of minor defects as per IS 2062 Clause 7.2 acceptable) Rolled shapes and plates shall be free from defects like - Scaling, scabbing, pipy, fish ends,

CIP B K U Z - Y CIP at Reroller’s works

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

cracks, prominent rolling marks, deep scratches, deep grooves, waviness, twists ,lamination, and any other harmful defects hampering safety and ease of fitments during tower assembly

A. Raw Material Inspection (Indigenous)

Sr. No.

Components/ Operation

& Description

of Test

Type of Check

Quantum of Check / Sampling

with basis

Reference document

for Testing

Acceptance NormsFormat

of Record

Applicable Codes Remarks

1 2 3 4 5 6

1.1.4

Dimensional Inspection

Measurement

5 samples/section IS 808/ IS 1730 / IS 1852 & PowerGrid Specn.

CIP B K U Z - Y CIP at Reroller’s works

1.1.5

Tolerances For Leg Length Of Angles Equal / Un Equal

- do -

IS 1852/ IS 808 (i) Up to 45 mm Leg

Length ± 1.5 mm

B K U Z - Y CIP at Reroller’s works

(ii) > 45 to 100 mm Leg Length ± 2.0 mm

(iii) >100 mm Leg Length ± 2.0 % of leg

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

length

Difference between Leg Length of Equal Angles shall be limited to 75 % of Total Tolerance (Plus & Minus)

1.1.6

Out ofSquare ness

Measurement - do -

IS 1852Power Grid

Specn.±1°

B K U Z - Y CIP at Reroller’s works

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

A. Raw Material Inspection (Indigenous)

Sr. No.

Components/ Operation & Description

of Test

Type of Check

Quantum of Check / Sampling

with basis

Reference

document for

Testing

Acceptance Norms

Format of

Record

Applicable CodesRemarks

1 2 3 4 5 6

1.1.7

Camber Measurement 5 samples/section IS 1852 (i) For Flange Less than 100 mmReasonably Straight

B K U Z - Y CIP at Reroller’s works

(ii) For Flange 100 mm & above Max 0.2% of length

1.1.8

Weight Tolerance For Angle Sections

Unit Weight Test

One Sample for 20 MT / section or part thereof.

IS 1852 /IS 808

Up to 3 mm thick ±5%> 3 mm thick + 5%, - 3 %over weights specified in IS 808 THIS TOLERENCE IS FOR TEST SAPMLE NOT FOR THE LOT UNDER OFFER

B K U Z - Y CIP at Reroller’s works

1.1.9

Weight Tolerances For Plates

Unit Weight Test

One Sample for 20 MT / section or part thereof.

IS 1852 /IS 1730

+5%, -2.5% over weights specified in IS 1730

B K U Z - Y CIP at Reroller’s works

1.1.10 Thickness Tolerance For Plates

Measurement 5 samples/section IS 2062/ IS 1730 / IS 1852

< 8 mm thick + 12.5 %, - 5 %8 mm - 12 mm + 7.5 %, - 5 %over 12 mm ± 5 %

B K U Z - Y CIP at Reroller’s works

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

Page of 42 17

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

A. Raw Material Inspection (Indigenous)

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of Check /

Sampling with basis

Reference document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

1.2 Zinc E

1.2.1 Zinc Receipt Chemical Composition

Chemical Analysis

One sample for50 MT orPart thereof

IS 209 (Grade 99.95%)

% of zinc 99.95 min in the spectro test results all the elements as specified in specification shall be measured and reminder will be the purity of zinc

A/D

J/L

S/V

Z N THIS IS APPLICABLE FOR ZINC PROCURED FROM INDIAN ORIGIN NOT FOR IMPORTED ZINC. IMPORTED ZINC HAS TO CLEARED BASED ON DOCUMENTS & TEST CERTIFICATE HEATNO.WISE T/C AND IT VARIFICATION ON THE LOT AND RANDOM CHEMICAL COMPOSITION CHECK

a. Raw Material Inspection (Imported)

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of Check / Sampling with

basis

Reference

document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

1A. RAW MATERIALS As per remarks given under imported steel section.1A.1 Structural Steel

(Imported) E

1A.1.1(a)

Mechanical Properties

Test For Ultimate Tensile Strength

One sample for every 20MT / Section /lot or part thereofOne sample for 40 MT/Sec/CastOr part thereof as per BSEN 10025-2: 2004

BSEN 10025-2:2004/Power Grid Specn.

BSEN 10025-2:2004/

04.2209.82.04-1 / Steel Inspection Report

A/D

J/L

S &V

Z - N

(b) Test For Yield Stress

One sample for every 20MT / Section /lot or part thereofOne sample for40 MT/Sec/Castor part thereof as perBSEN 10025-2: 2004

BSEN 10025-2:2004/Power Grid Specn.

BSEN 10025-2:2004/

04.2209.82.04-1 / Steel Inspection Report

A/D

J/L

S&V

Z - N

Page of 42 19

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

A. Raw Material Inspection (Imported)

Sr. No.

Components/

Operation &

Description of Test

Type of Check

Quantum of Check / Sampling with basis

Reference document

for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(c) Percentage Elongation Test

One sample for every 20MT / Section /lot or part thereofOne sample for 40 MT/Sec/CastOr part thereof as per BSEN 10025-2: 2004

BSEN 10025-2:2004 /Power Grid Specn.

BSEN 10025-2:2004/

A/D

J/L

S&V

Z - N

(d)

Bend Test

BSEN 10025-2:2004 BSEN 10025-2:2004// Power Grid Specn.

BSEN 10025-2:2004/16

A/

J S Z - N

(e) 'V' notch impact test

One sample for every 20MT / Section /lot or part thereofOne sample for 40 MT/Sec/CastOr part thereof as per BSEN 10025-2: 2004

BSEN 10025-2:2004 /Power Grid Specn

BSEN 10025-2:2004/

A/D

J/L

S&V

Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

A. Raw Material Inspection (Imported)

Sr. No.

Components/

Operation &

Description of Test

Type of Check

Quantum of Check /

Sampling with basis

Reference document for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

1 A.1. 2

Chemical Composition

Chemical Analysis

One sample for every 40 MT per section per heat or part thereof

BSEN 10025-2:2004/ Power Grid Specn.

BSEN 10025-2:2004/

A/D

J/L

S/V

Z - N

1A.1.3

Visual Inspection

Visual 8 samples/section

BSEN 10025-2:2004/

Power Grid Specn.

BSEN 10025-2:2004/

A/D

J/L

S&V

Z - N

1A.1.4

Dimensional Inspection

Measure-ment

- do -BSEN 10056-1/

BSEN 10025-2:2004/

1A.1.5

Tolerance For Leg Length Of Angles

- do - BSEN 10056 - 2

BSEN 10025-2:2004/

04.2209.82.04-1 / Steel Inspection Report

A/D

J/L

S&V

Z - N

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

Components/ Operation &

Description of Test

Type of Check

Quantum of Check /

Sampling with basis

Reference document for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

1A.1.6

Out of Squareness

Measurement

8 samples/section

BSEN 10056–2/

BSEN 10056-2

A/D

J/L

S&V

Z - N

1A1.7

Camber Visual/Measurement

- do - BSEN 10056-2/

BSEN 10056-2Leg Length

A/D

J/L

S&V

Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

A. Raw Material Inspection (Imported)

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of Check / Sampling with

basis

Reference document for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

1A.1.8

Weight Tolerance for Angle Sections

Unit weight test

2 - Samples per Cast/Heat

BSEN 10056–2/

BSEN 10056-2

A/D

J/L

S&V

Z - N Unit weight test has to be done during final inspection as per remark no -as above

1.A.1.9

Thickness Tolerance For Angle Sections

Measure-ment

8 samples/section BSEN 10056–2

BSEN 10025-2:2004/

A/D

J/L

S&V

Z - N

A. Raw Material Inspection (INWARD / RECEIPT)(NOT APPLICABLE IF FABRICATOR & REROLLER ARE SAME PARTY LOCATED AT SAME PLACE)

Sr. No.

Components/

Operation &

Description of Test

Type of Check

Quantum of Check / Sampling with basis

Reference document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

1B. RAW MATERIALS

1B.1 Structural Steel (Angle Sections, Plates and sheets)

1B.1.1 MechanicalProperties

(i) UTS Test(ii) Yield Stress Test(iii) Percentage Elongation Test(iv) Bend Test(v) Min. Charpy ‘V’notch Impact Test

One sample for40MT/section or part thereof

A J S Z - N

1B.1.2 Chemical Composition

Chemical Analysis One sample for 40MT/section or part thereof

A J S Z - N 1B.1.2

A. Raw Material Inspection (INWARD)

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

Sr. No.

Components/ Operation

& Description

of Test

Type of Check

Quantum of Check / Sampling with basis

Reference document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

1B.1.3 Visual Inspection

Visual 8 samples/se

ction

A J S Z - N

1B.1.4 Dimensional Inspection

Measurement- do -

1B.1.5 Tolerances For Leg Length Of Angles Equal / Un Equal

Measurement- do -

1B.1.6 Out ofSquare ness

Measurement- do -

1B.1.7 Camber Measurement- do -

1B.1.8 Weight Tolerance For Angle Sections

Unit Weight Test

One sample for 40MT/section or part thereof

1B.1.9 Weight Tolerances For Plates

Unit Weight Test

One sample for 40MT/section or part thereof1B.1.1

0Thickness Tolerance For Plates

Measurement8

samples/section

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation &

Description of Test

Type of

Check

Quantum of Check / Sampling with basis

Reference document for

TestingAcceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

2.0 INPROCESS INSPECTIONFabrication of Tower Parts

IS 802 Part II/ IS 7215/ Power Grid approved Drwg., Shop Sketches

(a) Straightening Visual 100 %

(b) Cropping (Cutting)

Dime-nsional

Ist 3 Pieces and random sample

Free hand torch cutting is not permitted.

Guided torch cutting is permitted. All burned edges shall be ground smooth and neatly finished with lumps and imperfections removed.

A J S Z - N

(c) Stamping Visual Ist 3 Pieces and random sample

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(d) Punching / Drilling

Dime-nsional

Ist 3 Pieces and random sample

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

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of Check /

Sampling with basis

Reference document for

TestingAcceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(e) Edge Security Dimensional

Ist 3 Pieces and random

IS 802 Part II/ IS 7215/ Power Grid approved Drwg., Shop Sketches

sampleDistance of the hole to the rolled edge or sheared edge of the member to be maintained as specified in the drawing.  Tolerance - +/- 2 mm

A J S Z - N

(i) For 13.5 mm dia Hole

Sheared 20mm Min.Rolled 16mm Min.

(ii) For 17.5 mm dia Hole

Sheared 23mm Min.Rolled 20mm Min.

(iii) For 21.5 mm dia Hole

Sheared 28mm Min. Rolled 25mm Min.

(iv) For 25 mm & 25.5 mm dia Hole

As per approved Drawing

(f) Drilling & Punching Hole To Hole Distance

Ist 3 Pieces and random sample

Tolerance cumulative and between consecutive hole shall be within ± 2 mm and ± 1mm respectively

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(g) NotchingFlange CutCorner CutBevel Cut

Ist 3 Pieces and random sampleS C

Cutting to be done by shearing up to 8 mm thickness Above 8 mm thickness cutting is to be done by flame Cutting Tolerance on flange cutting

Up to 100 mm cut - +/- 2 mm

Above 100 mm cut - +/- 3 mm

04.2202.75.01-7 / Route card

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation & Description

of Test

Type of Check

Quantum of Check /

Sampling with basis

Reference document for

TestingAcceptance Norms

Format of

Record

Applicable Codes

Remarks

1 2 3 4 5 6

h) Heel Cutting Dimensi-Onal

Ist 3 Pieces and random sample

Power Grid Approved Drwgs./Shop Sketches

Length and width of heel cutting as specified on approved drawing or sketch. Heel cutting up to 10 mm heel width, heel to be cut on heel cutting machine More than 10 mm heel width, heel to be cut with flame cutting. Heel to be cut with guided flamecutting. Heel cutting Tolerance Length - + 5 mm Width - up to 6 mm - +/- 1 mm

7 mm and above - +/- 2 mm

All burned edges shall be ground smooth and neatly finished with lumps and imperfections removed.

04.2202.75.01-7 / Route card

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(i) Bending Ist 3 Pieces and random sample

IS 802(Part II)/IS 7215/ Power Grid Approved Drawing / Shop Sketches

(1) HT Sections / PlatesAll Sections & all plates to be hot bent.

The bending shall be done either in hot condition or cold condition with the help of bending dies. Sections below MS 75 x 75 x 6 mm size Cold Bending- up to 10 degree angle Hot bending - Above 10 degree angle

Section above MS 75 x 75 x 6 mm

Hot bending only

Plates up to MS 6 mm thickness Cold Bending - up to 15 degree angle Hot bending - Above 15 degree angle Plates above MS 6 mm thickness Hot bending only All sections and plates

of any thickness-Hot Bending only

04.2202.75.01-7 / Route card

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

Hot bending is done at specified temperatures Temperature range -700 to 850 degree Celsius. Bend angle is verified by approved bend gauges

Tolerances:

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

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of Check / Sampling with basis

Reference document for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(j) Welding (a) WPS Approval(b) PQR Approval

Random samples

As per Power Grid Technical specn. /approvedDrg./Power Grid approved Welding procedure & Welder`s qualification

Weld Card A J S Z - N CIP

(k) Final Inspection of Fabricated Parts

Random samples

All parameters from (a) to (j) Above are checked and record maintained before releasing the Materials for galvanizing.

04.2202.75.01-7 / Route card

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation & Description of Test

Type of Check

Quantum of Check /

Sampling with basis

Reference

document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

3.0 GALVANIZING

3.1 Zinc Bath Chemical Composition

Chemical Analysis

Two samples in a Month

The molten metal in galvanizing bathshall contain l 98.5% zinc by mass or more

TLT MANUFACTUTER Chemical Report/ TPL Reports

A/D

J/L

S/V

Z N

3.2 A J S Z - N(a) Degreasing

Degreasing in Acid base degreasing solution at room temperature which does not require water rinsing

Chemical One sample Daily

IS 2629

TLT MANUFACTUTER Norms

Strength of solution .5% to 15%

04.2209. 82.04-17 Daily Analysis Report/ 04.2207. 75.01-1 Beam card

04.2209. 82.04-17 Daily Analysis Report/ 04.2207. 75.01-1 Beam card

(b) PicklingPickling is done in Hydrochloric acid at room temperature.

Chemical

One sample daily

IS 2629

TLT MANUFACTUTER Norms

Acid concentration 1%-15%

Iron contents 120 gm/ltr Max

(c) RinsingOnly in absence of Auto neutralization Pre Flux Solution.

Chemical

One sample daily

IS 2629

TLT MANUFACTUTER Norms

pH Value5 to 6

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation & Description of Test

Type of Check

Quantum of Check / Sampling with basis

Reference

document for

Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(d) Pre FluxingIn Zinc Chloride and Amonium Chloride solution patent fluxing reagent.

Chemical

One sample daily

IS 2629

TLT MANUFACTUTER Norms

The Specification of solution are kept as mentioned below:

3Specific Gravity

1.16 – 1.32(15 – 35 Be)

3pH Value – 4-5

3Iron Content – 0.3%max

04.2209. 82.04-17 Daily Analysis Report/ 04.2207. 75.01-1 Beam card

A J S Z - N

(e) Pre-heatingOn hot plate / dry air oven

Measurement

One checkper day

IS 2629

TLT MANUFACTUTER Norms

The Temp is kept between 500C to 1200C

04.2207. 75.01-6 Furnace Register/ 04.2207. 75.01-1 Beam card

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation & Description of Test

Type of

Check

Quantum of

Check / Sampling with

Reference

document for

Testing

Acceptance NormsFormat

of Record

Applicable Codes Remarks

1 2 3 4 5 6

3.2 DippingAfter drying is over the material is dipped in molten zinc. Following parameters are controlled

04.2207. 75.01-6 Furnace Register/ 04.2207. 75.01-1 Beam card

A J S Z - NA J S Z - N

(a) Zinc bath temperature Recording is done by graphical manner or actual verification by thermometer.

Hourly check

IS 2629

TLT MANUFACTUTER

440° to 460° C.

(b) Immersion & Withdrawal time.

IS 2629 Articles to be immersed till reaction takes place which is indicated by stoppage of bubbling, withdrawal to be controlled so that Zinc drains freely

(c) Quenching: After dipping the material is quenched in water

(d) Dichromating: One Sample daily

IS 2629

TLT MANUFACTUTER Norms

Strength of the solution to be maintained between 0.2 to 1% Sodium Dichromate to 0.5% H2SO4. Temperature of solution should be less than 65°C

04.2209. 82.04-17 Daily Analysis Report/ 04.2207. 75.01-1 Beam card

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

B. In Process Inspection

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of

Check / Sampling with

Reference

document for

Testing

Acceptance NormsFormat

of Record

Applicable Codes Remarks

1 2 3 4 5 6

3.3 Galvanizing Checking

(a) Visual Checking

Visual 100 % IS 2629 Surface to be free from defects like bare / black spots, (except when small and suitable for patching) heavy ash & flux inclusions, lumps, pimples, runs etc

04.2207. 75.01-1 Beam card

A J S Z - N

(b) Thickness of Zinc coating

Measurement

6 samples / shift

IS 4759 Minimum value or Average Coating thickness5 mm thick and over 86micronsUnder 5 mm, 65microns

04.2209. 82.04-12 Galvanizing Inspection Report

A J S Z - N

(c) Weight of Zinc coating

Measurement

4 samples / shift

IS 4759 / IS 6745

Minimum value or Average Mass of Coating (g/m2)]5 mm thick and over - 610 Under 5 mm, but not less than 2 mm - 460

04.2209. 82.04-12 Galvanizing Inspection Report

A J S Z - N

(d) Uniformity of Zinc coating

Measurement

4 samples / shift

IS 2633 Material to withstand 4 dips of one minute each without showing signs of copper deposits in CuSO4 Solution of 1.186 Sp.Gr at 18o 2oC temperature.

04.2209. 82.04-12 Galvanizing Inspection Report

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(e) Adhesion Tests of Zinc coating

Pivoted Hammer Test

4 samples / shift

IS 2629 No removal or lifting of coating in areas between hammer impressions

04.2209. 82.04-12 Galvanizing Inspection Report

A J S Z - N

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MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

C. Final Inspection & Testing

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of Check /

Sampling with basis

Reference document for

Testing

Acceptance Norms

Format of Record

Applicable Codes

Remarks

1 2 3 4 5 6

4.0 FINAL INSPECTION & TESTING(Inspection Engineer to Check/ensure compliance to notes/General Requirements given on Page (30, 31 & 32) of MQP.

A J U W/Z

- Y

(a)

MECHANICALPROPERTIES

(i) UTS Test(ii) Yield Stress Test(iii) Percentage Elongation Test

Any3 Coupons

(representative sample )

from the offer lot.

Please refer Sl No 5

under Notes in Page No 2

Please Refer Cl. No.1.1.1(a), 1.1.1(b) & 1.1.1(c), 1A.1.1(a),1A. 1.1(b),

Please Refer Cl. No.1.1.1(a), 1.1.1(b) & 1.1.1(c), 1A.1.1(a),1A. 1.1(b), 1A.1.1(c)

CIP

Please refer Cl. No. 1.1.1(d), 1A.1.1(d)

Please refer Cl. No. 1.1.1(d), 1A.1.1(d)

CIP (iv) Bend Test

(v) Min. Charpy ‘V’ notch Impact test

Please Refer Cl. No. 1.1.1(e) & 1A.1.1 (e)

Please Refer Cl. No. 1.1.1(e) & 1A.1.1 (e)

CIP

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Page 40: Sample Smqp Final-1

MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

C. Final Inspection & Testing

Sr. No.

Components/ Operation &

Description of Test

Type of Check

Quantum of

Check / Sampling with

Reference document

for Testing

Acceptance Norms

Format of

Record

Applicable Codes Remarks

1 2 3 4 5 6

(b) GALVANIZING TESTS

(i)

(ii)

(iii)

Thickness of Zinc CoatingWeight of Zinc Coating

Adhension Test of Zinc Coating

Any3 Coupons (represen

tative sample ) from the offer lot. Please refer Sl

No 5 under

Notes in Page No

2

Please refer Cl. 3.3 (b) to 3.3 (e)

CIP

Page of 42 40

Page 41: Sample Smqp Final-1

MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

(c) VISUAL & DIMENSIONAL INSPECTIONFor Fabrication (as per approved dwg.) & Galvanizing

1 sample per mark no per offered lot

Please referCl. No 2(a) to 2(j) & Cl. No. 3.3 (a)

Surface to be free from defects like bare/ black spots, (except when small and suitable for patching) heavy ash & flux inclusions, lumps, pimples, runs, sharp edges, spikes, dross etc. Surface shall be smooth so that interconnecting partswill fit properly and parts may be readily assembled.

CIP for 10 random samples per lot

Page of 42 41

Page 42: Sample Smqp Final-1

MANUFACTURING QUALITY PLANManufacturer’s Details Customer :

POWERGRID

Vendor’s Code :

Item :Galvanized Tower Structures / Parts

Q.P.No. :Rev. No. : Date :

Valid From :

Valid Upto :

Power Grid Specification --means Power Grid Technical Specification, Approved Drawing, Approved Technical data sheet and LOA provi-sions applicable for the specific contractShall ---Shall is an absolute requirement which shall be followed strictly in order to conform with the standard.Should ----Should is a recommendation. Alternative solutions having the same functionality and quality are acceptable.May --- May indicates a course of action that is permissible within the limits of the standard (permission).Can -- Can-requirements are conditional and indicate a possibility open to the user of the standard.NDT -Non Destructive Testing

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