general mqp.pdf

MANUFACTURING QUALITY PLANOF

ITEM CONTROL & RELAY PANELS UPTO 220kV SYSTEM

Sampling Plan Testing Agency Remarks

i Raw Material Inspection

I Sheet Steel CRCA IS 513

z IS 513

b 100% IS 513

c Physical properties IS 513 IS 513 Manufacturer

d Chemical Composition IS 513 IS 513 Manufacturer

II Sheet metal fabricated parts

a Dimensional check

b Visual check

III

a Dimensional check

b Visual check

c

Venson Electirc Private Limited Works : 331,9th Cross , 4th Phase, Peenya Industrial Area, Banaglore - 560 085

S.NoComponent / Operation &

description of testRef Doc &

acceptance norm

Venson / Manufacturer

Review of test record/manufacturers test certificate at the time of final inspection. (surveillance basis)

Dimensional confirmity incl. thickness

Venson Plant Std Venson / Manufacturer


Surface Finish and visual check incl.





Venson Plant Std Venson Plant std Venson Review of test record at the time of final inspection (surveillance test)

Venson Plant Std Venson Plant std Venson Review of test record at the time of final inspection (surveillance test)

Fasteners ( Nuts, Bolts & Washers )

Venson Plant StdIS 1363 / 1364/ 1367/ 2016 / 2389



Venson Plant StdIS 1363 / 1364/ 1367/ 2016 / 2389



Mechanical test (TORQUE TEST AT 70N-M)

Venson Plant Std Venson Plant Std Venson / Manufacturer








acceptance norm

IV Insulating Material

a Dimensional check IS 2036

b Visual check IS 2036

c Tensile Strength IS 2036 IS 2036 Manufacturer

d Dielectric Strength IS 2036 IS 2036 Manufacturer

V Name Plate

Dimensional check 100%

Visual check 100%

VI PVC insulated Cable

a Conductor

i Resistance Check IS 694

ii Annealing Check IS 694 IS 694 Manufacturer

iii Diameter Check IS 694 IS 694

b IS 694 IS 694 Manufacturer

c Visual check IS 694 IS 694






Venson Plant Std Venson / ManufacturerReview of test record at the time of final inspection (surveillance test)








High Voltage test at 2.5 kv for 1 min










acceptance norm

d IS 694

e IS 694 IS 694 Third Party Lab

f HV Water Immersion Test IS 694 IS 694

VII

a 100%

b IS 1248

c Calibration check 100% IS 1248

VIII

a Visual inspection 100%

b Check for healthiness 100%

VIII

a 100%

b 100%

Check for thickness of insulation & Overall dimension


Flammability test ( When required )




Measuring and other panel mounted (Instruments Voltmeter, Ammeter, Frequency Meter, Wattmeter, etc )



Operational checks including current injection test


Venson / ManufacturerReview of test record at the time of final inspection (surveillance test)

Chart Recorders (if applicable)





Control Switches Selector switches

Visual inspection incl rating and type



Check for proper fixing of inscription plates in Panel









acceptance norm

c 100%

d 100%

IX

a Visual check 100% Manufacturer

b Functional check 100% Manufacturer

i. Calibration 100% Manufacturer

ii. Accuracy and range 100% Manufacturer

100%

X HRC Fuse Link

a Visual check 100%

b Continuity test 100%

XI Space heater

a Visual check 100%

b IR value 100%

Continuity check for contact in different position ( Mechanical operation )



High Voltage test in control panel



Energy meter (if applicable) 3 ph, 3 wire

Venson Plant Std


Venson Plant Std


Venson Plant Std


Venson Plant Std


iii. High voltage test in control panel assembly





Venson Plant Std Venson / Manufacturerrecord/manufacturers test certificate at the time of final











acceptance norm

c H.V. Test 100%

d Functional test 100%

XII Rubber Gasket

a Hardness 100%

b Chemical Composition 100% Manufacturer

c Visual and dimensional 100%

d 1 x sample per batch Manufacturer

e Verification of shelf life 100% Manufacturer

f 1 per lot Manufacturer

XIII Thermostat

a Visual check 100%

b H.V. Test in panel assembly 100%

c 100%



Venson Plant Std Venson




Venson Plant Std




Fire retardant test for neoprene rubber

Venson Plant Std


Venson Plant Std


Accelerated ageing Venson Plant Std




Functional test in panel assembly








acceptance norm

XIV Terminal blocks

a Visual check 100%

b 100%

c 100%

d 100%

XV Plug socket and switch

a Visual check 100%

b 100%

c Insulation resistance 100%

XVI

a Dimensional check 100%

b 100%

XVII Push button with element 100%

a Visual check 100%

b 100%

c 100%

d 100%

XVIII Indicating lamp assembly


IR value check in panel assembly


Continuity check in panel assembly


Dielectric test in panel assembly (HV test)



High voltage test (in panel assembly)



Earth busbar



Visual check for surface defects and waviness





High voltage test in panel assembly


Continuity test in panel assembly


Operational test in panel assembly









acceptance norm

a Visual check 100%

b 100%

c 100%

XIX

a Visual check (range) 100%

b Accuracy 100%

c 100% Venson Plant Std Venson / Manufacturer

d 100%







Transducer ( if applicable)
















acceptance norm

XX

a Functional check 100%

b 100%

c 100%

d Routine test 100%

XXI Mimic strip

a 100%

b Dimensional check 100%

XXII

a 100% Manufacturer

b 100% Manufacturer

c 100% Manufacturer

Annunciators (including window)

Venson Plant standard

Venson Plant Std

Review of test record / manufacturers test certificate at the time of inspection ( Surveillance basis)



Venson Plant Std


Visual check- Rating, type, inscription and size


Venson Plant Std



Venson Plant Std


Visual check for colour and symbol


Venson Plant Std



Venson Plant Std


Semaphore indicators/hooter/bell/buzzer/test terminal block/door switch/ lamp/ fluroscent/incandescent lamp /fuse fittings

Visual check/type and rating check



Functional check in panel assembly












acceptance norm

XXIII Current operated relay

a Continuity check 100% IS 3231 / IEC 255 Manufacturer

b 100% IS 3231 / IEC 255

c Visual check 100% IS 3231 / IEC 255 Manufacturer

XXIV Voltage operated relay

a Check for healthiness 100% IS 3231 / IEC 255 Manufacturer

b 100% IS 3231 / IEC 255 Manufacturer

c Visual check 100% IS 3231 / IEC 255 Manufacturer

XXV Trip circuit supervision relay

a Functional check 100% Manufacturer

c Indication check

d HV test for 2 KV for 1 minute

e

XXV

a Pickup / Dropout test 100% IEC 255/IS 3231 Manufacturer

b HV test at 2 KV for 1 minute 100% IEC 255/IS 3231 Manufacturer

c 100% IEC 255/IS 3231 Manufacturer

d Timing check as applicable 100% IEC 255/IS 3231 Manufacturer

e Contact configuration check 100% IEC 255/IS 3231 Manufacturer

Review of test record at the time of final inspection ( Surveillance basis)


Venson Plant StdReview of test record at the time of final inspection ( Surveillance basis)








Routine tests as per IS3231 / IS8686 / IEC255

Fully assembled Aux. Relays / Latch realys



Routine tests as per IS3231 / IS8686 / IEC255










acceptance norm

f 100% IEC 255/IS 3231 Manufacturer

g 100% IEC 255/IS 3231 Manufacturer

h 100% IEC 255/IS 3231 Manufacturer

I fixing of name plate/ sticker 100% IEC 255/IS 3231 Manufacturer

XXVIII Paints

a) Paint shade IS 101/IS 5 Manufacturer

b) Viscosity IS 101 Manufacturer

Flag / indication check as applicable


Reset operation check as applicable


Adjust the required settings / resetting characteristices



1x Drum per batch%


1x Drum per batch%








acceptance norm

B IN PROCESS INSPECTION

1 Fabrication of enclosure

I Visual check Manufacturer

ii Dimensional check Manufacturer

2 100%

a 100% Manufacturer

Daily Manufacturer

-Bath temperature Every four hour 75-85 deg C Manufacturer

b 100% Manufacturer

c 100% Manufacturer

Daily 20 - 26 Manufacturer

d 100% Manufacturer

e 100% Manufacturer

Daily 2-4 pH

Bath temperature Every four hour

f) 100%

g) 100%

Daily 2-4 pH

h) Hot air drying 100%

Shearing, punching, bending marking, deburring & nibbling

1 x sample from each batch



1 x sample from each batch



Pre-treatment by 7 tank process


Degreasing for 20-25 minutesReview of lab test record at the time of inspection ( on random basis)

-Bath pointage80-100 for P20 , 50-70 for S 398

Review of lab test record at the time of inspection ( on random basis)


Water rinsing( 30-60 seconds) at ambient temperature

Degreasing Solution should be removed


De Rusting for 5 - 10 minutes at ambient temperature



- Bath pointageReview of lab test record at the time of inspection ( on random basis)

Water rinsing( 30-60 seconds) at ambient temperature

Degreasing Solution should be removed


Phosphating for 8-12 minutesVenson Plant standard


Bath pointage Venson / ManufacturerReview of lab test record at the time of inspection ( on random basis)

65-700 C Venson / Manufacturer


Water Rinsing (30 to 60 seconds) at ambient temperature



Passivation for 1 minute Venson Plant Std Venson / Manufacturer

Bath pointage Venson / ManufacturerReview of lab test record at the time of inspection ( on random basis)

Venson Plant Std Venson / ManufacturerReview of lab test record at the time of inspection ( on random basis)







acceptance norm

i) Scratch test

Scratch by blunt knife Once/lot IS 3618 should show wh

j) Visual Once/lot

3 Painting

a) Paint shade 1x Sample from batc

b) Surface finish 1x Sample from batc

c) Coating thickness 1x Sample from batc

4

i. Visual check 100%

ii. Dimensional check 100%

c)

Relay and Control panel

I ROUTINE TESTS

a) 100% IS 8623 Inspection report

b) 100% IS 8623 Inspection report

c) Verification of bill of material 100% Approved drawing Inspection report

d) 100% IS 8623 Inspection report

e) IS 8623 Inspection report

f) -

Venson / ManufacturerReview of lab test record at the time of inspection ( on random basis)



Uniform grain size and should be free from crystal growth

Venson / ManufacturerReview of lab test record at the time of inspection ( on random basis)

Venson Plant Std Venson / ManufacturerLog book and NCR in case of deviations



Structural sub-assembly and assembly including bolting

Venson Plant Std Venson / ManufacturerReview of test record at the time of inspection ( Surveillance basis)

Venson Plant Std Venson / ManufacturerReview of test record at the time of inspection ( Surveillance basis)

FINAL INSPECTION & TESTING


Visual check for basic assembly and mimic diagram/dimensional confirmity/finish and workmanship/door alignment/dust proofing/door earthing


Visual check for mounting of all equipments and terminal block marking



Verification of wiring/continuity check


Operation and scheme test for all relays,metres,annunciations etc.


Operation test (electrical control interlock & sequential operation)








acceptance norm

100% IS 8623 Inspection report




g) 100% IS 8623 Inspection report

h) IR value test (after HV test) 100% IS 8623 Inspection report

i) Approved drawing Inspection report

i. Dry film thickness check 100% Inspection report

100% Inspection report

iii. Check for shade 100% Inspection report

iv Adhesion check 100% Inspection report

for VENSON ELECTRIC PRIVATE LIMITED

i. Current injection test on all instruments/meters


ii. Annunciation sequence check


iii. Annunciation inscription detail test


iv. Check for earthing continuity between earth apparatus and earth bar by buzzer.


H.V. test between all terminal and earth



Painting (As per POWERGRID approved proceedure)



ii. Surface finish (visual check0




general mqp.pdf

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