KEC INTERNA TIONAL L TD.

, JABA LPUR

,SECTION

QPM/QA/20

REV NCl,

OJ

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

r------,, 1~'P.7,-.-~rH.I
i.

1 ~~;(~;~~~;'.~
I,

STEEL
&.

I
I
I

1.1.

SHWCH}RAL PLATES)

(ANGLE SECTiONS

Steef as per IS 2062 to b:-::: procured from main l.e. SAIL,

Tiseo,
RoBers

Hsee),
or Remain 1

producers and CESC approved sources. For l re-rollers specific approval ofCESC is to be ensured if required as per contract for Direct Purchase.

i.i.r

PHYSICAL PROPERTIES Test for ultimate Tensile Strength .

(a)

lone

sample for 50 1\1T or I!S 2067 Grade ' QA, s r,)."', .,In',;;/f', (KEC) part thereof as per IS -,".-'Pu D. n." ' 2062 E350

I ;'2 ""-',~_ ~
is E350

Verification of ManuTest , Certif-icates.

i facturers

(b

1-

Test tor Yield Stress

(c)

I Test
I Bend T C;t

One for 50 r<l1'T or part thereof as pe~ ~S

2062

Grade

~~.!.Pi

Verification of r,,1anufacturers Test

Certif-icates.

(KEC:) lS 2062 Grade E250A/BRlBO EJ50

2062

Verification of Manu .. facturers Test Certif-icates,

2062

( d)

2062

350 Pieces at room temp. shall withstand

bending through 1800

To an internal dia not greater for Dia ~25 mm ".21 for Dia > 25mm-3t , with both side

_~__J

c
L

KEC INTERNATIONAL

L TD.,JABALPUR

SECTlON

QPM/QAl20

REV,NO.

01

rSI-:Nc;,-,

Comp{;;~ntlOperati;n

and rSampling 1

P!a~~~ith

ba;T~

Remarks

~_J~ __ ?~~~~!i~n_of Test

J_~__ a~ce~tancenorms
cracking.

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

1.1.2

CHEMICAL COMPOSITION

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

IS 2062

Main Produc-

Verification of Manufacturers Test

ers
Worksl QA (KEC)I Thi-rd Party Independent Lab. RY (KEC)

Certif-icates.

1.1.3

VISUAL CHECKS SURFACE FINISH

FOR

IS 2500 - Level - II AQL -1.5 as per table - 1

i be

IS 2062 Material to free from surface!

fOU- I'

Record Review (Rem-

enclosed.

: flaws.lamination,

oval of minor surface defects as per is 2062

012t!5e-7

gh ! Jagged Edge and imp-erfect edges, cracks, rounded apex, deep roll marks, pipy and any harmful defects. 1.1.4 DIMENSIONAL CHECKS INCLUDING ROOT Rl\DIUS TOLERANCE FOR LEG LENGTH OF ANGLES ;
!

Same as 1.1.3.

IS 808

RY (KEC)

Record Review

1.15

Same as I. j .3

- IS 1852

RY (KEC)

Record Review

(a)

EQUAL ANGLES Upto 45 mm Leg Length Same as 1.1.3 ..1.5mm

RY
(KEC)

Record Review

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

KEC INTERNATIONAL L TD.,JABALPUR

PLAN

SECTION

QPM/QAl20 01

REV. NO.

(ir)

>

45 to 100 lnm! Length

RY (KEC)

RecordReview

(iii)

>

100 rnm Leg Length

Same as 1.1.3

2.0 % of Leg Length Difference between the leg length equal angles shall be limited to 75% of total tolerance (plus & minus) specified

RY

Record Review

(KEC)

of

on the leg length.

(b) lJNEQUAL ANGLES Short Leg Length Long Leg Length : Same as 1.L3

1.5 mm

RY (KEC)

Record Review

+ 2.0mm/-L5mm

1.1.6

OUTOFSQUARENBSS

Sameas1.L3

IS 1852,

1
1.1.7 (i) CAMBER For flange less

RY (KEC)

Record Review

than

Same as 1.1.3

lOOmm

IS 1852, Max 0.02% of length.

RY
(KEC)

Record Review

(ii)

For flange 100 mm and above

Same as 1.1.3

Max. 0.2% of length

RY
(KEC)

Record Review

1.1.8

Weight Tolerance Angle Sections

for

One sample tor 20 MT

Per section or part thereof

- Uoto Irnm i
U~ .. tLU

1852. IS 808 .r, "" "i,?/ -- thick It.... ..!() > 3 mm thick +5%,-3% over weights specified in IS 808.

IS

QA (KEC)

Record Review

QA (KEC)

Record Review

Ire
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TITLE: 1.1.10 Thickness Plates

KEC INTERNA TlONAL L TD.,JABALPUR

SECTION REV. NO.

QPM{QN20

01 13.08.2010 Page 4

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

of 22

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms

Remarks

Tolerance

tor

Same as 1.1.3

IS 2062, IS 8500 IS 1730, IS 1852. < 8 mm thick + 12.5 %,- 5.0 % 8 mmto 12 mm + 7.5 %, - 5.0 % Over 12 mm 5.0 %

RY (KEC)

Record Review

1.2

ZINC (To be procured from HZL or Imported ) CHEMICAL COMPOSITION One sample for 50 MT or as per CESC's specification which ever is less. One sample every month from Bath. IS 209 - 99.95 %,

1.2.1

KECI
Third party Independent Lab.

Verification of Manufacturers Test Certif-

icates.

IS 209 - 98.50 %

I.3

LEAD (To be procured from HZL or Imported)

1.3.1

CHEMICAL COMPOSITION

One sample for 100 MT

IS 3717 Grade: As per P.O.

IA

RAW MATERIALS (IMPORTED) STRUCTURAL PHYSICAL PROPERTIES Test for Ultimate Tensile Strength One sample for 20 MT per section per lot or part thereof , one sample for 40MT/sec/cast/or part there of as per BSEN BSEN 10025 STEEL

KECITh ird party Independent Lab.

Verification of Manufacturers Test Certificates.

IA.l IA.1.
1 (a)

QA (KEC)

Verification icates.

of Manu-

facturers Test Certif-

10025

I[e
I
TITLE:

KEC INTERNA TlOHAL L TD.,JABALPUR

SECTION REV.NO.

QPM/QAf20

01
13.08.2010

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE

SHEET NO.

Page'S of22

MANUFACTURING

ComponentlOperation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms

Remarks

(b)

Test for Yield Stress

One sample for 50 MT or part thereof as per JIS G 3101 One sample for 40 MT or part thereof as per DIN 17100 / ASTM - A36 I A572 One sample tor 20 MT. per section per lot or part thereof , one sample for 40MT/seclcastlor part there of as per BSEN 10025 One sample for 50 MT or part thereof as per JIS G 3101 One sample for 40 MT or part thereof as per DIN
17100 I ASTM - A 361 A

JIS G 3]01

DIN 17100 ASTM- A361 A36M

A572/A572M-Gr.50

BSEN 10025

QA

(KEC)

Verification of Manufacturers Test Certificates.

JIS G 3101

DIN J 7 100 __ ASTM - A36/A36M

A 572fA572M

572 (c) Percentage Elongation Test

One sample for 20 MT per section per lot or part thereof , one sample for 40MT/seclcastlor part there of as per BSEN 10025

BSEN J 0025

QA

(KEC)

Verification of Manufacturers Test Certificates.

(d)

Bend Test

One sample for SOMT or JIS G 3101 part thereof as perJIS G 3101 One sample for 40 MT or DIN 17100 part thereof as per DIN ASTM - A36/A36M 17100 I ASTM -A 36 / A A.572/A572M 572 One sampJe for 20 MT or Not required for steel part thereof as per DIN as per BSEN 10025 17100 DIN 11100 Bend Test 180"

QA

(KEC)

Verification of Manufacturers Test Certificates.

One sample for 40 MT or

\\

APPROVED~.

STAMP HERE

Ire
I
TITLE:

KEC INTERNA nOHAL

L TD.,JABALPUR

SBCTlON

QPMIQAI~()

REV. NO.

01
13.08.2010 Page 6 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms

Remarks

part thereof as per ASTM and KEC Specification. ASTM-A6/6M Grade A36/A36M Bend Test - 1800 Grade A572/A572M Bend Test - 1800 NOTE: For Acceptance Norms refer Table -2 for Chemical Properties and Table -3 for Mechanical Properties.
-,-_.

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

JIS G 3101 Sample shall withstand bending through 180 to an internal dia. Not> 2t with both sides parallel with out cracking.
0

(e)

Minimum Charpy 'V' Notch Impact Test For BSEN t 0025 Grade S 355 10

IAJ. 2

CHEMICAL COMPOSITION

One. sample for 20 MT per section per lot or part thereof , one sample for 40MT/sec/cast/or part there of as per BSEN 10025 One sample for 40 MT or part thereof as per BSEN 100251 JIS G 31011 DIN 171001 ASTM-A36! A572.

BSEN 10025 for acceptable norms, please refer Table 3, enclosed.

BSEN 10025 JIS G 3101 ! DIN 17100/ ASTM -AJ.6 I A572.

KECITh ird party Independent Lab. QA / Third Party Lab./ Manufacturer T.C.

Verification of Manufacturers Test Certificates.

Verification of Manufacturers Test Certificates.

IA.1. 3

VISUAL CHECKS

IS 2500 LEVEL - II, AQL - 1.5 as per Table1 enclosed.

BSEN 10025 / lIS G 31011 ASTM A6 / DIN 17100

RY (KEC)

Record Review.

IA.I. 4

DIMENSIONAL CHECKS (Including Root Radius)

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

BSEN 10056-1 , JIS G 3101/ ASTM A6 / DIN 1028 &1029

RY (KEC)

Record Review.

IA.1.

TOLERANCES

FOR

IS 2500 LEVEL - II,

BS 10056-2

RY II I'

Record Review

APPROVED~<D;

~/

.,:.~

STAMP HERE

Ire
I
TITLE: 5 LEG LENGTH

KEC IHTERHA TlOHAL L TD.,JABALPUR

SECTION

QPM/OAl20

REV.NO.

01 13.08.2010 Page 7 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms Leg Length up to "50mm, Imm > 50 to::: 100 mm +1-2 mm > 100 to::: 150 mm +/-3 mm > ISO mm to 200mm (KEC)

Remarks

AQL - 1.5 as per Table I enclosed.

+1-4mm
JISG3192 Leg Length <50mm 1.5 mm 50 to < 100 mm 2mm 100 to < 200 mm 3mm 200 mm and more 4mm ASTM-A6 Leg Length up to 50mm lmm RY (KEC) Record Review

RY (KEC)

Record Review

>/= 50 mmto </=75 mm 2mm >75

mm

to < 100

mm

+ 31-2 mm
>/= 100 mm to </= 150 mm 3mm
f\

..APPROVED ~

'i~tDEORI ~}j
~

((If ~~

,~

&
IO':~\.
STAMP HERE
h"

...

I~I~Y

3(~~

Ire
I
TITLE: IA.1.

KEC INTERNA TlONAL L TD.,JABALPUR

SECTION

QPM/QN20

REV.NO.

01
13.08.2010

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE

SHEET NO.

Page 8 of 22

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms Over 150 mm + 5/-3 mm

Remarks

OUT OF SQUARENESS

IS 2500 LEVEL - n, AQL - 1.5 as per Table1 enclosed.

BSEN 10056-21 1ISG3192 J[S G 3192 Up to 2.5% of flange ASTM-A6 + 1'.1,,0 BSEN 10056-2 Leg Length '::;100 "'Imm Above 100 up to 150 I.5mm > 150 upto 200 mm 2mm

RY (KEC)

Record Review

Record Review

lA.l. 7

CAMBER

IS. 2500 LEVEL -II, AQL - 1.5 as per Table1 enclosed.

BSEN 10056 -2/ J[S G 3[92 BSEN 10056-2 Leg Length < 150 mm 0.4% of Length
>150 to ':::;200 - 0.2%

RY (KEC)

Record Review

> 200 mm

of Length - 0.1% of Length

JISG 3192 0.3% of Length ASTM-A6 Leg Length <75mm - 0.4% of Length >/=75 mm - 0.2% of Length

APPROV ,~..4::." ., . ~ ~ ...,.

b r~~,
.~. ,DeOR
..

STAMP HERE

I~~~

/',e./ ,{";/
~{-

.~~) ~ \

,(Cl"~

S}

Ire
I
TITLE: IA.1. 8

KEC INTERNA TIONAL L TD.,JABALPUR

SECTION REV.NO.

QPM/QAl20

01 13.08.2010 Page 9 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms

Remarks

WEIGHT TOLERANCE FOR ANGLE SECTIONS

One sample for 20 MT per lot or part there of.

BSEN 10056-2! JIS G 3101 ! JIS G 3192 BS 10056-2

QA (KEC)

Record Review

::;:4 mmthick
6% >4 mmthick +/- 4.0% JIS G 3192 < 10 mmthick - 5% 10 mm thick & above 4% ASTM- A6 - 2.5%

lA.I. 9

THICKNESS TOLERANCE FOR ANGLE SECTIONS

IS 2500 LEVEL - II, AQL - 1.5 as per Table1 enclosed.

BSEN 10056-2 / JIS

G 3192IJIS G 3101
BSEN 10056-2 .::; 5 mm thick - O.5 mm > 5 to.::; 10 mm 0.75 mm

RY
(KEC) Record Review

> 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

lEe
I TITLE:

KEC INTERNA TlONAL L TD.,JABALPUR

SECTION

QPM/QN20

REV.NO.

D}
13.08.2010 Page 10 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms. > 10mmthick- O.4mm JIS G 3192 For Leg Length up to 130mm < 6.3 mm thick O.6mm :::6.3 to < 10 mm 0.7mm ::: 10 to < 16mm O.8mm

Remarks

~ 16mm -

1.0nim

For Leg Length more than 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 INSPECTION FABRICATION OF TOWER PARTS Straightening

IS 802 PartII IS 1215 & Approved DrawingS/Shop Sketches 100%

(KEC)

RY
(KEC)

Ire
I
TITLE: 2.0 (a) Stamping

KEC INTERNA nONAL

L TD.,JABALPUR

SECTION REV.NO.

QPM/QAJ20 01 13.08.2010 Page 11 of22

MANUFACTURING QUALITY PLAN

CUSTOMERCESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms

Remarks

Cropping (Cutting)

Ist piece and subsequently any piece before soth and soon.

Length tolerance 2 mm. The cut surface to be clean, reasonable square & free from distortion. Letter Size 8x16 mm or 8xl4

FAB (KEC)

Record Review

Same as 2.0 (b)

mm

FAB (KEC) FAR (KEC)

Record Review

(b)

Punching/Drilling

Same as 2.0 ( b )

Punching to be clone for the thickness up to 12 mm. Drilling to be done for thickness more than 12mm. Holes near bend to be Punched I Drilled after bending. Hole should be perpendicular to surface & difference in dia on both sides of "flange should not be more than 0.8 mm

Record Review

FAB (KEC TL) FAB (KEC)

Record Review

(c)

Edge Security (i) For 13.5 mm dia hole

Same as 2.0 ( b )

Sheared 20 mm Min. . Rolled 16 mm Min.

Record Review

(ii) For 17.5 mm dia hole

Sheared 23 mm Min. Rolled 20 mm Min. Sheared 28 mm Min. Rolled 25 mm Min. Sheared 38 mm Min. Rolled 33 mm Min. Same as 2.0 ( b ) Tolerance cumulative and between conceeutive hole shall be within 2 mm and 1 mm respectively. '. FAB (KEC)

Record Review

(Hi) For 21.5 mm dia hole

(iv) For 2S/2S.Smm dia hole (d) Drilling & Punching Hole to Hole Distance

Record Review

\'

APPROVED BY.-'l"':

"....."

STAMP HERE

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I
TITLE: (e) (f) Notching, Flange Cut, Comer Cut, Bevel Cut

KEC INTERNA TIONAL L TO.,JA BAL PUR

SECTION REV.NO.

QPMJQA/20 01
13.08.2010 Page 12 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test Gauge Distance ( Back Mark)

Sampling Plan with basis

Reference Document & acceptance norms :!:Imm FAB (KEC)

Remarks

Same as 2.0 ( b )

Record Review

Same as 2.0 ( b )

+ 5 mm on specified length of cut operation by Shearing upto 12 mm thick, and by gas cutting for material above 12mm thick After grinding the thickness on heel should be equal or more than the thickness of the member with + 2 mm and -0 mm tolerance. -IS 802 Part II IS 1215, Drawing All sections and all angles to be hot bend Process Cold Bend: Upto 75x6 - upto 10 ,Upto 100x8 - upto 5 All other angle sections and bend angle shall be hot bend.

.FAB (KEC)

Record Review

(g)

Heel Grinding

Same as 2.0 ( b )

FAB (KEC)

Record Review

(h)

Bending

100% Pieces

FAB (KEC)

Record Review

(i)

HT Section/Plates

(ii)

MS Sections

(Hi) MS Plates

Cold Bend - upto 12 mm thick (MS) upto 15 angle. Greater bend & other thickness shall be hot bend.

( i)

Welding

Same as 2.0 ( b )

per KEC As Approved Welding Procedure & Welding Qualification.

FAB (KEC)

Record Review

APPROVED

k~'
BY/?!;;'~,
v;:.y
,
STAMP HERE

1 i\

~
155U ~y

'''''

Ire
I
TITLE:. (j) (k)

KEC INTERNA TlONAL L TD.,JABALPUR

SECTION REV.NO.

OPM/OAl20 01 13.08.2010 Page 13 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test Final Inspection Fabricated Parts of

Sampling Plan with basis

Reference Document

Remarks

& acceptance norms

As per Sampling Plan QPM/QAl26 All parameters froin (a) to (k) above are checked and records maintained before releasing the materials for galvanizing. KEC Approved Structural Drawings, Bill of Materials, Tower to be assembled and checked for dimensions, angle, size. By this, to verify interchange ability of members, etc. QA (KEC TL) Record Review

Proto (Model Assembly as per requirement of the CESC)

One structure of each type

R&D (KEC)

Record Review

Record Review

Record Review

Record Review 3. 3.1 (a) GALVANIZING PROCESS Degreasing solution CONTROL in DEOIL One sample daily Pointage of 10% solution 9 3 ML Temperature degreaser - Room to 60 of QA (KEC) Record Review

(b)

Pickling (i) Acid Content One sample daily IS 2629 50 - 210 GmsILtr. IS 2629 120 GmslLtr.Max. 12 to 30 Beaume QA (KEC) Record Review

(ii)

Iron Content

Om: sample daily

(Hi) Density

One sample daily

(c)

Rinsing

One sample daily

IS 2629 PH value to be betw-

QA (KEC)
f\

Record Review

APPROVED B~NAT~

STAMP HERE

In:c
I
TITLE: (d) (i) (ii)

KEC INTERNA TlOHAL LTD.,JABALPUR

SECTlON

QPM/QA/20

REV. NO.

01
13.08.2010 Page 14 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
QUALITY PLAN

REV. DATE SHEET NO.

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document & acceptance norms een 5 and 6

Remarks

Pre-Fluxing in ZnCl2 and NH4CI Solution

One sample daily

IS 2629
~.

QA (KEC)

Record Review

Iron content Density in Be

50 Gm/Ltr. Max. 36 to 44 Beo 2 to 3 Room to One sample daily

(Hi) Ph Value (iv) Temperature (e) Stripping

se-e
QA (KEC) Record Review

Density in Beo Iron Content

(f)

17 to 45 Beaume 25 GmslLtr. Max. Once in a day IS 2629 120C to 150C -Hot Chamber Temp. (2300 to 3300 C) QA (KEC) Record Review

Pre-heating

3.2 (a)

DIPPING (GALV.)
bath Zinc temperature continuous recording by graph or manual. Hourly recording verifiand cation by Temperature Meter. Immersion time withdrawal time and Once in a day. IS 2629 4400 e to 4750 e - Galvanizing Workjug Temperature ( 4450 to 4650 C ) QA
(KEC)

Record Review

(b)

IS 2629 Article to be immersed till reaction takes place which is indio-

GP (KEC)

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TITLE:
(c)

KEC INTERNA TlONAL L TD.,JABALPUR

SECTION REV. NO.

QI'M/QAl20 01
l3.08.2010 Page 15 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC

REV. DATE SHEET NO.

MANUFACTURING QUALITY PLAN

Component/Operation and Description of Test Sampling Plan with basis Reference Document Remarks

& acceptance norms

ated by stoppage of bubbling withdrawal to be controlled, so that zinc drains freely.

Quenching and Dichromating in running water .lDeoxident

Once daily.

IS 2629 Strength of solutions to be maintained Between 0.2% to 1% Sodium Dichromate. Or as per supplier recommendation

QA (KEC)

Visual Check colour matching.

by

3.3

GALVANIZING CHECKING Visual Checking 100 % IS 2629 Surface to be free from defects like bare 1 black spots (except when and small suitable for patching) heavy ash & flux lumps, inclusion, pimples, runs, etc. GP (KEC) Record Review

(a)

( b)

Thickness ing

of Zinc Coat-

Eight Samples per Shift IS 2629 / IS47591 BS729 Material <5mm thick min 65 Microns

KEC (QA)

Record Review

average.
Smm thick & above min 86 Microns average ASTM A 123 ; ::s3.2mm- 65 Microns (Average) >3.2 to 6.4 mm - 85 Microns (Average): >6.4 mm-IOO Microns (Average) IS 2629 !IS 4759 ! IS 6745 !BS 729

(c)

Weight of Zinc Coating

Three Samples per Shift

QA (KEC)

Record Review

"
~.

~~
STAMP HERE

APPROVEDB~~~~