MQAP - Long Rod Insulator
MQAP - Long Rod Insulator
MQAP - Long Rod Insulator
MANUFACTURING QUALITY PLAN -- For composite Long Rod Polymer Insulators upto 400kV and upto 160KN
Plant standard
2.1 SQP-CI-01-1, PG
Metal fittings(Socket and ball) Specification /
Approved drawings GTSL-
QA-07-02
1/lot of 1000
a Mass of Zinc coating Physical or part (600g/m2) 85 microns by
thereof Elcomter EMTR A J U W/Z Y
1/lot of 1000
b Uniformity of Zinc coating Chemical or part Min. 6 dips of I minute each
thereof EMTR A J U W/Z Y
1/lot of 1000
c Adhesion test Physical or part IS:2629
thereof EMTR A J U W/Z Y
1/lot of 1000
d Purity of Zinc used Chemical or part Not less than 99.95%
thereof IS 209 & BSPTCL.S EMTR D L V W/Z Y
2.2 Metalurgical test
2.2.1 Ball fitting (Forging) E
1/lot of 3000
a Chemical composition Chemical or part En8 BS:970
thereof TPL / CMTC D/B L/K U W/Z Y
1.Carbon 0.35-0.45%
2.Manganese 0.60-1.0%
3.Silicon 0.05-0.35%
1/lot of 3000
b Grain size Physical or part IS:4163 G.no.5-8
thereof TPL / CMTC D/B L/K U W/Z Y
1/lot of 3000
c Inclusion Rating Physical or part IS:4748
thereof Inclusion Rating no.2 TPL / CMTC D/B L/K U W/Z Y
5/lot of 5000
d MPI Visual or part IS3703 No cracks
thereof TPL / CMTC D/B L/K U W/Z Y
1/lot of 3000
2
e Yeild stress Mechanical or part 38kg/mm (Min)
thereof TPL / CMTC D/B L/K U W/Z Y
1/lot of 3000
f Tensile strength Mechanical or part 61kg/mm 2(Min)
thereof TPL / CMTC D/B L/K U W/Z Y
1/lot of 3000
g %Elongation Mechanical or part 16% (Min)
thereof TPL / CMTC D/B L/K U W/Z Y
1/lot of 3000
h Hardness Physical or part 175 - 210 BHN
thereof TPL / CMTC D/B L/K U W/Z Y
2.2.2 Socket fitting (Casting) E
a Chemical composition Chemical 1/heat SGCI Grade 500/7
IS:1865 TPL / CMTC D/B L/K U W/Z Y
1.Carbon 3.55-3.75%
2.Manganese 0.40% (max)
3.Silicon 2.60-3.00%
BIHAR STATE POWER TRANSMISSION COMPANY LIMITED
MANUFACTURING QUALITY PLAN -- For composite Long Rod Polymer Insulators upto 400kV and upto 160KN
a. 1. Visual Examination Physical 100% IS: 3063 Confirms to IS:3063 EMTR A J U W/Z Y
2.Dimensional verification Physical 1% of the lot IS: 2486 Pt. IV Within limits given in
IS:2486 Pt.IV EMTR A J U W/Z Y
1 Sample at
3.Hardness test Physical random IS: 2486 Pt. IV Not less than 152BHN EMTR A J U W/Z Y
1 sample at
4.Operational test Physical random IS: 2486 Pt. IV As per IS:2486 Pt.IV EMTR A J U W/Z Y
1 Sample at
5.Resistance to bending test Physical random IS: 2486 Pt. IV Dimensions as per
IS:2486 Pt.IV EMTR A J U W/Z Y
b. Chemical composition Chemical 1/heat S.S-304
TPL / CMTC D/B L/K U W/Z Y
1.Carbon 0.08% Max
2.Silicone 1.00% Max
3.Manganese 2.00% Max
4.Phosphorous 0.04% Max
5.Sulphur 0.01% Max
6.Nickel 8.00-10.00%
7.Chromium 18.00-20.00%
Section: 3 ECR fibre glass reinforced epoxy resin core rod inspection
Manufacture
r's
3.1 Boron content of Fribre Glass Chemical sampling Manufacturer's test Boran free
plan standard CMTC B K U W/Z Y
3.2 Visual inspection Physical 100% Transperent,uniform incolor.
Be free from cracks,flaws
air holes,foreign substance
defects and air holes. EMTR A J U W/Z Y
2%/lot of
3.3 Diameter tolerance, mm Physical 500 or part 24.00-24.10
there after EMTR A J U W/Z Y
BSPTCL specification/
2%/lot of Approved drawing
3.4 Length tolerance, mm Physical 500 or part 0-+5
there after EMTR A J U W/Z Y
5 specimens
per lot of
3.5 Dye penetration test, min Physical 500 or part IEC 61109 Cl 5.4.1
thereof EMTR A J U W/Z Y
3 specimens
per lot of
3.6 Water diffusion test(12kV) Electrical 500 or part BSPTCL specification/ IEC 61109 Cl 5.4.2
power frequency withstand Physical thereof Approved drawing Leakage current <=1 mA
voltage test No external flashover,no
puncture occur EMTR A J U W/Z Y
Section: 4 Grading Ring E
4.1 Visual inspection
1/lot of 500
Chemical Composition Chemical or part IS:1865
thereof Grade:500/7 TPL D L U W/Z Y
B) Clamp for Grading ring (Cast Steel)
1.Carbon 3.55-3.75%
2.Manganese 0.40% (max)
3.Silicone 2.60-3.00%
4.Phosphorous 0.035%max
5.Sulphur 0.02%max
6.Magnesium 0.045-0.055%
2 % /lot of
4.3 Dimensions(Ring & Clamp for Physical 500 or part Conformance to drawings
Grading ring) thereof A J U W/Z Y
4.4 Clamp Galvanising
5/lot of 1000
1. Mass of Zinc coating Physical or part (600 g/m 2) 85 microns by
thereof Elcometer EMTC A J U W/Z Y
3/lot of 1000
2. Uniformity of Zinc coating Chemical or part Min 6 dips of 1 minute each
thereof EMTC A J U W/Z Y
1/lot of 1000
3.Adhesion test Physical or part IS:2629
thereof EMTC A J U W/Z Y
BSPTCL specification/
Modification of silicon rubber Physical Approved drawing
Once/day QC-Working & Check Records
5.1 compound
c Curing time(set value) 1 time/shift 640 to 660 Sec 640 to 660 Sec A J S W N
BIHAR STATE POWER TRANSMISSION COMPANY LIMITED
MANUFACTURING QUALITY PLAN -- For composite Long Rod Polymer Insulators upto 400kV and upto 160KN
5.6 10%
Semi-finished products inspection Standard quality plan Standard quality plan Check sheet PS-CI-05/1
Doc.No:QP-CI-02 Doc.No:QP-CI-02 A J S W N
a Visual inspection Physical 10% Clause 8.2 IEC 61109 / Clause 8.2 IEC 61109 /
The thickness of sheath Approved drawing Approved drawing A J S W N
EMTR A J S W/Z N
IEC61109 Cl 8.3(To
c Load test Mechanical 100% IEC61109 Cl 8.3 withstand
Mechanical routine test 50% of SML for 10s.)
EMTC A J U W/Z Y
IEC61109 Cl
c Verification of the specified Mechanical 7.1 IEC61109 IEC61109 Cl 7.4
mechanical load Cl 7.4
EMTC A J U W/Z Y
IEC61109 Cl
d Physical 7.1 IEC60383. BSPTCL IEC61109 cl 7.3
Verification of the locking system Approved drawing/
Specification
On 2 BSPTCL specification/ EMTC A J U W/Z Y
samples Approved drawing
from one
insulator of
each rating
e Recovery of hydrophobicity Electrical BSPTCL specification.
per offered Clause 2.2 Annexure-A
lot
7.2 Marking destination details as per Visual 100% BSPTCL specification/ BSPTCL specification/ EM Rcord A J S W N
BSPTCL norms Approved drawing Approved drawing
7.3 Verifivation of Dispatch Verification 100% Dispatch Clearance/ Dispatch Clearance/ EM Rcord A J S W N
Clearance/ Instructions/PACKING Instructions Instructions
LIST
BIHAR STATE POWER TRANSMISSION COMPANY LIMITED
MANUFACTURING QUALITY PLAN -- For composite Long Rod Polymer Insulators upto 400kV and upto 160KN
Manufacturing Quality plan -- For composite Long Rod Polymer Insulators upto 400kV and upto 160KN
Customer Vendor code ITEM
Manufacturer Name and Address Composite long rod insulator M.Q.P No - 32
BSPTCL (160kN and/or 120kN) Rev. 00
applicable for 400kV System Valid From- 15.01.2016
Dispatch Clearance/
F. Not specified Instructions
Code 3: Indicate who shall witness the test i.e Witnessing Code 4: Review of Test Reports / Certificates
Agency
E. Envisaged Y. Yes
N. Not Envisaged N. No
BIHAR STATE POWER TRANSMISSION COMPANY LIMITED
MANUFACTURING QUALITY PLAN -- For composite Long Rod Polymer Insulators upto 400kV and upto 160KN
PROCESS FLOW CHART FOR- Composite Long Rod Polymer Insulators upto 400kV and upto 160KN
CIP
CUTTING TO REQUIRED
LENGTH
PRESET INJECTION AND
PARAMETERS CURING
TESTING
MOULD OPENING
TAKEN FOR
PRODUCTION
TAKEN FOR
PRODUCTION
EXTRACT THE
COMPONENT FROM THE
MOULD
FLASH CLEANING
CRIMPING OF
END FITTINGS
ROUTINE
TESTING
INSPECTION
AND DESPATCH
BIHAR STATE POWER TRANSMISSION COMPANY LIMITED
MANUFACTURING QUALITY PLAN -- For composite Long Rod Polymer Insulators upto 400kV and upto 160KN
21. DESIGN AND TYPE TEST: ALL DESIGN AND TYPE TEST TO BE CARRIED OUT AS PER BSPTCL SPECIFICATION AND AS PER AGREEMENT WITH BSPTCL . APPROVAL OF
DESIGN AND TYPE TEST BY BSPTCL OR WAIVAL THEREOF TO BE SHOWN AT THE FINAL INSPECTION TO ENABLE ISSUE OF Dispatch Clearance/ Instructions