KWALITY CABLE INDIA

MANUFACTURER QUALITY PLAN

Component / Method of Check / Requirement / Internal Acceptances
Characteristics Tests Sample Plan
Process Test Equipment Ref. Doc (If any) Norms
I. RAW MATERIALS – PVC/XLPE WIRES/CABLES
A. CONDUCTOR 1). Diameter Vernier / Micrometer 10% IEC 60228, IS 8130 IEC 60228, IS 8130
(COPPER /
ALUMINIUM) 2). Tensile Test (for Aluminium) Tensile Test Machine 10% IS 8130 IS 8130
3). Wrapping Test (for Aluminium) Wrapping Test Machine 10% IS 8130 IS 8130
The Conductor Should
4). Surface Finish Visual 10% be smooth Confirms to the Requirement

5). Annealing Test (for Copper) Tensile Test Machine 10% IS 8130 IS 8130
6). Conductor Resistance at 20ºC Digital Micro Ohm Meter 10% IEC 60228, IS 8130 IEC 60228, IS 8130
7). Visual Check Visual 10% Bright Color, No Dents Confirms to the Requirement

8). Physical & Chemical Properties Review M.T.C 100% IS 8130 IS 8130
B. INSULATION / By Weight on Weighting As Per Manufacturer As Per Manufacturer
1). Specific Gravity Machine One Sample Per Lot Specification Specification
SHEATH
COMPOUND 2). Tensile Strength and Elongation
Review M.T.C 100% IS 5831 IS 5831
(PVC / XLPE) (Before and After Ageing)
3). Loss of Mass Review M.T.C 100% IS 5831 IS 5831
4). Thermal Stability Thermal Stability Oven One Sample Per Lot IS 5831 IS 5831
C. ARMOUR (G.I. 1). Physical Dimensions Vernier / Micrometer 10% IS 3975 IS 3975
WIRE / STRIP /
TAPE) 2). Tensile Strength Tensile Test Machine 10% IS 3975 IS 3975
3). Elongation at Break Tensile Test Machine 10% IS 3975 IS 3975
4). Winding Test Tensile Test Machine 10% IS 3975 IS 3975
5). Galvanization Test (Mass of Zinc
Chemical 10% IS 3975 IS 3975
Coating)
6). Resistivity Test Electrical 10% IS 3975 IS 3975
7). Torsion Test of Armour Torsion Test Machine 100% IS 3975 IS 3975
8). Visual Check Visual 10% IS 3975 IS 3975
II. INPROCESS (SEMI FINISHED WIRES / CABLES) INSPECTION
A. BUNCHING / Measurements at the
1). No of Wires / Strands Self Device start of each job IS 8130 IS 8130
STRANDING
Measurements at the
2). Diameter of Wires / Strands Vernier / Micrometer start of each job IEC 60228, IS 8130 IEC 60228, IS 8130
Measurements at the
3). Direction of Lay Visual As Per Requirement Conforms to the Requirement
start of each job
4). Lay Length Meter Scale Two Samples Per Lot As Per Requirement Conforms to the Requirement
Measurement at the
5). Overall Dimensions Vernier / Micrometer IS 8130 IS 8130
start of each job
Measurement at the
6). Conductor Resistance Digital Micro Ohm Meter start of each job IS 8130 IS 8130
B. CORE Visual Check of Grade Once when the new bag
1). Type of Compound Used is opened for use As Per Requirement Conforms to the Requirement
EXTRUSION
Each Setting & Twice
2). Thickness of Insulation Vernier Calliper IEC 60502-1, IS 1554-1 IEC 60502-1, IS 1554-1
in a Shift
Each Setting & Twice
3). Core Identification Visual IEC 60502-1, IS 1554-1 IEC 60502-1, IS 1554-1
in a Shift
4). Void Test Visual 5% As Per Plants Std. No Voids
5). Spark Test (On Line) On Line Spark Tester 100% IS 1554-1 IS 1554-1
Each Setting & Twice
6). Diameter Check Vernier Calliper in a Shift IS 1554-1 IS 1554-1
Start and end of each
Should be Smooth and Should be Smooth and free
7). Surface Finish Visual Setting & Twice during the
Processing for that Setting free from porosity from porosity
Conductor Should Conductor Should Show
8). Continuity of Conductor Continuity Tester 100%
Show Continuity Continuity
C. TESTS ON Random Check for
1). Thickness of Insulation Vernier Calliper each Size and Color IS 1554-1 IS 1554-1
CORES IN
LABORATORY One for each Size and
2). Concentricity of PVC / XLPE Vernier Calliper IS 1554-1 IS 1554-1
Color (if changes)
3). Tensile Strength and Elongation Tensile Test Machine -Do- IS 1554-1 IS 1554-1
4). Insulation Resistance & Volume One for each Size and
Insulation Tester IS 1554-1 IS 1554-1
Resistivity Color (if changes)

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D. PRINTING /
Visual Check Visual 100% IS 1554-1 IS 1554-1
EMBOSSING
E. LAYING UP 1). Number / Sequence of Cores Visual Each Setting IS 1554-1 IS 1554-1
2). Identification of Cores Visual Each Setting IS 1554-1 IS 1554-1
3). Lay Direction Visual Each Setting IS 1554-1 IS 1554-1
4). Lay Length Meter Scale Each Setting As Per Requirement Conforms to the Requirement
Conductor Should Conductor Should Show
5). Continuity of Conductors Continuity Tester 100%
Show Continuity Continuity
F. INNER Visual Check of Grade
1). Type of PVC Random As Per Requirement Conforms to the Requirement
SHEATH Used
2). Thickness of Inner Sheath Vernier / Micrometer Each Setting IS 1554-1 IS 1554-1
3). Color of Inner Sheath Visual Check of each Size IS 1554-1 IS 1554-1
Conductor Should Conductor Should Show
4). Continuity Test Continuity Tester 100%
Show Continuity Continuity
5). Surface Finish Visual 100% Smooth Surface Smooth Surface
G. ARMOURING 1). Material Visual Check of Material Random Check IS 1554-1 IS 1554-1
2). No. of Wires / Flat Strip / Tape Visual At the Start of each drum IS 1554-1 IS 1554-1
3). Lay Direction Visual Each Setting IS 1554-1 IS 1554-1
4). Dimensions of Wires/Strip/Tape Vernier Calliper At the Start of each Drum IS 1554-1 IS 1554-1
5). Lay Length Meter Scale Each Setting As Per Requirement Conforms to the Requirement
6). High Voltage Test High Voltage Tester 100% IS 1554-1 IS 1554-1
Armour Should Show Armour Should Show
7). Continuity Test Continuity Tester 100%
Continuity Continuity
H. OUTER 1). Type of Material Visual Check of Grade Random As Per Requirement Conforms to the Requirement
SHEATH
EXTRUSION 2). Thickness of Outer Sheath Vernier / Micrometer Each Setting IS 1554-1 IS 1554-1
3). Overall Diameter Vernier Calliper Each Setting IS 1554-1 IS 1554-1
4). Color of Sheath Visual Check on each Drum IS 1554-1 IS 1554-1
5). Embossing / Sequential Marking Visual Check on each Drum IS 1554-1 IS 1554-1
6). Cable Length Visual Check on each Drum As Per Requirement Conforms to the Requirement
7). Surface Quality Visual Check on each Drum Smooth Surface Smooth Surface
Conductor Should Conductor Should Show
8). Continuity Test Continuity Tester 100%
Show Continuity Continuity
9). High Voltage Test High Voltage Tester 100% IS 1554-1 IS 1554-1
I. DRUM 1). Marking on Drum Visual 100% IS 1554-1 IS 1554-1
2). Checking of Length Visual 100% As Per Requirement Conforms to the Requirement
III.FINISHED CABLE INSPECTION
A. ROUTINE 1). Conductor Resistance Digital Micro Ohm Meter IS 1554-1 IS 1554-1 IS 1554-1
TEST
2). High Voltage Test High Voltage Tester IS 1554-1 IS 1554-1 IS 1554-1
B. ACCEPTANCE 1). Annealing Test (for Copper) Tensile Test Machine IS 1554-1 IS 1554-1 IS 1554-1
TEST
2). Conductor Resistance Digital Micro Ohm Meter IS 1554-1 IS 1554-1 IS 1554-1
3). Tensile Test (for Aluminium) Tensile Test Machine IS 1554-1 IS 1554-1 IS 1554-1
4). Wrapping Test (for Aluminium) Wrapping Test Machine IS 1554-1 IS 1554-1 IS 1554-1
5). Thickness of Insulation/Sheath Vernier / Micrometer IS 1554-1 IS 1554-1 IS 1554-1
6). Tensile Strength of PVC/XLPE
Tensile Test Machine IS 1554-1 IS 1554-1 IS 1554-1
Insulation / Sheath
7). Elongation of PVC/XLPE
Tensile Test Machine IS 1554-1 IS 1554-1 IS 1554-1
Insulation / Sheath
8). Insulation Resistance Test Insulation Resistance Tester IS 1554-1 IS 1554-1 IS 1554-1
9). High Voltage Test at Room Temp. High Voltage Tester IS 1554-1 IS 1554-1 IS 1554-1
10). Flammability Test Flammability Chamber IS 1554-1 IS 1554-1 IS 1554-1
C. TYPE TESTS 1). Annealing Test (for Copper) Tensile Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
2). Tensile Test (for Aluminium) Tensile Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
3). Wrapping Test (for Aluminium) Wrapping Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
4). Conductor Resistance Digital Micro Ohm Meter One Sample Per Lot IS 1554-1 IS 1554-1

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5). Thickness of Insulation/Sheath Vernier / Micrometer One Sample Per Lot IS 1554-1 IS 1554-1
6). Tensile Strength of PVC/XLPE
Tensile Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
Insulation / Sheath
7). Elongation of PVC/XLPE
Tensile Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
Insulation / Sheath
8). Ageing in Air Over Oven, Tensile Test M/C One Sample Per Lot IS 1554-1 IS 1554-1
9). Shrinkage Test on PVC/XLPE
Oven Scales One Sample Per Lot IS 1554-1 IS 1554-1
Insulation / Sheath
10). Hot Deformation Test for
Oven Scales One Sample Per Lot IS 1554-1 IS 1554-1
Insulation / Sheath
11). Loss of Mass Test for Insulation
Oven, Weighting One Sample Per Lot IS 1554-1 IS 1554-1
/ Sheath
12). Heat Shock Test for Insulation /
Sheath Oven, Scales One Sample Per Lot IS 1554-1 IS 1554-1
13). Thermal Stability Test for
Stability Oven One Sample Per Lot IS 1554-1 IS 1554-1
Insulation / Sheath
14). Insulation Resistance Test Insulation Resistance Tester One Sample Per Lot IS 1554-1 IS 1554-1
15). High Voltage Test at Room
Water Tank, HV Tester One Sample Per Lot IS 1554-1 IS 1554-1
Temp. & Water Immersion Test
16). Test for Armour IS 1554-1 IS 1554-1
- Wire Dia / Strip / Tape Size Vernier / Micrometer One Sample Per Lot IS 1554-1 IS 1554-1
- Tensile Test Tensile Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
- Elongation Test Tensile Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
- Resistivity Test of Armour Resistance Meter One Sample Per Lot IS 1554-1 IS 1554-1
- Torsion Test for Armour Torsion Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
- Winding Test for Armour Tensile Test Machine One Sample Per Lot IS 1554-1 IS 1554-1
- Galvanizing Test (Mass of Zinc
Chemical One Sample Per Lot IS 1554-1 IS 1554-1
Coating)
17). Flammability Test Flammability Chamber One Sample Per Lot IS 1554-1 IS 1554-1
D. SPECIAL 1). Oxygen Index Test Oxygen Index Test Set One Sample Per Lot ASTM-D-2863 ASTM-D-2863
TEST (FOR
FRLS CABLE 2). Temperature Index Test Temperature Index Test Set One Sample Per Lot ASTM-D-2863 ASTM-D-2863
ONLY) 3). Halogen Acid Gas Evolution Halogen Acid Gas Evolution
Test Test Set
One Sample Per Lot IEC-754-1 IEC-754-1

4). Smoke Density Test Smoke Density Test Set One Sample Per Lot ASTM-D-2863 ASTM-D-2863
Note: All Routine and Acceptance Tests can be carried out in the presence of Inspection agencies. Type Tests can however only be reviewed.

Submitted By:
KWALITY CABLE INDIA

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