Ire

I
TITLE:

KEC INTERNA TIONAL L TD.,JABALPUR

SECTION

QPM/QA/20

REV.NO.

O!
13.08.2010 Page 16 of 22

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 Material <5mm thick 460 Gmslm2 5mm thick & above 610 Gms/rrr', ASTM A 123 : <3.2mm460 GmsIM2 >3.2 to 6.4 mm - 605 Gm5lM2 >6.4 mm-710 GmsIM2 IS 2629/ IS 47591 IS 6745 / BS 729 Material to withstand four dips of one Minute each in CUS04 Solution with out showing signs of Copper deposits. ASTMA-239 : Material to withstand Six dips of one Minute each in CUS04 Solution with out showing signs of Copper deposits. IS 2629/ IS 47591 IS 6745 I BS 729 I ASTM A-239 No removal or lifting of coating in areas between hammer impression 1 coating should not peel-off. IS 802 Packing List to be submitted along with despatch documents.

Remarks

(d)

Uniformity of Zinc Coat-

ing (at room temperature)

Three Samples per Shift Three Samples per Shift

QA (KEC)

Record Review

(e)

Adhesion Test of Zinc Coating (Pivot Hammer TestlKnife Test)

Three Samples per Shift

QA (KEC)

Record Review

PACKING, 4.

STORING,100

BUNDLING,
ING

HANDL-

FMY (KEC)

Stacking to have proper ventilation and kept inclined. Damage to galvanizing coating to be avoided while handling.

STAMP HERE

lEe
!
TITLE:

KEC INTERNA nONAL MANUFACTURING

L TD.,JABALPUR QUALITY PLAN

SECTION REV.NO. REV. DATE SHEET NO.

QPM/QN20 01 13.08.2010

CUSTOMERCESC
QUALITY PLAN

Page 17 of22

MANUFACTURING

Component/Operation and Description of Test

Sampling Plan with basis

Reference Document
& acceptance norms

Remarks

Final Inspection & Testing

(a) Visual & Dimensional Inspection for Fabrication (as per approved drawing) & Galvanizing Mechanical Properties (i) UTSIYS/EI (ii) Bend test (Hi) Charpy V notch impact test (only for BSEN material) Galvansing Test (i) Thickness of Zinc Coating (ii) Weight of Zinc Coating (iii) Uniformity of Zinc Coating (iv) Adhesion Test of Zinc Coating As per Table-I Please refer Clause 1.1.3 & 3.3 (a)

CESCI
TPI

CESCITP inspection

(b)

One Sample for every 50 MT

IS2062 Please refer Clause 1.1.1

CESCI
TPI

CESCITP Inspection

(c)

One Sample for every 50 MT

IS2629/1S47591
IS6745/1S2633 Please refer clause

CESCI
TPI

CESCITP Inspection

3.3

APPROVED

BY

KEC INTERNATIONAL

LTD.,JABALPUR

SECTLON

OPM/OAJ2D

lEe
I
TITLE:

REV.NO.

01 13.08.2010 Page 18 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
MANUFACTURING QUALITY PLAN
TABLE-l VISUAL AND DIMENSIONAL SAMPLING CHARACTERISTICS

REV. DATE SHEET NO.

OF STRUCTURAL 1.5

STEEL

PLAN AS PER IS : 2500 LEVEL-II.AOL NUMBER OF PIECES

SI.No.

Lot Size

Sample Size

Acceptance Number

Rejection Number

01 02 03 04 05 06

02 TO 08 09 TO 15 16 TO. 25 26 TO 50 51 TO 90 91 TO 150 151 TO 280 281 TO 500 501 TO 1200 1201 TO 3200 3201 TO \0000 10001 TO 35000 35001 TO 150000 150001 TO 500000

100 % inspection 8 8 8

0 0 0 0 0 I
I

0 I 1 1 I 2 2 3 4 6 8 11 15

8
32 32 50 80 125 200 315 500 800

07
08 09 10 11 12 13 14

2 3 5

7
10' 14 21

22

Note: If the lot is failing in respect ofIS 2500 Level - II, AQL 1.5, the lot should be verified 100 % in respect to the specific defects and good pieces shall be accepted and defective pieces shall be sent to Defective Pieces Yard.

Ire
I TITLE:
S.No Standard

KEC INTERNATIONAL

L TD.,JA BA LPUR

SECTION REV. NO.

QPM/QA/20

01
13.08.2010 Page 19 of22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
MANUFACTURING QUALITY PLAN

REV. DATE SHEET NO.

ACCEPTANCE

TABLE-2 NORMS FOR CHEMICAL COMPOSITION ANALYSIS IN NA TIONAL/INTERNATIONAL

AS SPECIFIED STANDARDS

PRODUCT

Grade of Steel

Carbon
%

Sulphur
%

Phosphorus
0/0

Manganese
%

Silicon
%

CE

Remark

(Maxl
01 IS 2062 E250A (Fe 41O-WA)
-

(Max.)
0.055

(Max.)
0.055

(Max.)'
1.55

(Max.)
0.43 0.42

0.25

E250BR&BO (Fe 410-W8) E350 (Fe490) E410 (Fe540)

0.24

0.05

0.05

1.55

0.43

0.41

0.22

0.05

0.05

1.55

0.48

0.42

0.22

0.05

0.05

1.65

0048

0.44

02 03 04

SAILMA IS 1079 8SEN lO025

350HIfHIHY 0 S275 S275 S355 S355 JO JR JO JR

0.20 0.15 0.2] 0.24 0.23 0.27 NA 0.30

0.040 0.055 0.04 0.045 0.04 0.045 0.050 0.040 0.05 0.050

0.040 0.055 0.04 0.045 0.04 0.045 0.050 0.040 0.05 0.040

1.50 0.60 1.60 1.60 1.70 1.70 NA 1.60

0.60 0.60 N8

0.40 0.45

0040
0.40 0.45

0045
N8

05

JI803101

88400 SS 540 SS 490 A36

0.26

06

ASTM

1.35
(KEC

0.40

NS N8

A 572 - 50 A 572 -60

. 0.23 0.26

0.050 0.050

0.040 0.040

Specification) 1.35 1.35

0.40 0040

07

DIN 17100

44.2 52.3

0.24 0.22 0.22

0.060 0.050 0.040

0.060 0.050 0.040

1.70 1.60

Maximum 1.50 % of MD. is permissible within Associated reduction of the carbon Maximum of 0.03%.

0.60 0.60

08

JINDAL Grade Plate

ssc
Equivalent

APPROVED

BY

KEC IHTERHA TlOHAL L TD.,JABALPUR

SECTION

OPMJOAJ20

lEe
I
TITLE:
ACCEPTANCE

REV. NO.

01
13.08.2010 Page200f22

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
MANUFACTURING QUALITY PLAN

REV. DATE SHEET NO.

NORMS FOR MECHANICAL Yield Stress

TABLE-3 PROPERTIES AS SPECIFIED STANDARDS Ultimate Stress N/mmz Kgf/mml

IN NATIONAUINTERNATION

Standard

Grade of .Steel

N/mml <20mm 250 20 to 40mm 240 >40mm 230 <20 mm 350 20to40mm 330 >40mm 320 <20 mm 410 20 to 40 mm 390 >40mm 380

Kgf/mmZ <20mm 25.5 20to40mm 24.5 >40mm 23.5 <20 mm 35.7 . 20 to 40mm 33.7 >40mm 32.64 <20 mm 41.82 20 to 40 mm 39.78 >40mm 38.76

Percentage Elongation

Bend Test

Cbarpy Test

IS 2062

E250AI E2S0BRI E250BO

410

41.82

23

2 t for .:::25 mm 3t for >25 mm 2t for::::;2S mm NSfor>25 mm

For E2S0/BRI BO- 27 J min

IS 2062

E350 (FE 4901 490B)

490

49.98

22

490

49.98

22

FE 5401 540B

540

55.08

20

2t for::::;25 mm NS for >25 mm

IS 2062 Applicable for > 12mm,IS 1757 for impact testing applicable only for grade in room temperature minenergy required 50 joules.

SAILMA

350 HIHI 350HY 0

350 350 N.A.

35.70 35.70 NA

490 to 610 490 to 610 NA

49.98 to 62.2 49.98 to 62.2 NA

21 20 NA

3t 3t 2t

IS 1079

KEC INTERNA TlONAL L TD.,JABALPUR

SECTION REV.NO.

OPM/OAJ20

I[C
I
TITLE:
Standard Grade of Steel

01
13.08.2010

MANUFACTURING

QUALITY PLAN

REV. DATE SHEET NO.

CUSTOMER-CESC
MANUFACTURING QUALITY PLAN

Page 21 of22

Yield Stress N/mm2 Kgf/mm2

Ultimate Stress N/mm2 Kgf/mm2 Percentage Elongation Bend Test Cbarpy Test

S 275 10

:::.16mm 275 >16:::.40mm 265 :::.16mm 275 >16 -:::,40mm 265 S 16mm 355 :>16 - ::;40mm 345 S 16 mm 355 >16 -:::,4Omm 345 Upto 16mm 245 16 to 40 mm 235

:::.16mm 28 >16:::.40mm 27 :::.16mm 28 >16- :::.40mm 27 s16mm 36.21 :>16 - ::;40mm 35.19 S16mm 36.21 >16 - s40mm 35.19 Upto 16 mm 25 16 to 40 mm 24

410 - 560

41.86-57.12

23

Not required

0C-27J

S 275 JR
BSEN -10025

410 - 560

41.86 - 57.12

23

Not required

20C-27J

S 355 JO

470 - 630

47.94 - 64.26

22

Not required

0C-27J

S 355 JR

470 - 630

47.94 - 64.26

22

Not required

200

e - 27J

JISS G 3101

SS400

400 - 510

40.8 - 52

SS 540

Upto 16 mm 400 16 to 40 mm 390

Upto 16mm 40.8 16t040mm 39.7

540

55

s5mm 21% >5 to 16mm 17% 16to 50 mm 21% s5mm 16% >5 to 16mm l3% 16t050mm 17% S5mm 19% >5 to 16mm 15% 16 to 50 mm "19%

1.5t

2t

SS 490

Upto 16 mm
285 16 to 40 mm 275

Upto 16 mm
29.07 16 to 40 mm 28.05 490-610 49.98 to 62.22 2t

APPROVED

BY

Ire
I TITLE:
DIN17100 44.2

KEC INTERNA TlONAL L TD.,JABALPUR

SECTION REV.NO.

QPM/QAl20

01
13.08.2010

MANUFACTURING QUALITY PLAN

CUSTOMER-CESC
MANUFACTURING QUALITY PLAN

REV. DATE SHEET NO.

Page 22 of22

S 16mm 275 >16 to40mm 265

S 16mm 28 >16 to 40mm 27

410 - 540

41 - 55

20

3t

52.3

S16mm 355 >16 to 40mm 345

Sl6mm 36.2 >16 to 40mm 35.2

490 - 630

56-64.2

20

3t

Yield Stress Standard Grade of Steel

N/mm1 Kgf/mml"

Ultimate Stress
N/mml

Kgf/mml

Percentage Elongation

Bend Test

Charpy Test

<20mm

A-36

250

25.5

400 - 550

40.8-56.1

20 on 200 GL

ASTM

A-572 Gr.50

<20mm 485 345

35.2

<20mm 49.5 ::::,20mm 45.9 53.04 18 on 200 GL

12.7 0 > 20 to 25 25.4 0 <20mm

25.4D >20 to

::::,20mm 450 A-572 Gr.60 415 42.33 520

16 on 200 GL

"25mm 38.10 <20mm 50.80 >20 to 25 mm 63.50

55C Jindal Grade

Equivalent

410

41.82

540 -700

55.08 -71.40

19 on 200 GL

Not Required

OnC-271

APPROVED BY

__

........

~II'11

... '-

. .--.--

...-.

Manufacturer's Details :KECInternational Ltd., Deori Works, Jabalpur (M.P.)

Customer: CESC
-_.
--

Vendor's Code:

Item: Galvanized Tower Structures I Parts

Q.P.No.: QPM/QA/20 Rev. No. : ,01 Date: 13.08.2011

Valid From : 13.08.2011 Valid Up to: 31.03.14

NOTESIGENERAL REQUIREMENTS TO BE CHECKED/ENSURED

(1)

The KEC may approach CESCfor giving clearances of Imported Billets or imported angle section, based on review of an unpriced copy of purchase order and KECstest certificate, before shipment, to avoid discrepancy detection at later stage. In case Steel sectionsare purchased by KEC from the main producers, or KEC is purchasing the steel sections directly from the re-rollers, the following conditions shall be fulfilled:(a) The Re-rollers have to be approved by CESe. KEC's shall ensure that the materials bear the identification marks of the re-rollers for MS material and 'HT' embossing along with re-roller identification mark on HT re-rolled section. Copy of MQP should be available at re-roller's works. (b) The KEC shall ensure that the billets to be procured from the Billet producer like SAIL, RINL, TIseo, lISCO, SISCON, Jindal (Raigarh), JayaswalNeco (Raipur) & Adunik Metaliks (Sundergarh). In case of other parties KECshall submit approval request to CESe. ' (c) The KEC shall offer the Steel sections rolled out of indigenous / imported billets at re-roller's works for Inspection to CEse and inform at least one week before proposed inspection date. Testing shall be carried out as per clause 1.1 of this MQP. This shall be an inspection point. The rolled angle section shall be duly co-related with corresponding billets, eESe shall have the option of establishing the co-relation by review of records or by conducting chemical analysis on rolled products. (d) All section shall be offered for inspection as per relevant standard at the re-roller's works. The grade of the billets should be suitably selected to meet the raw material requirements.
I

(2)

Nuts & Bolts and Step BoltS & Nuts & other bought out items to be' procured from CESeapproved sources and this will be inspection point at sub-vendor's works. Welding procedure and Welders performance qualification approval by CESe is required in case welding is involved at any stage of fabrication/erection. 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 met~hod and pieces are cleared process. If the holes are to be made near the bend line the same shall be done after bending.

(3)

~.a:;l~",.jUl
~\~oy..osy..
. :\

(4)

()
. !\ \,IO\ec.\s\,

);';:;,'"
'.\ 1f

i\~.lit~A f/O,.,

<r.
~.4'

~:'fu

{lS~f:,'o\O

~\.\DEORf)
/1'4

Gj}
II

Page 1 of 3

SI ..~~\~ee~~~c \.i~i\eO

,,~\~::~~.-~;:\::~.:.;.,

.... ----Manufacturer's Details :KECInternational ttd., Deer! Works, Jabalpur (M.P.) Customer: CESC

........ ~ ,

....- .....~~..,.-... ~

..
Q.P.No.: QPM/QA/20 Rev.No.:Ol Date: 13.08.2011 Valid From: 13.08.2011 Valid Up to: 31.03.14
I

Vendor's Code:

Item: Galvanized Tower Structures / Parts

(5) (6)

The sample pieces consumed in a testing shall be replenished by the KEC at the time of despatch. CESe Specification means CEse Technical Specification, Approved Drawing, Approved Technical data sheet and LOA provisions applicable for the specific contract. ' The KEC shall furnish all the concerned calibration certificates for testing machines/measuring equipments for review at the time of final inspection. , Grades of. steel used and the standards to which they conform shall be as approved by CESCEngineering for the specific contract and shall be indicatl:Clin approved Drawings/80M/offer list at the time of inspection. Steel plates below 6 mm used for packing plates/Packing washers shall be as per CESCspecification/ approved drawings by Engineering Department, Produced as per IS 1079 1994 (Grade-O) are also acceptable however if below 6 mm thickness plates are used as load bearing plates viz. gusset plates,Joint splices etc. same shall confirm to IS 2062 or equivalent standard. The KEC shall maintain proper co-relation of test certificate with respect to the material from raw material stage to finished material stage. The KEC shall strip off galvanizing of rejected material before re-galvanizing in case rejection is due to galvanizing testing defects. The KEC shall dispose off entire section rejected in physical testing by gas cutting or by machine cutting from any end of rejected mark number. In case of any contradiction between Technical Specification Specification / Approved Drawing shall be final.

(7)

(8)

(9)

(10) (11) (12)

(13)

Approved Drawing and MQP, the details mentioned in" the Technical

(14)

The KEC should proqressivelyallqn 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 CESe. The KEC shall ensure that the ~~~ material bears the embossing of re-rollers identification The KEC to ensure that

,.. \ A.~ ~
~

..-:-:-'\

(15)

f)VW

~~J

,
.

_L~\\ \'t G~
ro\SSiOIl \lIO, _.t'\ll~IIS.. d""

'..
\e.c\S\

\ . f.&
I

1 DEOP,' ~~~ ~\,

unt .. .
. \~
<1,-

/~;~liAfto

~a. chine is having valid calibration certificate issued by NABLaccredited testing agency only.

SI,t.l\~\\le\:\cscUI11\te",~'::~~t!;~t:f:.\~~/

, -_________ /J .'

* 1/1/

Page20f3
~

I., ..

Manufacturer's

Details :-

- -- -- Customer:

--- -

..

- .. -

"""""'--

--

...

KECInternational Ltd., Deori Works, Jabalpur (M.P.)

Vendor's Code:

Item:

-- -

Q.P;No.: QPM/QA/20

Valid From: 13.08.2011 Valid Up to: 31.03.14

eESe

GalvanizedTower Structures / Parts

Rev. No.:Ol Date: 13.08.2011

(17)

Inspection of angle sections at Black stage of Tower structures irrespective of specific contract can be followed as detailed hereunder. (a) You may raise inspection call for angle section at black stage at re-roller' s work against anyone of the ongoing Contract. (b) You or your fabricator may fabricate the raw material cleared BY eESCfor a particular contractor, for any of your project under execution. Your fabricator may do so against specific instruction from you in this regard. -

(c) The fabricator (i.e. you) will maintain a separate register indicating splitting and swapping of material between different Projects awarded same contractor, which can be reviewed by CESCinspection engineer, separate register for each Contractor is to be maintained if the , fabricator is executing jobs for different contractor. (d) You as a contractor on whom CESe has placed the contract, will only be allowed to split and swap materials in black stage only between your different ongoing contracts with eESe, without any obligation to CESC. (e) The final inspection after fabrication and galvanizing, however, will continue to be contract - wise and CIPs will be issued for each contract only. (is) Impact testing applicable for nominal thickness ~ 6 mm as per BSEN:10025-2:2004. For E350Agrade testing will be as per IS:2062 Piecesof 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. KEC to ensure sequential supplies and other details as per eESe Technical Spedtlcation Prior approval of eESe is required to be taken for any activity or process that is out sourced. In case tower part to be used at sub zero temperature, we may carry out Impact testing at -200 C during final inspection.

(19)

(20) (21)

~~
~

q, At>i"'o-I-:d
OJ-\OSj-\ . Page 3 of 3 ~

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. -0\\ ?~oiec\S) , { \~a\\S(\\'SSI $(t\\\JI\\ee 2ESC limited