BIHAR STATE POWER TRANSMISSION COMPANY LIMITED MANUFACTURING QUALITY PLAN -- BATTERY CHARGER. Quantum of Check / Sampling with basis

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1 A. Section : RAW MATERIAL INSPECTION 1.0 ELECTRONIC COMPONENTS 1.1 RESISTORS (Metal Film, Wire Wound) 1.2 POTENTIOMETERS 1.3 CAPACITORS (Polystyrene, electrolytic) 1.4 TRANSISTORS 1.5 L E D INTEGRATED CIRCUITS (LINEAR) THYRISTORS/SCR AND POWER DIODES / BLOCKING DIODES Electrical / Visual Electrical / Visual Electrical / Visual Electrical / Visual Electrical / Visual Visual Visual 100% 2.0 CRGO LAMINATIONS Visual 100% 3.0 ENAMELED WIRE 4.0 POWER TRANSFORMERS/ AUX. TRANSFORMER EM/ Mechanical a) IR Measurement b) H.V.Test c) Double Voltage / Double frequency test (For Power Transformers Only) 5.0 CONNECTORS 6.0 RELAYS 7.0 PCB (GLASS EPOXY) Type of Electrical / Visual Electrical / Visual / Visual & EM/ Mechanical EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ EM/ IS : 2026/ EM IS : 2026/ EM norms/ norms/ IS : 2026/ EM IS : 2026/ EM norms/ norms/ IS : 2026/ EM IS : 2026/ EM norms/ norms/ EM/ EM/ EM/ EM/ EM/ N E during final during final Page: 1 of 14

2 8.0 Switches (TOGGLE)/ROTARY) 9.0 METER (VOLTMETER, AMMETER) Type of / EM/ Mechanical Electrical/Mechani cal/visual 100% Sub-vendor's Catalogue/ IS:1248 EM norms/bsptc L EM/ Sub-vendor's Catalogue/ IS:1248 EM norms/bsptc L 10.0 CHOKE E a) Inductance b) H.V. Test c) Insulation Resistance measurement 11.0 Over Load Relay 12.0 Rotary Switch 13.0 Current Shunt 14.0 MCB Electrical/Visual Electrical/Visual Electrical/Visual 100% 100% 100% EM/ Mechanical EM/ EM/ EM/ EM/ EM/ EM/ EM/ 15.0 MCCB 16.0 WIRES/ CABLES 17.0 SLEEVES 18.0 TERMINAL BLOCKS EM/ Mechanical Electrical/Mechani cal/visual Mechanical/Visual 100% Mechanical 100% 19.0 FRONT PANEL & CARD GUIDE Mechanical/Visual 20.0 HEAT SINK 21.0 FUSE & FUSE HOLDERS Mechanical/Visual 100% EM/ Mechanical EM/ Sub-vendor's Catalogue/ EM norms/bsptc L EM/ EM/ EM/ Sub-vendor's Catalogue/ EM norms/bsptc L EM/ EM/ N ISI marked N during final Page: 2 of 14

3 22.0 NEOPRENE GASKET 23.0 LUGS & CRIMPED TERMINAL 24.0 FERRULES 25.0 IC & RELAY SOCKET 26.0 ANNUNCIATOR/HOOTER 27.0 FASTNERS & SPACERS 28.0 CABLE CONDUITS 29.0 PANEL From Vendor Type of Mechanical/Visual Mechanical/Visual Mechanical/Visual / 100% 10% Mechanical 100% Mechanical 100% Visual & Mechanical 100% Visual & Mechanical 100% a) Type and Make Visual 100% b) Dimensional Mechanical 100% c) Finish Visual 100% EM/ Catalouge/ IS:1365/2016/ 1366/2269 /EM EM/ Catalouge/ IS:1365/2016/1 366/2269 /EM A J S Y N do A J S Y N do A J S Y N do E during final Page: 3 of 14

4 30.0 CRCA SHEET From Vendor Type of a) Type and Make Visual 100% b) Chemical Analysis Chemical c) Tensile Test Mechanical d) Thickness of the Sheet Mechanical 31.0 INDICATION LAMPS & HOLDERS 32.0 PUSH BUTTONS 33.0 CONTACTORS / One Sample/ Lot One Sample/ Lot One Sample/ Lot Mechanical 100% Mechanical 100% Mechanical 100% Catalouge/ Catalouge/ IS:513 IS:513 / / Catalouge/ Catalouge/ IS:513 IS:513 / / Catalouge/ Catalouge/ IS:513 IS:513 / / Catalouge/ Catalouge/ IS:513 IS:513 / / E B K P W N A J S W E N Review of Test records by during final during final Page: 4 of 14

5 34.0 a) PANEL OF Vendor Degreasing including water rinsing Type of Chemical 100% b) Descaling Chemical 100% c) Water Rinsing Chemical 100% d) Phosphating Chemical 100% e) Water Rinsing Chemical 100% f) Hot Chromating Chemical 100% g) Sealing Chemical 100% / EM / EM / EM / EM / EM / EM / EM / EM / EM / EM / EM / EM / EM / EM / E B K P W N 35.0 PRIMER COATING E a) 1st Coat Chemical 100% / / b) Oven Drying Chemical 100% / / B K P W N during final Review of Test records by during final Page: 5 of 14

6 Type of c) 2nd Coat Chemical 100% d) Oven Drying Chemical 100% / / / / / 36.0 PAINTING (SPRAY) E a) 1st Coat Chemical 100% / / b) Oven Drying Chemical 100% c) 2nd Coat Chemical 100% d) Oven Drying Chemical 100% 37.0 IN CASE OF DRY POWDER COATING a) Powder Coating Chemical 100% / / / / / / Coating Coating process as per process as per acceptance acceptance norms, paints norms, paints thickness etc. thickness etc. as per as per appro appro ved Drg/Tech. ved Drg/Tech. / DFT / microns microns min min. for. E B K P W N during final Page: 6 of 14

7 Type of / INPROCESS INSPECTION 1.0 PANEL OF Vendor a) Paint Type and Make Visual 100% b) Finish Visual 100% c) Paint Thickness Mechanical 100% Of reputed make / spec. Of reputed make / spec. EM EM Drg./ Drg./ / / EM Drg./ / Drgs/DFT 60 microns min for powder coat. EM Drg./ / Drgs/DFT 60 microns min for powder coat. 2.0 COMPONENT KITTING (PCB) N a) Quantity Visual 100% b) Identification Visual 100% 3.0 COMPONENT PREPARATION Visual 100% 4.0 COMPONENT (PCB) PLACEMENT/ASSEMBLY Visual 100% 5.0 SOLDERING Visual 100% 6.0 PCB TESTING N a) Visual for missing components, orientation of component etc. Visual 100% EM procedures EM procedures E during final Page: 7 of 14

8 Type of b) Functional on test jig / EM procedures EM procedures 7.0 SOAK (BURN IN) TEST a) On assembled cards at 70± 5deg. for 120 Hrs. and functional test after burn in Environmental 100% test procedures test procedures EM norms/ 8.0 MODULE ASSEMBLY N a) Component Fitting Visual 100% 9.0 ROUTINE TESTS a) Full load testing of the Completed assembled Equipment for 48 hours (Observed for no failure of the output of the charger) b) All the acceptance tests / approved / approved Apprd / approved Apprd / approved during final Page: 8 of 14

9 : INSPECTION & TESTING 1.0 ACCCEPTANCE TESTS on the assembly & wiring (complete physical examination) and BOM check. Insulation Resistance Test on the complete Equipment Type of Visual 100% 1.3 H.V. TEST DC output voltage stability for the specified variation in mains input and DC load variation for 0 to 100% (Regulation Test) Ripple voltage test on full load output condition/ half load/ no load Over current limit test at 105% load (voltage drooping test/load limiter operator) Under/Over voltage adjustable limit test / / approved Apprd / approved Apprd Apprd Apprd Apprd Apprd Apprd Instructions/ Clearance by Instructions/ Clearance by Instructions/ Clearance by Instructions/ Clearance by Page: 9 of 14

10 Type of 1.8 Short circuit test (DC output side) / Apprd Annunication circuit test by 1.9 simulation fault condition for : a) AC incoming supply failure Electrical Apprd b) SCR/Diode fuse failure Electrical Over voltage across the battery c) Electrical under boost charging d) Charger Fail Electrical 1.10 Heat run temperature rise test for minimum 8 hrs on following test Environmental 100% points. a) Main transformer (one Coil) Apprd Rectifier diode/scr (One number b) each) c) Filter Choke d) Core of Transformer e) Blocking Diode f) Mid Zone of panel inside 1.11 Spares- check for make/ type etc Visual 100% Apprd 1.12 Functional check on Temperature sensor for battery Bank. Specs Specs Page: 10 of 14

11 Type of / 1.13 Mechanical Interlock check for two no of input MCCB's. Mechanical 100% Specs Specs 1.14 Paint shade and thickness check visual/mechanical check random Specs/60 microns min for powder coating Specs/60 microns min for powder coating 2.0 TYPE TESTS 1.1 All Type Tests required as per contract in question need to be conducted/ approval from Engg. to be obtained As agreed with Engg. As agreed with Engg. As agreed with Test Report Engg. Page: 11 of 14

12 Type of / 1.0 PACKING & DESPATCH 1.1 ing for completeness of the equipment and accessories including spares as per order Visual 100% 1.2 for proper packing Visual 100% Ensure supply of operation manual, packing list and test reports along with copy of ing for reports number on the packing case Visual 100% Visual 300% packing list packing Standard packing Standard packing Standard packing Standard packing Standard packing Standard packing Standard Page: 12 of 14

13 Type of / Code 1 Indicates place where testing is planned to be performed i.e. Code 2 Indicates who has to perform the tests i.e. Agency A B C D E F At Equipment Manufacturer's works At Component Manufacturer's works At Authorised Distributor's place At Independent Lab At Turn Key Contractor's location Not specified J K L M The Equipment Manufacturer The Component Manufacturer The Third Party The Turnkey Contractor Code 3 Indicates who shall witness the tests i.e. Witnessing Agency Code 4 Review of Test Reports/Certificates P Component Manufacturer itself W By Equipment manufacturer during raw mate Q Component Manufacturer and Equipment Manufacturer X By Contractor during product/proce R Component Manufacturer, Equipment Manufacturer and Contractor Y By during product/process insp S Equipment Manufacturer itself Z By Contractor and/or during product T U V Equipment Manufacturer and Contractor Equipment Mannufacturer, Contractor and Third Party itself Code 5 Whether specific approval of sub-vendor / Component make is Code 6 Whether test records required to be submitted after final E Envisaged Y Yes N Not Envisaged N No Page: 13 of 14

14 Notes : Type of / 1. The MQP should be read in conjunction with specification and shall deem to include additional tests if any required as per the contract. 2. specification shall include provisions of letter of Award, approved drawings /technical data sheet / BOM / test schedule / test procedure applicable to the specific contract. 3. In case of any contradiction between the manufacturer s plant standards, this MQP and specification following precedence shall be followed :- a) specification. b) This Manufacturing Quality plan. c) Manufacturer s plant standards. 4. It is the responsibility of the manufacturer to ensure that this document is readily available at their works, as well as at the works of their sub vendors in order to avoid any delay at the time of 5. The manufacturer shall ensure that their as well as their sub vendors control, metering & testing instruments are duly calibrated and should have calibration certificates traceable to Indian / International standards. Calibration records should be available during by. Key testing instruments will be calibrated only by NABL accredited laboratories. 6. In case of any tests being carried out at third party lab, such lab / facility should be NABL accredited / accepted by. 7. The manufacturer shall maintain the proper co-relation of test certificates from raw material stage to finished product stage and the records should be available during by. 8. Manufacturer shall show the approval of engineering for all contract specific type tests, including specific type tests if any as per the specification at the time of final. 9. All packing cases should be marked with LOA details, name of project, item description and (by which material has been cleared for dispatch ). 10. One copy of test report, shall also be sent along with consignment. 11. Inspection of spare items ordered by shall also be governed by the provisions of this MQP. Items if not governed under MQP shall be offered for as per specifications / Relevant-Indian / International Specification 12. The manufacturer shall align their quality system and that of their sub-vendors to the requirements of latest ISO 9000 quality standards in a time bound manner. 13. The relevant details of plant standards and quality plan for different ratings are shown in attached Annexure. 14. may review the effective implementation of the processes during the product- / process- In case any violation in process or process parameters are observed, the reason along with corrective & preventive measures shall be conveyed to within 2 weeks EM : Equipment Manufacturer CM : Component Manufacturer Page: 14 of 14