QUALITY ASSURANCE PLAN
Doc NO : IMS-QH-QAP-009-001
Date:
23.12.2015
Rev No :07
Item : Inverter Transformer & Aux. Transformer (Oil Filled)
Mahindra SUSTEN
Rating: up to 33 KV
SL.
COMPONENT &
No.
OPERATION
1.01 Core Lamination
1.02 Winding conductor
(PICC)
CLASS
CHARACTERISTICS
1 Thickness
Critical
2 Edge Burr
Major
3 Specific core Loss
Critical
TYPE OF
QUANTUM
REFERENCE
ACCEPTANCE
FORMAT OF
CHECK
OF CHECK
DOCUMENT
NORMS
RECORD
S
M
C/E
Physical
Measurement
Physical
Measurement
Electrical
Each Lot
S/M/C Drawing
S/M/C Spec
Supplier TC /
QA report
P
P
V
"
S/M/C Spec
S/M/C Spec
"
P
P
P
P
P
V
V Vendor to share the
Work Procedures
V
for transportation
and handling of
CRGO
V
P
P
P
P
V
V
"
S/M/C Spec/IS3024/IS649 S/M/C Spec/IS3024/IS650
"
4 Source - Japanese &
Corian Mills (Posco,
Nippon)
5 Dimensions
Critical
MTC review
"
Susten Requirement
Susten Requirement
MTC
Minor
Physical
Measurement
"
S/M/C Drawing
S/M/C Spec
"
1 Dimensions- Bare &
Covered
Major
Physical
Measurement
Each Lot
2 Conductivity
Critical
Electrical Test
"
S/M/C
Spec/IS13730/IS18971983
"
3 Hardness
Critical
Mechanical Test
"
4 Tensile Strength
Critical
Mechanical Test
5 Elongation
Major
6 No of Papers
Major
7 Source - Sterlite,
Hindusthan Copper
8 Paper Application
(Overlap)
Major
1 Thickness
2 Apparent Density
Major
Major
1.03 Pressboard
AGENCY
QC Rep./TC
S/M/C
Spec/IS13730/IS1897-1983
"
QC Rep./TC
P
P
V
"
"
QC Rep./TC
P
P
V
"
"
"
supplier TC
/
P
V
V
Mechanical Test
"
"
"
"
P
V
V
Physical
Measurement
MTC review
"
"
"
"
P
P
V
"
"
"
MTC
P
V
V
Physical
Measurement
"
"
"
"
P
P
V
S/M/C Spec/IS1576
S/M/C Spec/IS1576
supplier TC
/
P
P
V
"
"
"
P
V
V
Physical
Measurement
Each Lot &
Size
Mechanical Test
"
REMARK
Major
3 Tensile Strength
Mechanical Test
"
"
"
"
P
V
V
Mechanical Test
"
"
"
"
P
V
V
Mechanical Test
"
"
"
"
P
V
V
Major
4 Air- Shrinkage
Major
5 Moisture Content
Major
Mechanical Test
"
"
"
"
P
V
V
Chemical Test
"
"
"
"
P
V
V
Major
Major
Chemical Test
"
"
"
"
P
V
V
Critical
Major
Electrical Test
Chemical Test
"
P
P
V
V
V
V
6 Oil absorption
Major
7 Conductivity of Aqueous
extract
8 pH of Aqueous extract
9 Electrical Strength
10 Ash Content
PREPARED BY : ( Mahindra SUSTEN)
"
"
LEGEND :
"
"
"
"
CHP - Customer Hold Point
S: Supplier, M- Manufacturer/Vendor
C - Customer, E- End User
P - Agency Performing The Test
V - Agency Verifying The Test Reports
W - Agency Witnessing The Test
Note: Customer specifications supersedes IS for
routine and type tests
"
Page No : 1 of 5
QUALITY ASSURANCE PLAN
Doc NO : IMS-QH-QAP-009-001
Date:
23.12.2015
Rev No :07
Item : Inverter Transformer & Aux. Transformer (Oil Filled)
Mahindra SUSTEN
Rating: up to 33 KV
SL.
COMPONENT &
No.
OPERATION
Core Lamination
1.01 Densified
Laminated
1.04
Wood
1.05
1.06
1.07
Transformer Oil
Gaskets
Structural Steel
CLASS
TYPE OF
QUANTUM
REFERENCE
ACCEPTANCE
FORMAT OF
CHECK
OF CHECK
DOCUMENT
NORMS
RECORD
S
M
C/E
Each Lot &
Size
"
S/M/C Spec/IS 3513
S/M/C Spec/IS 3513
supplier TC
P
P
V
Major
Physical
Measurement
Measure
"
"
"
P
V
V
Major
Mechanical.
"
"
"
"
P
V
4 Oil absorption
Major
Measure
"
"
"
"
P
V
5 Moisture Content
6 Cross Breaking Strength
Major
Measure
"
"
"
"
P
V
Mechanical.
"
"
"
"
P
V
V Vendor to share the
V Work Procedures
for transportation
V
and handling of
V
CRGO
CHARACTERISTICS
Thickness
1 Thickness
2 Density
3 Tensile Strength
Major
AGENCY
REMARK
7 Compression Strength
Major
Major
Mechanical.
"
"
"
"
P
V
V
8 Electrical Strength
Critical
Electrical Test
"
"
"
"
P
V
V
Critical
Minor
Major
Major
Major
Major
Major
Major
Major
Major
Major
Electrical
Physical
Measure
Chemical
Chemical
Chemical
Chemical
Chemical
Chemical
Chemical
Chemical
IS:6855
"
"
"
"
"
"
"
"
"
"
S/M/C Spec/IS 335
"
"
"
"
"
"
"
"
"
"
S/M/C Spec/IS335
"
"
"
"
"
"
"
"
"
"
QC Rep./TC
"
P
P
P
P
P
P
P
P
P
P
P
P
P
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
P
P
V
P
P
P
P
P
P
P
V
P
V
V
V
V
V
V
V
V
V
V
V Not applicable in
V case of nitryl
gaskets
P
P
P
P
V
V
V
V
V
1
2
3
4
5
6
7
8
9
10
11
Electrical Strength
Appearance
Density
Viscosity
Interfacial tension
Flash Point
Pour Point
Neutralisation Value
Corrosive Sulphur
Tan Delta
Water Content (ppm)
supplier TC
"
"
"
"
"
"
"
"
1 Thickness
Major
Measure
Each Size
S/M/C Spec/IS 4253 for
Cork gaskets & IS 11149
for Nitry gaskets
S/M/C Spec/IS 4253 for
Cork gaskets & IS 11149
for Nitry gaskets
QC Rep./TC
2
3
4
5
6
7
8
Major
Major
Major
Major
Major
Major
Major
Mechanical.
Mechanical.
Mechanical.
Measure
Measure
Measure
Chemical
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
supplier TC
Major
Measure
Each Lot
S/M/C Spec/IS2062
S/M/C Spec/IS2062
QC Rep./TC
Major
Major
Mechanical.
Mechanical.
Tensile Strength
Hardness
Compressibility
Recovery
Flexibility
Compression Set
ph Value of Water Extract
1 Dimensions
2 Tensile Strength
3 Chemical Comp.
PREPARED BY : ( Mahindra SUSTEN)
"
"
LEGEND :
"
"
"
"
CHP - Customer Hold Point
S: Supplier, M- Manufacturer/Vendor
C - Customer, E- End User
P - Agency Performing The Test
V - Agency Verifying The Test Reports
W - Agency Witnessing The Test
Note: Customer specifications supersedes IS for
routine and type tests
QC Rep./TC
supplier TC
"
"
"
"
"
"
Page No : 2 of 5
QUALITY ASSURANCE PLAN
Doc NO : IMS-QH-QAP-009-001
Date:
23.12.2015
Rev No :07
Item : Inverter Transformer & Aux. Transformer (Oil Filled)
Mahindra SUSTEN
Rating: up to 33 KV
SL.
COMPONENT &
No.
OPERATION
Core Lamination
1.01
1.08 Tank
CLASS
CHARACTERISTICS
TYPE OF
QUANTUM
REFERENCE
ACCEPTANCE
FORMAT OF
CHECK
OF CHECK
DOCUMENT
NORMS
RECORD
1 Thickness
Dimensions
Major
Measure
Each Unit
S/M/C Drawing/Spec
S/M/C Drawing/Spec
2 Welder Qualifications
Critical
Testing
S/M/C Spec/
ASME Sec IX, WPS, PQR
S/M/C Spec/
ASME Sec IX, WPS, PQR
3 Matching and Alignment
of Components
Major
Physical
Each
person
Each unit
S/M/C Drawing/Spec
S/M/C Drawing/Spec
5 Surface preparation
check
6 Paint thickness & Peel
Off test
7 Raw Material grade
Major
Mechanical.
"
"
"
Critical
Measure
"
MTC
Final
inspection by
Transformer
Manufacturer
at Tank
Supplier's
premise
AGENCY
M
P
W
P
P
V
W
P
W
P
W
P
V
P
W
For Inverter
W Transformer
MSUSTEN will
V witness
Vendor tothe
share
Air the
V Pressure,
Work Procedures
Vacuum
for transportation
Test,
Leak test, DP
andSurface
handling of
Test,
CRGO
Prepration
check,
W Dimensions of
main Tank for One
V unit only and
thereafter on
V random basis for
different
W Fabricators.
P
P
P
P
W
V
P
P
W
V
V
V
P
P
P
P
P
V
V
V
V
P
P
P
P
P
P
P
P
P
P
V
P
V
V
P
V
P
P
V
P
V
V
V
V
V
V
V
V
V
V
P
P
V
P
P
P
P
P
P
P
V
V
V
V Busbars to be send
V
loose while
V
transportation to
V avoid LV breakages
V
of LV insulators
8 DP Test
1.09
Instruments
WTI / OTI/B Relay
MOG &
9 Air Pressure Test,
Vacuume Pressure Test,
Leak Test
1 Model /Make
2 Calibration
3 Operational checks
Critical
Mechanical
"
"
"
Minor
Major
Major
Physical
Testing
Testing
Each Unit
"
"
S/M/C Spec
S/M/C Spec
QC Rep./TC
"
"
"
"
"
"
1
2
3
4
Open Shut marking
Size
Leakage Test
Operational check
Major
Major
Major
Major
Physical
Physical
Physical
Physical
Each unit
S/M/C Spec
S/M/C Spec
Supplier TC
"
"
"
"
"
"
"
"
"
"
"
"
1
2
3
1
2
3
1
2
3
4
Type/ Model
Leakage Test
Silica gel capacity
Type /rating
Dimension
Operational Check
Dimensions
Leakage test
Visual check
Paint Shade,thickness &
peel off
Major
Major
Major
Major
Major
Major
Major
Major
Major
Major
Physical
Physical
Physical
Physical
Measure
Physical
Physical
Physical
Measure
Measure
Each unit
S/M/C Spec
S/M/C Spec
Supplier TC
"
"
"
"
"
"
"
"
Each unit
S/M/C Spec
S/M/C Spec
Supplier TC
"
"
"
"
"
"
"
"
Each unit
S/M/C Spec
S/M/C Spec
Supplier TC
"
"
"
"
"
"
"
"
"
"
"
"
Major
Physical
Each unit
Major
Major
Major
Physical
Mechanical.
Electrical
Electrical
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
"
REMARK
S
C/E
balance instruments
1.10
1.11
1.12
1.13
Valves
Silica Gel Breather
OCTC
Radiator
1 Dimensions
1.14
S/M/C Spec/IS 3347/2099 S/M/C Spec/IS 3347/2099
Supplier TC
Bushings
2 Rating /Type
3 Porosity test
4 Temp Cycle test
5 Electrical Routine Test
PREPARED BY : ( Mahindra SUSTEN)
Major
LEGEND :
CHP - Customer Hold Point
S: Supplier, M- Manufacturer/Vendor
C - Customer, E- End User
P - Agency Performing The Test
V - Agency Verifying The Test Reports
W - Agency Witnessing The Test
Note: Customer specifications supersedes IS for
routine and type tests
Page No : 3 of 5
QUALITY ASSURANCE PLAN
Doc NO : IMS-QH-QAP-009-001
Date:
23.12.2015
Rev No :07
Item : Inverter Transformer & Aux. Transformer (Oil Filled)
Mahindra SUSTEN
Rating: up to 33 KV
SL.
COMPONENT &
No.
OPERATION
Lamination
1.01 Core
1.15
Marshalling
Box
2.00 In process Checks
2.01 Winding
2.02 Core
2.03 Core Coil Assembly
CLASS
CHARACTERISTICS
1
2
3
4
2.05 Core Coil Assembly
REFERENCE
ACCEPTANCE
FORMAT OF
OF CHECK
DOCUMENT
NORMS
RECORD
S
M
C/E
Physical
Meas.
Meas.
Meas.
Each unit
S/M/C Spec
S/M/C Spec
QC Rep.
"
"
"
"
"
"
"
"
P
P
P
P
V
P
V
V
V
"
"
"
"
P
P
V
P
P
NA
P
NA
P
NA
NA
NA
NA
NA
NA
NA
P
P
P
P
P
P
P
P
"
"
"
1 Dimensions
2 Block Alignment,Position
and tightness
Major
Meas.
Each unit
S/M/C Spec
S/M/C Spec
QC Rep.
3 Absence of Interstand
short circuit (ContinuityBefore and After coil
Pressing)
Major
Physical
"
"
"
"
4
5
6
1
2
3
1
Major
Major
Major
Major
Major
Major
Major
Physical
Electrical
Physical
Meas.
Meas.
Meas.
Physical
"
"
"
"
"
"
"
"
"
"
"
"
Each unit
Each unit
Each unit
Each unit
S/M/C Spec
S/M/C Spec
QC Rep.
"
"
QC Rep.
"
"
QC Rep.
S/M/C Spec
S/M/C Spec
QC Rep.
Major
Major
Physical
Electrical
Each unit
Each unit
"
"
QC Rep.
"
"
QC Rep.
Major
Electrical
Each unit
"
"
QC Rep.
Insulation Scheme
Resistance
Insulation condition
Dimensions
Core Diameter
Stack Thickness
Coil Supporting
Arrangement
Assembly of Windings
2 kV test between core &
frame
Turns ratio and Vector
group verification
Ovening Temp
Meas.
Major
"
"
3 Polarisation Index
"
"
S/M/C Spec
S/M/C Spec
Major
Meas.
Each Unit
2 Insulation Resistance
Visual
Each unit
Tanked
PREPARED BY : ( Mahindra SUSTEN)
Vendor to share the
Work Procedures
for transportation
and handling of
V
CRGO
P
NA
P
V
NA
P
V
NA
NA
P
P
NA
S/M/C Spec
1 Electrical clearances
REMARK
V SUSTEN reserve
the right to do the
on stage
V inspection of
Transformer at
any of the
manufacturing
V stages mentioned
V in this QAP before
V final inspection,
V SUSTEN can also
V check the QC
V process of any
Supplier of Vendor
V
and vendor has to
V
fecilitate the same
in all respect
V
without any further
V
financial
implications.
V
NA
S/M/C Spec
1
AGENCY
"
Major
4
Ovening
Major
Major
Major
Major
QUANTUM
CHECK
5 Paint Shade,thickness &
peel off
2
3
2.04
Thickness
Dimensions
Wiring Quality-Tidiness
HV Test 2kv for 1 Min
Operational check
TYPE OF
LEGEND :
QC Rep.
"
CHP - Customer Hold Point
S: Supplier, M- Manufacturer/Vendor
C - Customer, E- End User
P - Agency Performing The Test
V - Agency Verifying The Test Reports
W - Agency Witnessing The Test
Note: Customer specifications supersedes IS for
routine and type tests
Page No : 4 of 5
QUALITY ASSURANCE PLAN
Doc NO : IMS-QH-QAP-009-001
Date:
23.12.2015
Rev No :07
Item : Inverter Transformer & Aux. Transformer (Oil Filled)
Mahindra SUSTEN
Rating: up to 33 KV
SL.
COMPONENT &
No.
OPERATION
1.01
3.00 Core
FinalLamination
Testing
3.01
Routine tests
CLASS
TYPE OF
QUANTUM
REFERENCE
ACCEPTANCE
FORMAT OF
CHECK
OF CHECK
DOCUMENT
NORMS
RECORD
Critical
Electrical
Each Unit
"
Critical
"
"
Critical
"
Critical
CHARACTERISTICS
Thickness
1 Measurement of Winding
Resistance
AGENCY
S
REMARK
M
C/E
Manufacturer
Test Rep.
P
W
"
"
P
at all tap Positions
Vendor to share the
Work Procedures
for transportation
all Tap of
andathandling
W
Positions
CRGO
"
"
"
P
W
"
"
"
"
P
W
Critical
"
"
"
"
P
W
Critical
"
"
"
"
P
W
P
W
P
W
2 Measurement of Voltage
ratio and check for Vector
relationship
3 Measurement of
Impedance Voltage &
short Circuit Impedance
4 Measurement of No Load
Losses & Current
5 Measurement of Load
Losses
6 Induced Over voltage
Withstand test
7 Magnetic Balance Test
Critical
8 Separate Source Voltage
withstand test
As per customer
specifications/GTP (In absence
of customer specifications as
per IS 2026)
Critical
"
"
"
Critical
"
"
P
W
Critical
"
"
IR on each
unit, PI on
one unit of
each rating
"
P
W
"
P
W
"
P
W
"
P
W
"
P
W accessories
9 Oil BDV Test
10 Insulation Resistance &
Polarization Index
11 Lightning Impulse Test
One Unit for
Each Rating
Critical
13 Calculation of Efficiency
& Regulation
14 DPT Test for welding
Critical
Major
15 Oil Pressure Test
Critical
"
"
"
Chemical
Random
Mechanical
Each Unit
on any Tr & at any
portion of welding
with radiator & all
connected to main
tank
16 Temperature Rise Test
Critical
4.00
Electrical
One Unit for
Each Rating
1 Packing of accessories
Dispatch
2 Touch up Painting
Major
Physical
Each Unit
"
"
"
"
P
QC Rep
P
"
"
P
S/M/C Spec/ Dispatch
clearance
"
P
"
S/M/C Spec
"
S/M/C Spec
CHP, Radiators to be
3 Packing and Dispatch
(Packing should be done
as per the attached SOP
for Packing & dispacth )
"
"
"
W
dispatched in
disassembled/loose
condition, Every
loose accessories
must be specific
identification no.,
Cable Terminations &
dressing must be
completed in all
respect on Tr. Tank &
at MB end
Note : For trafo more than 5 MVA rating vendor has to dispatch along with Impact Recorder.
PREPARED BY : ( Mahindra SUSTEN)
LEGEND :
CHP - Customer Hold Point
S: Supplier, M- Manufacturer/Vendor
C - Customer, E- End User
P - Agency Performing The Test
V - Agency Verifying The Test Reports
W - Agency Witnessing The Test
Note: Customer specifications supersedes IS for
routine and type tests
Page No : 5 of 5