PROJECT:

MANUFACTURING QUALITY PLAN

QP No.:
1 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
RAW MATERIAL
1.0 I) CRGO Coils a) Dimensions Major Measurement 100% - IS:3024:1997 IS:3024:1997 QC Record P - -
b) Specfic Losses " Measurement " - " " " V - -
c) Thickness &Finish " " sampling - " " " P - -
d) Surface Resistivity " Test " - " " " V - -
e) Stacking Factor " " " - " " " V - -
f) Permeability " " " - " " " V - -
g) Bend Test / Ductility " " " - " " " V - -
h) Transit Damages " Visual 100% - " " Supplier TC V - -
i) Waviness & Camber " Visual 100% - " " " V - -
2.0 Copper wire rods a) Tensile Strength Major Measurement 1Sample / lot - IS 12444 / ASTM B 49 IS 12444 / ASTM B 49 QC Record V - -
b) Elongation " Measurement " - " " " V - -
c) Dimensions " Measurement " - " " " P - -
d) Visual " Visual " - " " " V - -
e) Resistivity " Measurement " - " " " P - -
f) Chemical Analysis " Measurement " - " " " V - -
Transit Damages & Packing
3.0 Kraft Paper a) Major Visual 100% IEC 554 IEC 554 QC Record V - -
Condition -
b) Dimensions " Measurement 1Sample / lot - " " " P - -
c) Density " " " - " " " V - -
d) Elongation " " " - " " " V - -
e) Moisture content " " " - " " " V - -
f) Ash Content " " " - " " " V - -
g) Dielectric strength " " " - " " " V - -
h) Tensile strength " Test " - " " Supplier TC V - -
i) Water Absorption " " " " " " " V - -
j) pH value & Conductivity aqueous " " " " " " " V - -
k) Electrical strength " " " " " " " V - -
l) Air Permeability " " " " " " " V - -
m) Tear Index " " " " " " " V - -
n) Heat Stability (>3 mil) " " " " " " " V - -
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Manufacturer/ Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
and "V" Verification.
Sub Supplier Main- Supplier
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
2 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
LEGEND: * Records, Identified with tick shall be essentially included by
NO. OPERATIONS CHECK
contractor in QA documentation. CHECK / Sub Contractor.
** M: Manufacturer DOCUMENT
C: NORMS RECORD **
Contractor / Nominated Inspection Agency
M . Indicate "P"
C/NPerform "W" Witness M C
and "V" Verification.
1 2 3 4 5 6 7 8 9 D* 10 11
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
3 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
Sample from
4.0 Insulating Oil a) Appearance Major Visual each tanker IS 335 IS 335 QC Record
- P - -
b) Density at 27 C 0 " Measurement " - " " " V - -
c) Viscosity at 270C " " " - " " " V - -
d) Interfacial Tension at 270C " " " - " " " V - -
e) Flash point " " " - " " " V - -
f) Pour point " " " - " " " V - -
g) Neutralisation value - - -
I) Total Stability " " " - " " " V - -
ii) Inorganic Acidity " " " - " " " V - -
h) Corrosion Sulphur Copper strip Sample from
19 hrs @ 1400C " " each Batch " " " V
- - -
Sample from
I) BDV " " each tanker " " " V
- - -
j) Dielectric dissipation factor @ 90°C
" " " - " " " V - -
k) Specific resistance - - -
i) at 27°C " " '
- " " " V - -
ii) at 90°C " " " - " " " V - -
l) Oxidation Stability Sample from
" " each Batch - " " " V - -
m) Accelerated aging test Sample from
" Test each Batch - " " " V - -
Sample from
n) Presence of oxidation inhibitor " Measurement each tanker - " " " V - -
o) Water content " " " - " " " V - -
IEC: 641
IEC: 641
5.0 Insulating Press a) Finish Appearance Major Visual 10 % of lot IS - QC Record V
- IS - 1576 - -
1576
Boards b) Dimensions " Measurement 10 % of lot - “ “ " P - -
c) Density " " Sample/lot - “ “ " V - -
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
4 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
d) Tensile Strength Test Sample/lot IEC: 641
IEC: 641
Major IS - QC Record
- IS - 1576 V - -
1576
e) Electric Strength in air & oil " " “ - " " " V - -
f) Ash content " " “ - " " " V - -
g) Moisture content " " “ - " " " V - -
h) Shrinkage in Air & Oil " " “ - " " " V - -
i) Flexibility " " “ - " " " V - -
j) pH value / Conductivity of water
" " “ - " " " V
extract - -
k) Compressibility " " “ - " " " V - -
l) Oil absorption " " “ - " " " V - -
m) Cohesion between piles " " “ - " " " V - -
Plant Std. Plant Std.
Finish Appearance Visual 10 % of lot
6.0 a)
Perma Wood Major - QC Record V - -
IS - 3513 IS - 3513
b) Dimensions " Measurement 10 % of lot - " " " P - -
c) Electric Strength in oil & air " " Sampling - " " " V - -
d) Density " " " - " " " V - -
e) Tensile Strength " " " - " " " V - -
f) Cross breaking strength " " " - " " " V - -
g) Compressive strength " " " - " " " V - -
h) Shear strength " " " - " " " V - -
I) Oil absorption " " " - " " " V - -
k) Moisture content " Test " - " " " V - -
l) Specfic gravity " " " - " " " V - -
7 Paper Covered a) Finish Appearance Major Visual 100% - IS 13730 IS 13730 QC Record V
Conductor - -
b) Dimensions (Bare & Covered)
Major Measurement Each bobbin - " " " P
- -
c) Resistivity Major Electrical test Sample /lot - " " " P - -
d) Tensile Strength Major Physical test " - " " " V - -
e) Elongation Major Physical test " - " " " V - -
f) Covering Thickness Major Measurement Each bobbin - " " " V - -
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
and "V" Verification.
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
5 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 LEGEND:
4 * Records, Identified
5 with tick shall be
6 essentially included by7 8 9 D* 10 11
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
6 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
8.0 MS material (Plates, a) Finish Appearance Major Visual 100% - IS 2062 IS 2062 QC Record V - -
Channels) b) Dimension " Measurement Sampling - " " " P - -
c) Chemical composition " " " - " " " V - -
d) Tensile strength " " " - " " " V - -
e) Yield strength " " " - " " " V - -
f) Elongation " " " - " " " V - -
9.0 Hardware a) Dimensions Major Measurement Sampling - CS / AD IS 1367 CS / AD IS 1367 QC Record P - -
b) Appearance " Visual " - " " " V - -
c) Tensile Strength Test " Test " - " " " V - -
10.0 Gaskets a) Finish Appearance Major Visual Sampling - IS4253 IS 4253 QC Record V - -
b) Dimensions " Measurement " - " " " P - -
c) Compressibility " " “ - " " " V - -
d) Tensile Strength " " “ - " " " V - -
e) Recovery % " Measurement “ - " " " V - -
f) Hardness " Test " - " " " V - -
g) Compression Set " " " - " " " V - -
h) Flexibility " " " - " " " V - -
I) Chloride/ Sulphat content of
" " " " " " V
water extract - - -
11.0 Insulators a) Finish appearance Major Visual 100% - IS 5621, IS 7421 IS 5621, IS 7421 QC Record V - -
b) Dimensions " Measurement 10% of lot - " " " P - -
c) Temperature cycle test " " 5 Nos / lot - " " " V - -
d) Porosity test " Test " - " " " V - -
e) Electrical routine Tests " " " - " " " V V V
b) Metal parts a) Finish Appearance Major Visual Sampling - IS 3347/ AD IS 3347/ AD QC Record V - -
b) Dimensions " Measurement " - " " " P - -
12.0 Plating a) Finish appearance Major Visual Sampling - IS 1572 / IS IS 1572 / IS 1573/ QC Record V - -
b) Thickness of coating " Measurement " - 1573/ IS 4759 IS 4759 " P - -
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
7 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
13.0 Paints
a) Primer a) Appearance Major Visual 100% - SDS SDS QC Record V - -
b) Hot oil resistance
paint b) Viscosity " Measurement Sampling " " " V
- - -
c) Enamel Paint a) Appearance " Visual 100% - " " " V - -
b) Viscosity " Measurement Sampling - " " " V - -
c Shade " Visual 100% - " IS 5 " P - -
d) Drying time " Measurement Sampling - " SDS " V - -
e) Finish " Visual 100% - " " " V - -
14.0 HV & LV a) Finish appearance Major Visual 100% - CS / AD/ IS 5561 CS / AD/ IS 5561 QC Record V - -
connectors b) Dimensions " Measurement Sampling - “ “ " P - -
c) Acceptance Test " Measurement " - " " " V - -
15.0 Pressure Relief a) Type, Size & Make Major Measurement Sampling - Plant Std. Plant Std. QC Record P - -
devices b) Operation pressure & Flag " Test Sampling " " "
indication) - V - -
c) Switch contact " " " - " " " V - -
d) HV test " " " - " " " V - -
e) Pressure Test " " " - " " " V - -
16.0 Bucholz Relay a) Type, Size & Make Major Visual Sampling - IS 3637 IS 3637 QC Record P - -
b) Contunity for Alaram & trip " Test " - " " " V - -
c) Porosity test " " " - " " " V - -
d) High Voltage tests " " " - " " " V - -
e) Element Test " " " - " " " V - -
f) Gas Volume test " " " - " " " V - -
g) Loss of oil & surge test " " " - " " " V - -
17.0 Off- Circuit Tap a) Dimensions Major Measurement 10% - Manufacturer Drg. Manufacturer Drg. QC Record P - -
changer b) Physical Condition " Visual 100% - " " " P - -
c) Operation of Switch " Test " - " " " P - -
d) Insulation Resistance test " Test " - " " Supplier TC V - -
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
8 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
18.0 Magnetic Oil Level a) Type, Size & Make Major Visual Sampling - Supplier TC Supplier TC QC Record P - -
Gauge b) Dial Marking " " " - " " " V - -
c) Switch Contunity " " " - " " " V - -
d) HV Test " Tset " - " " " V - -
e) Operational Test " " " - " " " V - -
19.0 OTI & WTI a) Type, Size & Make Major Visual Sampling - Supplier TC Supplier TC QC record P - -
b) HV Tset " Test " - " " " v - -
c) Temperature Calibration " " " - " " " V - -
d) Switch setting & switch
" " " - " " " V - -
Deferential
e) Calibration & Operation of
" " " - " " " V - -
Switch
20.0 Silicagel Breather a) Type, Size & Model Major Visual Sampling - Supplier TC Supplier TC QC Record P - -
b) Pressure / Leakage Test - " " Supplier TC V - -
c) Colour of Silica Gel - " " " V - -
21.0 Radiators & a) Dimensions & No. of Elements Major Meassure sampling - Apd. Drg / IEEMA 9 Apd. Drg / IEEMA 10 QC Record P - -
radiators welding
requirement b) Paint shade, Finish, & Film Visual /
" - " " " P
Thickness Measure - -
c) Pressure test " test " - " " " V - -
d) Adhension test on paint " " " - " " " P - -
e) Fitup for weld joints " Visual " - " " " V - -
22.0 Roller Assembly a) Dimensions Major Measure One/Lot/Size - Apd. Drg Apd. Drg QC Record P - -
23.0 Valves a) Dimensional Check Major Measure Sampling - Apd. Drg Apd. Drg QC Record P - -
(Gate/ Globe/ b) Type, Size & Make " Visual " - " " " P - -
Butterfly) c) Leakage Test " Test " - " " Supplier TC V - -
d) Operational test " " " - " " " V - -
24.0 Marshling Box a) Visual Check Major Visual Sampling - Apd. Drg Apd. Drg PS V - -
b) Dimensional Check " Measure " - " " " P - -
c) Terminal arrangement / ferruling /
labeling " Visual " - " " " V - -

LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
9 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
IN PROCESS CHECKS
Fabrication of Tank, a) Cutting of material as per given
1.0 Cover, convservator drawing Major Measurement Sampling - PS PS PS P - -
& Welding
Requirements b) Finish dimensions & completeness as " " " - " " " P - -
per drawing
c) Fitup for Butt weld joints of tank and
cover " Visual " - " " " V - -

d) Conservator Dimensions " " " - " " " P - -

e) Finish of weld " Visual " - " " " P - -
f) Finish of material after gas
cutting and welding " " " - " " " P - -

g) Welding Process Specification Approved WPS / Approved WPS /

" Verify 100% - " V - -
ASME-IX ASME-IX
h) Process Qualification Records
" Test " - " " " V - -

i) Welders Qualification " " " - " " " W - -

Approved WPS /
j) Welding Electrodes Approved WPS /
" Verify " - IS " V - -
IS 814
814
k) DP Test on welded joints of load
" Test " - PS / IS 3658 " P - -
bearing member "
l) Leak test " Test 100% - " " " P - -
m) Surface cleaning by Shot/ Sand
" Visual 100% - Plant Std. Plant Std. " V - -
Blasting
n) Surface finish prior to paint
" Visual Sampling - " " " P - -
application
o) Application of Paint " " " - " " " P - -
p) Paint thickness " Measurement " - " " " P - -
q) Visual check on weldment " Visual 100% - Plant Std. Plant Std. QC Record V - -
r) Dimensional check after welding " Measure Sampling - " " " P - -
s) Check for flatness of gasketing
surface " Visual Sampl;ing - " " " P - -

t) Rim Flatness " Measure Sampling - " " " P - -

u) Paint shade, Film Thickness spot check on
inside and outside " measure random basis
- " " " P - -

v) Paint film adhesion test " Tset " - " " " P - -
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
10 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
11 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
2.0 Core assembly / a) Formation of core section Major Measurement Sampling - PS PS PS P - -
Core Building b) Core dia " " " - " " " P - -
c) Stack thickness " " " - " " " P - -
d) Burr & Bow " " " - " " " P - -
e) Leg length " " " - " " " P - -
f) Window width " " " - " " " P - -
g) Leaning of core (i.e. verticality) " Visual " - " " " P - -
i) Rectungalirity of core Assembly " " " " " " " P - -
j) Limb clamping & Binding " " " " " " " P - -
Freedom from overlaps, air gaps " " " " " " "
k) at joints P - -
l) Earthing of core " " " - " " " P - -
m) Pre core loss measurementy " " 100% - " " " P - -
Insulation test at 2KV for 1
min between core end and end
n) " " " - " " " P - -
frame to yoke bolts, core
clamp to yoke bolt
3.0 Winding a) Conductor Size Major Measurement Sampling
- PS PS PS P - -
b) Coil dimensions ( ID, OD, AH,
RD) " " “ " " " P
- - -
c) Insulation arrangement " Visual “ - " " " V - -
d) Turns arrangement " " “ - " " " V - -
e) Transposition " " “ - " " " V - -
f) Contunity Test for leads " Test 100% - " " " P - -
Brazing Procedure & Brazer
g) " Review One time - Apd. Drg Apd. Drg PS P - -
Qualification
h) Radial depth of winding " Measure Sampling - " " " P - -
j) No Of turns " " " - " " " P - -
k) Brazing joints " Visual " - " " " P - -
l) Free from Damages " " " - " " " P - -
m) Anchoring & Binding at start & " Measure "
" " " P - -
finish -
n) Lead & coil identification " Visual " - " " " P - -
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
and "V" Verification.
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
12 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 LEGEND:
4 * Records, Identified
5 with tick shall be
6 essentially included by7 8 9 D* 10 11
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
13 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
4.0 Core & Coil a) Dimensions Major Measurement 100% - PS PS PS P - -

Assembly b) Axial and Radial Insulation " " " - " " " P - -
arrangement
c) Electrical clearances " " " - " " " P - -

d) HV & LV connections " Visual " - " " " V - -

Insulation and finishing of
e) " " " - " " " V - -
brazed / crimped joints
f) Core to frame HV test " Test " - " " " P - -

f) Ratio test Major Test 100% - IS 2026 IS 2026 IS 2026 P - -

g) Cleaniliness of assembly of core
Apd. Drg Apd. Drg - -
" Visual 100% - PS P
h) Alignment of Spacers/ blocks " " " - " " " P - -

5.0 Connection and Tap a) Ratio test on all taps Major Test 100% - Apd. Drg/ PS Apd. Drg/ PS PS P - -
switch Assembly
b) Lead dispiation " Visual " - " " " P - -
c) Brazing of joints " " " - " " " P - -
d) Crimping of joints " " " - " " " P - -
e) Insulation over joints " " " - " " " P - -
f) Vector group " Test " - " " " P - -
Drying of core coil a) Temperature Major Measurement Every one
6.0 PS PS PS - -
Assembly hour - P
b) Time duration Major Measurement “ - " " " P - -
7.0 a) Cleanliness of tank Major Visual 100% - PS PS PS P - -
Ovening, Tanking & -
b) Insulation Resistance " " " " " " P - -
Oil filling
c) Clamping of CCA " " " - " " " P - -
d) Job locking " Mechanical " - " " " P - -

e) Completeness " Visual " - " " " P - -

f) Winding Height " Measurement " - " " " P - -
g) Electrical clearances " " " - " " " P - -
h) Oil filling & Air release " " " - " " " P - -
Fixing of accessories & Fittings
i) " Visual " - " " " P - -
as per drawing
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
14 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
15 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11
4.0 FINAL TESTING
IS 2026 / Appd. IS 2026 / Appd.
1.0 Routine Test a) Dimensional checks Critical Measure 100% 1 job Test Sheet √ P -
Drgs Drgs
Measurement of Windings
Resistance of HV at normal,
b) Critical Test 100% 10% IS 2026 IS 2026 Test Sheet √ P -
extreme taps & full winding of
LV

Measurement of Voltage Ratio at

c) " " " " " " " √ P -
all taps, polarity & vector group.

Magnetic balance test with low

d) voltage single phase on LV side " " " " " " " √ P -
for 3 phase transformer

Measurement of No load loss &

e) magnetizing current at 90%, " " " " " " " √ P -
100% & 110% at 50Hz.

Measurement of impedance
voltage / short circuit impedance
f) " " " " " " " √ P -
at principal tap & two extreme
taps.

Measurement of insulation
g) " " " " " " " √ P -
resistance of winding
Induced over Voltage test on HV
h) " " " " " " " √ P -
& LV Terminals
Separate source Voltage with
i) " " " " " " " √ P -
stand Tests

j) Measurement of Load losses " " " " " " " √ P -

LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 01 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 PROJECT:
MANUFACTURING QUALITY PLAN
QP No.:
16 of 17
ITEM: Power Transformers (Three Phase) Rev No.: PACKAGE:
Date : CONTRACT NO.

PAGE : MAIN SUPPLIER:

SL. COMPONENT & CHARACTERSTICS CLASS TYPE OF QUANTUM OF REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK CHECK DOCUMENT NORMS RECORD **
M C/N M C
1 2 3 4 5 6 7 8 9 D* 10 11

k) 2kV core isolation test for 1 min. Critical Test 100% 10% IS 2026 IS 2026 Test Sheet √ P -

Repeat No Load current / loss

l) measurement after completation " " " " " " " √ P -
of dielectric test

Measurement of Capacitance &

m) " " " " " " " √ P -
Tan delta for winding to earth

Oil leakage test on tank with

n) turrets at normal pressure plus Critical Test 100% 10% IS 2026 IS 2026 Test Sheet √ P -
35kPA for 24 hours

Jacking test on oil filled Techanical Spec / Techanical Spec /

l) " " " " " √ P -
transformer followed by DP Test IS 3658 IS 3658

Paint shade thickness & Adhesion spot check

Visual/
m) test (Main tank, Conservator tank, " on random Technical Spec Technical Spec " √ P -
Measure/ Test
Radiator & MB) basis

One
One
n) Oil Sample Test (BDV test) " " Sample/ IS 1866 IS 1866 " √ P -
Sample/ Lot
Lot
TYPE TEST
2.0 As per Technical Specifications
Despatch Packing of loose items and main Plant Std Packing Plant Std
3.0 a) Major Physical 100% - QC Record P -
unit list Packing list
LEGEND: * Records, Identified with tick shall be essentially included by Doc No: REV: 00 CAT: 0
contractor in QA documentation. ** M: Manufacturer / Sub Contractor. C:
Contractor / Nominated Inspection Agency . Indicate "P" Perform "W" Witness
Manufacturer/ and "V" Verification.
Subcontractor Contractor
Reviewed By: Approved By Approval Seal
 Annexure - 1

LIST OF TRANSFORMER ITEMS / ACTIVITIES - WHICH REQUIRES NTPC's APPROVAL FOR

VENDORS

Sl No Bought-out Item Sub-Suppliers' Name

1 Copper Wire Rod

2 Paper Insulated Copper Conductor & Insulating Paper

3 CRGO Steel (Lamination Supplier)
4 MS Steel Plates & Pipes (for Tank & Oil lines)
5 Radiator
6 Insulating Transformer Oil
7 Bushings (Condensor / Porcelain / Epoxy)
8 Bushing Current Transformers
9 Gas Operated Relay (Bucholtz Relay)
10 Magnetic Oil Level Gauge (MOG)
11 Pressure Release Valve (PRV)
12 WTI, OTI & RTD
13 On Line Tap Changer
14 Fan, Pump & Motor
15 Pressboard Item under 'Noted' Category
16 Permawood Item under 'Noted' Category
17 Densified Wood
18 Silica Gel Breather
19 Gasket Item under 'Noted' Category
20 Valves (Radiator, Gun Metal, CI Valves)
21 Marshalling Box & RTCC
a LT AC Auxillary Contactor
b Control Selector, Control Switches & Push Buttons
c MCB / MCCB
d Thermal Overload Relays
e Indicating Lamps
f LT Fuse
g LT PVC Coper Wires
h Terminal Block
i Glands & Lugs

Sl No Out Sourced Activities

1 Tank Fabricators
2 Lamination Processors
3 Marshalling Box Fabricators
4 Remote Tap Changer Control Cabinet Fabricators