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QC/QP/01 ISSUE#02 PAGE 1 of 3

THATTA CEMENT COMPANY LIMITED


(Quality Control Department)

QUALITY PLAN

RAW MATERIALS

S.No.

Process

Referance of Procedure/ Work Instruction


No.

Characteristic

Specification & Tolerance


Process

Inspection & Testing

Report Granted

Reaction Plan

Product

Sample

Frequency

Report Number

1 2 3 4 5

Lime stone Makli Shale Iron Ore Jungshahi Shale / Silica Sand Coal

QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/14 QC/SOP/14 QC/SOP/14

1 2 3 4 5 6 7 1 1 2 3 1 2 3 4 5

CaO Al2O3 Fe2O3 SiO2 Moisture Sulphur Heating Value (Kcal/kg) SO3 Lime stone Iron Ore Additives Raw Meal A.M SM. LSF T.CaCO3

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Residue N/A N/A N/A N/A

35 to 55% 5 to 30% 20 to 50% 30 to 95% less then 20 5% 4000-7500 30 to 44% 70 to 95% 2 to 10% 1.0% to 30% 10.0 to 22% 0.7 to 1.80 2.00 to 2.80 0.70 to 1.15 75 to 79

Once Once As per supply do do do do do Once Once As Required Once Once Once Once Once

Fortnigthly Fortnigthly Truck wise Weekly Truck wise Truck wise Truck wise Daily Daily Daily As Required Hourly Hourly Hourly Hourly Hourly

Raw Material Analysis (QC/FM/02) Raw Material Analysis (QC/FM/02) Raw Material Analysis (QC/FM/02) Raw Material Analysis (QC/FM/02) Coal Analysis File (QC/FM/05) do do Raw Material Analysis (QC/FM/02) Pile Preparation Register (QC/FM/03) Pile Preparation Register (QC/FM/03) Pile Preparation Register (QC/FM/03) Daily Analysis Report (QC/FM/07) Daily Analysis Report (QC/FM/07) Daily Analysis Report (QC/FM/07) Daily Analysis Report (QC/FM/07) Raw Mill & Kiln Feed Register (QC/FM/04)

Face change -doRejection / dedection -do-do-do-do-doAdjust -do-doAdjust Adjust -do-do-do-

6 7

Gypsum (Incoming) Pile Prepration

QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22

PROCESS

Raw Meal Grinding

QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/13

Note: T. CaCO3 (Titration) will be carried out only when XRF is out of order or in maintenance. Note:- Additives contain Convertor Slag, Granulated Slag, and Boulder Slag.
-do-

QC/QP/01 ISSUE#02 PAGE 2 of 3

QUALITY PLAN
S.No. Process Referance of Procedure/ Work Instruction No. Pryo Processing (Kiln Feed) Characteristic Specification & Tolerance Process Inspection & Testing Report Granted Reaction Plan

Product

Sample

Frequency

PROCESS

QC/SOP/22 QC/SOP/22 QC/SOP/22 9 Clinker Checking QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/03 10 Cement Grinding/Packing QC/SOP/15 QC/SOP/20 Cement (O.P Cement) Clinker : 95 to 97% QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/04 QC/SOP/22 QC/SOP/22 Cement (SLAG Cement) Clinker : 60 to 79% Gypsum: 01 to 05% Granulated Slag :20 to 35% QC/SOP/ 22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22

1 2 3

A.M S.M L.S.F

N/A N/A N/A

0.70 to 1.80 1.90 to 2.80 0.70 to 1.15

Once Once Once

Alternate hour Alternate hour Alternate hour

Daily Analysis Report (QC/FM/07) -do-do-

Adjust * -do-do-

1 2 3 4 5 1 2 3 4 5 6 7 9 10

A.M S.M L.S.F C3S Litre weight Blaine Value Residue A.M S.M L.S.F SO3 LOI MgO Cl

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

0.80 to 1.70 1.90 to 2.80 0.85 ~ 0.95 40 to 70 1150 to 1550 g 225 m2 / kg (Minimum) 10 % (Maximum) 0.90 to 1.70 1.90 to 2.70 0.66 to 1.02 3.0 % (Maximum) 4.0 % (Maximum) 5.0 % (Maximum) 0.1 % (Maximum)

Twice -do-do-doOnce Once Once -do-do-do-do-do-do-do-

per Shift -do-do-doHourly Alternate hour -do-do-do-do-do-do-do-do-

Daily Analysis Report (QC/FM/07) -do-do-do-do-do-doDaily Analysis Report (QC/FM/07) -do-do-do-do-do-do-

Adjust * -do-do-do-doAdjust -doAdjust -do-do-do-do-do-doAdjust -do-do-do-do-do-do-

FIINSH PRODUCT

Gypsum: 03 to 05%

1 2 3 4 6 7 8

A.M S.M L.S.F LOI MgO Cl SO3

N/A N/A N/A N/A N/A N/A N/A

1.00 to 2.20 1.90 to 2.70 0.66 to 1.02 4.0 % (Maximum) 7.0 % (Maximum) 0.1 % (Maximum) 3.0 % (Maximum)

Once -do-do-do-do-do-do-

Alternate hour -do-do-do-do-do-do-

Daily Analysis Report (QC/FM/07) -do-do-do-do-do-do-

* Adjust through Raw Mill

QC/QP/01 ISSUE#02 PAGE 3 of 3

QUALITY PLAN
S.No. Process Referance of Procedure/ Work Instruction No. Cement (S.R Cement) Clinker :95% to 97% Gypsum :03%to 05% QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 QC/SOP/22 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 Characteristic Specification & Tolerance Process N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 0.70 to 0.90 1.90 to 2.70 0.66 to 1.02 3.0 % (Maximum) 4.0 % (Maximum) 5.0 % (Maximum) 0.1 % (Maximum) Less than 3.50 225 m / kg (Minimum) 45 minutes (Minimum) 600 minutes (Maximum) 10 mm (Maximum) 0.80 (Maximum) 10 % (Maximum) 25 to 35 % 20.0 N / mm (Minimum) 23.5 N / mm (Minimum) 40.0 N / mm (Minimum)
2 2 2 2

Inspection & Testing

Report Granted

FIINISH PRODUCT

Reaction Plan

Product A.M S.M L.S.F SO3 LOI MgO Cl C3A Blaine Value Initial Setting Time Final Setting Time Le Chatlier Expansion Auto Clave Residue on 90 Consistency % 03 Days 07 Days 28 Days

Sample Once -do-do-do-do-do-do-doOnce Once -do-do-do-do-doOnce -do-do-

Frequency Alternate hour -do-do-do-do-do-do-doDaily Daily -do-doweekly -do-doDaily -do-doA.M S.M L.S.F C3A C3S Daily Analysis Report (QC/FM/07) -do-do-do-do-do-do-doDaily Analysis Report (QC/FM/07) -do-do-doAuto Clave Test for Cement (QC/FM/10) Daily Analysis Report (QC/FM/07) -do-do-do-doAlumina Modulas Silica Modulas Lime Saturation Factor Tri Calcium Aluminate Tri Calcium Silicate Adjust -do-do-do-do-do-do-doAdjust -do-do-do-do-do-doAdjust * -do-do-

PHYSICAL TESTING

11

Physical Test

QC/SOP/15 QC/SOP/17 QC/SOP/17 QC/SOP/18 QC/SOP/25 QC/SOP/20 QC/SOP/16

12

Compressive Strength

QC/SOP/ 19 QC/SOP/ 19 QC/SOP/ 19

* Adjust through Cement Mill

NAME PREPARED BY APPROVED BY ZAHOORUDDIN BULAND IQBAL

DESIGNATION Dy. MANAGER (Quality Control) Dy. MANAGER (Quality Control)

SIGNATURE.