GAYATRI METALIC FOUNDRY

Mfg. Transmission line hardwares & Substation connectors

MANUFACTURING QUALITY PLAN (MQP).

ITEM

( √ ) Insulator String Hardwares. : Section : 01.

( √ ) Conductor Accessories. : Section : 02.

( √ ) Earthwire Accessories. : Section : 03.

( √ ) Clamp – Connectors(Bolted/Comp): Section : 04.

& Spacers.

Customer : GETCO/GETCO Projects/EPC.

Issue Date :

For Gayatri Metalic Foundry.

Office & Works : - 29, GIDC. ESTATE, VITHAL UDYOG NAGAR - 388 121. (GUJARAT)
PH.: 236166 FAX : (02692) 229104. M : 99798 98311 E-mail : gmfoundry@yahoo.com
 SECTION – 01
INSULATOR STRING HARDWARES.
Operation/ Quantum of Reference Acceptance
Testing Agency
Test check documents Norms
1. RAW MATERIALS.
1.1 M.S. Steel for Forgings
samples for Good surface
At our Steel yard.
Visual. quality and Plant standard finish, free from
Form 103.
workmenship. cracks & ovality.
At our steel yard by
Within IS
Dimension. Random. IS 2062-1999 gauge, scale & taps
Tolerance limit.
form 103.
IS 1875-1992 class –
II
%C - 0.15 to0.25. Manufacturer TC for
One No. in
%Si – 0.15 to 0.35 each lot. Randomly
Chemical. each batch of Within IS limit.
%Mn – 0.6 to 0.9 check by us at other
each size.
%S -- 0.04 Max. laboratory.
Class IV for 400 kv
line
Hardness. . BHN 120 Min. Within Limit. Manufacturer TC
1.2 M.S. Steel for Fabrication.
100%/
Good surface
samples for At our Steel yard.
Visual. Plant standard finish, free from
quantity and Form 103.
cracks & ovality.
workmanship.
At our steel yard by
Within IS
Dimension. Random. IS 2062-1999 gauge, scale & taps
Tolerance limit.
form 103.
IS 2004-1991.
Manufacturer TC for
One No. in % C – 0.15 to 0.25
each lot. Randomly
Chemical. each batch of %Si – 0.15 to 0.35. Within IS limit.
check by us at other
each size. %Mn – 0.6 to 0.9.
laboratory.
%S -- 0.4 Max.

1.3 Alliminum alloy. (LM 6) for casting.

IS 617/1994. grade
One No. in 4600 (LM 6). Manufacturer TC for
Chemical. Within IS Limit.
each batch Si – 10 to 13 % each lot..
.

1.4 Alluminium Sections- Tubes & Flats.

100%/
Good surface
samples for At our store.
Visual. Plant standard. finish, free from
quantity and Form-103
cracks & ovality.
workmenship.
Manufacturer’s Test
IS 5082-1998 Within IS
Dimension. Random. certificate & recheck
Tolerance limit.
at our laboratory.
 Form 103
IS 5082-1998
One No. in Alloy 19501. Manufacturer’s Test
Chemical. each batch of Aluminium – 99.5% Within IS limit. Certificate by spectro
each size. Min.. analysis.
Alloy 63501 for AL59
IS 5082 – 1998
One No. in Manufacturer’s Test
Mechanical. Alloy 19501. Within IS limit
each batch. Certificate.
60 N/Mn2
IS 5082-1998
One No. in Manufacturer’s Test
% elongation Alloy 19501 Within IS limit
each batch. Certificate.
25 % Min..
1.5 Zinc.
One No. in Zn – 98 of IS Manufacturer’s Test
Chemical. Within IS limit
each batch. Zn-99.98 % Min. Certificate.
2. INPROCESS MATERIALS.
2.1 Forgings.
100%
Good surface
/samples for At our Store
Visual Plant standard finish, free from
quality and .
cracks
workmanship.
Samples/All IS 2486 with gauges Within tolerance At incoming material
Dimensions.
shockets. & scales. limit. sampling desk.
IS – 2486 tested by Should withstood In house laboratory
Mechanical. Samples. applying rated load for 1 min on hydraulic testing
mechanical pull load. duration. set up.
2.2 Fabrication.
100%
Good surface
/samples for
Visual Plant standard finish, free from At our Shop floor.
quality and
cracks & ovality.
workmanship.
Should withstood
IS 2486 with gauges
Dimension Sample load for 1 min On shop floor.
& taps.
duration.
IS 2486 free from No sharp edges
Weld joints. Samples On shop floor.
cracks & dots. & cavities.
2.3 Alluminium Castings.
Free from Blow Defected Qty
100 % /
Visual. Plant standard holes, cracks removed / rejected
samples Qty.
inclusions. At foundry shop.

As per
Samples of manufacturing
Dimension. die casting Against Drawings drawings with At foundry shop.
pieces. gauges & taps
randomly.
2.4 Alluminium Extruction Parts.
Good Structure, Defected Qty
100 % /
Visual. Plant standard finish without rectified before
samples
edge. fabrication.
As per require
Dimensions. Random. Plant standard At shop floor.
drawing.
Surface finish
after No cracks, dots, Defective pieces
100 % Plant standard
compression rough ness. removed.
& bending.
2.5 Galvanizing.
Good Surface finish &
Meets the Such parts resend for
Visual. 100% Qty free from non-
requirements. re galvanizing.
galvanize portions.
5 nos. Qty lot tested
No Copper deposition No permenent
Uniformity if any piece found
Samples after 4-dip in CuSo4 copper
Test. defective in lot , lot
Soln as per IS 2633. deposition.
rejected.
3. BROUGH OUT ITEMS
3.1. HDG BOLT- NUT, WASHERS.
3 to 5 Good threads,
At our store.
Visual. samples from Plant standard finish without
Form-104
each batch. edge.
3 to 5
At our store.
Dimension. samples from Respective standard As per tolerance
Form-104
each batch.
3 to 5 No Copper deposition No permenent
if found defective ,
Galvanize. samples from after 4-dip in CuSo4 copper
lot rejected.
each batch. Soln as per IS 2633. deposition.
One No. in
Manufacturer TC for
Chemical. each batch of Respective standard Within IS limit.
each lot.
each size.
One no in Manufacturer TC for
Mechanical. Respective standard Within Limit.
each batch. each lot.
3.2. SECURITY PINS.
3 to 5
Good Surface At our store.
Visual. samples from Plant standard
finish Form-104
each batch.
3 to 5
At our store.
Dimension. samples from Respective standard As per tolerance
Form-104
each batch.
3 to 5
Operative No prmenent At our store.
samples from Respective standard
Test. deformations Form-104
each batch.
3 to 5
At our store.
Megnatic test samples from Respective standard Non magnitic
Form-104
each batch.
4. FINISH GOOD – FINAL INSPECTION.
4.1 Routine Test.
Meets the
Visual Lot as per IS. IS as per 2486 In house laboratory.
requirement.
IS as per 2486 Against In house testing
Dimension. Lot as per IS. approved laboratory by gauge,
Drawing. scales & taps.
IS as per 2486 Meets the In house laboratory
Mechanical. Lot as per IS.
requirement on hydraulic test.
4.2 Acceptance Test.
Acceptance Tests are carried out as per IS 2486 –P-1-1993 & GETCO norms.

For Gayatri Metalic Foundry.

 SECTION – 02
CONDUCTOR ACCESSORIES.
Operation/ Quantum of Reference Acceptance
Testing Agency.
Test. check. documents. Documents.
1 . RAW MATERIALS.
1.1 Alluminium Sections (Tubes for MSJ & RS).
100%
Good surface
/samples for At our store
Visual. Plant standard. finish, free from
quantity and .Form 103
cracks & ovality.
workmanship.
Manufacturer’s Test
IS 5082-1998 Within IS certificate & recheck
Dimension. Random.
Alloy 19501. Tolerance limit. at our store Form-
103.
IS 5082-1998
One No. in Manufacturer’s Test
Alloy 19501.
Chemical. each batch of Within IS limit. Certificate by spectro
Aluminium – 99.5%
each size. analysis.
63401 for AL59
IS 5082 – 1998
One No. in Manufacturer’s Test
Mechanical. Alloy 19501.& 63501 Within IS limit
each batch. Certificate.
One No. in IS 5082-1998 Manufacturer’s Test
% elongation Within IS limit
each batch. . Certificate.
1.2 Alluminium wire for PA Rod.
100%/
Good surface
samples for At our store.
Visual. Plant standard. finish, free from
quantity and Form 103
cracks & ovality.
workmanship.
Manufacturer’s Test
Within IS certificate & recheck
Dimension. Random. As per IS -2121.
Tolerance limit. at our laboratory.
Form-103
All. Alloy – 6061.
One No. in Si – 0.4 to 0.8 %. Manufacturer TC for
Chemical. Within IS Limit.
each batch. Mg. – 0.8 to 1.2 %. each lot .

One No. in Min 35.00 kg/mm2. Manufacturer TC for

Mechanical. Within IS Limit.
each batch. each lot
One No. in Manufacturer TC for
Conductivity. Min 39 % of IACS. Within IS Limit.
each batch. each lot.
1.3 C.I. Castings for Vibration Damper.
100%/
Good surface
samples for At our store.
Visual. Plant standard. finish, free from
quantity and Form 103
cracks & ovality.
workmanship.

1.4 All. Alloy A-6 for catings of V.D. clamp.

IS 617/1994. grade Manufacturer TC for
Chemical. . 4600 (LM 6). Within IS Limit. each lot Randomly
Si – 10 to 13 % check by us at other
 laboratory.
1.5 Zinc.
Zn – 98 of IS Manufacturer’s Test
Chemical. - Within IS Limit.
Zn-99.98 % Min. Certificate.
2 . INPROCESS MATERIALS.
2.1 Fabrication.
100%
Good surface
/samples for
Visual Plant standard finish, free from At our Shop floor
quality and
cracks & ovality.
workmanship.
IS 2486 with gauges Meets the
Dimension Sample On shop floor.
& taps. requirement.
IS 2486 free from No sharp edges
Weld joints. Samples On shop floor.
cracks & dots. & cavities.
2.2 Alluminium Extruction Parts.
Good Structure, Defected Qty
Visual. 100 % Plant standard finish without rectified before
edge. fabrication.
Against approved
Dimensions. Random. As per drawing. Meets the tolerance.
drawings
Surface finish
after No cracks, dots, Defective pieces
100 % Plant standard
compression rough ness. removed.
& bending.
2.3 Galvanizing.
Good Surface finish & Defective parts
Meets the
Visual. 100% Qty free from non- resend for re
requirements.
galvanize portion. Galvanising.
No Copper deposition No permeate
Uniformity if found defective , lot
Samples after 4-dip in CuSo4 copper
Test. rejected.
Soln as per IS 2633. deposition.
2.4 PA Rod.
Laying done on
PA Rod 3 Nos in each At shop floor.
respective conductor Good laying.
laying lot.
& losing observed
PA Rod 3 Nos in each
Plant slandered. Good Rounding. At shop floor.
Rounding lot.
3. BROUGH OUT ITEMS
3.1. HDG BOLT NUT, WASHERS.
3 to 5 Good threads,
At our store.
Visual. samples from Plant standard finish without
Form-104
each batch. edge.
3 to 5
At our store.
Dimension. samples from Respective standard As per tolerance
Form-104
each batch.
3 to 5 No Copper deposition No permeate
if found defective ,
Galvanize. samples from after 4-dip in CuSo4 copper
lot rejected.
each batch. Soln as per IS 2633. deposition.
One No. in
Manufacturer TC for
Chemical. each batch of Respective standard Within IS limit.
each lot.
each size.
 One no in Manufacturer TC for
Mechanical. Respective standard Within Limit.
each batch. each lot.
4. FINISH GOOD – FINAL INSPECTION.
4.1 Routine Test.
IS as per 2121 Meets the
Visual Lot as per IS. In house laboratory.
IS 9708-1993 requirement.
IS as per 2121 Against In house testing
Dimension. Lot as per IS. approved laboratory by gauge,
Drawing. scales & taps.
4.2 Acceptance Test.
Acceptance Tests are carried out as per IS 2486 –P-1-1993. & as per GETCO norms.

For Gayatri Metalic Foundry.

 SECTION – 03
EARTHWIRE ACCESSORIES.
Operation/ Quantum of Reference Acceptance
Testing Agency.
Test. check. documents. Documents.
1. RAW MATERIALS.
1.1 M.S. Steel for Forging.
100%
Good surface
/samples for At our Steel yard.
Visual. Plant standard finish, free from
quantity and Form 103.
cracks & ovality.
workmanship.
At our steel yard by
Within IS
Dimension. Random. IS 2062-1999 gauge, scale & taps
Tolerance limit.
form 103.
IS 1875-1992 class –
II Manufacturer TC for
One No. in
%C -0.15 to0.25. each lot Randomly
Chemical. each batch of Within IS limit.
%Si – 0.15 to 0.35 check by us at other
each size.
%Mn – 0.6 to 0.9 laboratory.
%S 0.4 Max.
Manufacturer TC for
One no in each lot Randomly
Hardness. BHN 120- Min. Within Limit.
each batch. check by us at other
laboratory.
1.2 M.S. Steel for Fabrication.
100% /
Good surface
samples for At our Steel yard.
Visual. Plant standard finish, free from
quantity and Form 103.
cracks & ovality.
workmanship.
At our steel yard by
Within IS
Dimension. Random. IS 2062-1999 gauge, scale & taps
Tolerance limit.
form 103.

1.3 Alliminum alloy. (A- 6) for casting.

IS 617/1994. grade Manufacturer TC for
4600 (LM 6). each lot Randomly
Chemical. - Within IS Limit.
Si – 10 to 13 % check by us at other
. laboratory.

1.4 Zinc.
Zn – 98 of IS Manufacturer’s Test
Chemical. -. Within IS Limit
Zn-99.98 % Min. Certificate.
1.5 Copper sheet & strip for copper bond.
100%/peices
Good surface
for quantity At our Store
Visual. Plant standard finish, free from
and Form 103.
cracks & ovality.
workmanship.
Within IS At our store by
Dimension. Random. IS 2062-1999
Tolerance limit. gauge, scale & taps
 form 103.
One No. in Manufacturer TC for
Chemical % Cu – 99% Min. Within Limit.
each batch. each lot
2. INPROCESS MATERIALS.
2.1 Fabrication.
100%/
Good surface
samples for
Visual Plant standard finish, free from On shop floor.
quality and
cracks & ovality.
workmanship.
IS 2486 with gauges Meets
Dimension Samples On shop floor.
& taps. requirements
IS 2486 free from No sharp edges
Weld joints. Samples On shop floor.
cracks & dots. & cavities.
2.2 Galvanizing.
Good Surface finish & Defective parts
Meets the
Visual. 100% Qty free from non- resend for
requirements.
galvanize parts. regularizing.
No Copper deposition No permeate
Uniformity if found defective ,
Samples after 4-dip in CuSo4 copper
Test. lot rejected.
Soln as per IS 2633. deposition.
2.3 Alluminium Castings FOR C BY C.
Free from Blow
100 %/ Defected Qty
Visual. Plant standard holes, cracks
samples Qty. removed / rejected.
inclusions.

As per
Samples of manufacturing
Dimension. dicasting Against drawings drawings with At foundry shop.
pieces. gauges & taps
randomly.
2.4 Fabrication.
100%/
Good surface
samples for
Visual Plant standard finish, free from On shop floor..
quality and
cracks & ovality.
workmanship.
IS 2486 with gauges Meets the
Dimension Samples On shop floor.
& taps. requirements
IS 2486 free from No sharp edges
Weld joints. Samples On shop floor.
cracks & dots. & cavities.
Crimping of Proper crimping
No loosing should
lug on copper Samples Plant standard of lugs on power
observe.
bond. press.
3. BROUGH OUT ITEMS
3.1. HDG BOLT NUT, WASHERS.
3 to 5 Good threads,
At our store.
Visual. samples from Plant standard finish without
Form-104
each batch. edge.
3 to 5
At our store.
Dimension. samples from Respective standard As per tolerance
Form-104
each batch.
Galvanize. 3 to 5 No Copper deposition No permeate if found defective ,
 samples from after 4-dip in CuSo4 copper lot rejected.
each batch. Soln as per IS 2633. deposition.
One No. in
Manufacturer TC for
Chemical. each batch of Respective standard Within IS limit.
each lot.
each size.
One no in Manufacturer TC for
Mechanical. Respective standard Within Limit.
each batch. each lot.
3.2. SECURITY PINS.
3 to 5
Good Surface At our store.
Visual. samples from Plant standard
finish Form-104
each batch.
3 to 5
At our store.
Dimension. samples from Respective standard As per tolerance
Form-104
each batch.
3 to 5
Operative No prmenent At our store.
samples from Respective standard
Test. deformations Form-104
each batch.
3 to 5
At our store.
Magnitic test samples from Respective standard Non magnitic
Form-104
each batch.
4. FINISH GOOD – FINAL INSPECTION.
4.1 Routine Test.
Meets the
Visual Lot as per IS. IS as per 2121 In house laboratory.
requirement.
Against In house testing
Dimension. Lot as per IS. IS as per 2121 approved laboratory by gauge,
Drawing. scales & taps.
4.2 Acceptance Test.
Acceptance Tests are carried out as per IS 2486 –P-1-1993.& as per GETCO norms.

For Gayatri Metalic Foundry.

 SECTION – 04
CLAMP – CONNECTORS (BOLTED & COMPRESSION TYPE)
& SPACERS.
Operation/Te Quantum of Reference Acceptance
Testing Agency.
st. check. documents. Documents.
1. RAWMATERIALS.
1.1 All. Alloy for casting of Bolted Connectors & spacers
IS 617/1994 grade
One sample Manufacturer’s
Chemical 4600 (LM 6) Meets the
from each Certificate. (Spectro
Analysis. Si – 10 to 13 %. analysis.
received lot. analysis.)
1.2 All. Extrusions for compression type connectors of equipment.
100%
Good surface
/samples for At our store.
Visual. Plant standard finish, free from
quantity and Form-103
cracks & ovality.
workmanship.
Manufacturer’s Test
IS 5082-1998 Within IS certificate & recheck
Dimension. Random.
Alloy 19501. Tolerance limit. at our
laboratory.Form-103
Manufacturer’s
IS 5082/1998 Alloy –
Meets the Laboratory.
Chemical. - 19501.
analysis. Spectro analysis
Aluminium 99.5%
certificate.
One sample Manufacturer’s
Tensile from each lot. 60 N / mm2. Within IS Limit Laboratory
certificate.
One sample Manufacturer’s
% Elongative from each lot. BHN 25 % Min Within IS Limit Laboratory
certificate.
2 INPROCESS MATERIALS.
2.1 Alluminium Castings.
Free from Blow
100 %/ Defeated Qty
Visual. Plant standard holes, cracks
samples Qty. removed / rejected.
inclusions.

As per
Samples of di manufacturing
Meets the
Dimension. casting Against Drawings drawings with
requirement.
pieces. gauges & taps
randomly.

2.2 Alluminium Extruction Parts.

Good Structure, Defective Qty
100 %/
Visual. Plant standard finish without rectified before
samples
edge. fabrication.
As per require
Dimensions. Random. Plant standard Meets the tolerance.
drawing.
Surface finish 100 % Plant standard No cracks, dots, Defective pieces
 after rough ness. removed.
compression
& bending.
3. BROUGH OUT ITEMS
3.1. HDG BOLT NUT, WASHERS.
3 to 5 Good threads,
At our store.
Visual. samples from Plant standard finish without
Form-104
each batch. edge.
3 to 5
At our store.
Dimension. samples from Respective standard As per tolerance
Form-104
each batch.
3 to 5 No Copper deposition No permenent
if found defective ,
Galvanize. samples from after 4-dip in CuSo4 copper
lot rejected.
each batch. Soln as per IS 2633. deposition.

One no in Manufacturer TC for

Mechanical. Respective standard Within Limit.
each batch. each lot.

3.3 BIMETALLIC SLEEVE.

3 to 5 Good Structure,
At our store.
Visual. samples from Plant standard finish without
Form-104
each batch. edge.
3 to 5
At our store.
Dimension. samples from Respective standard As per tolerance
Form-104
each batch.
One sample % Cu 99.5 Min. Manufacturer TC for
Chemical. Within Limit
from each lot. % All. 99.5 Min. each lot.

4. FINISH GOOD – FINAL INSPECTION.

4.1 Routine Test.
Meets the
Visual Lot as per IS. IS as per 5561-1970 In house laboratory.
requirement.
Against In house testing
Dimension. Lot as per IS. IS as per 5561-1970. approved laboratory by gauge,
Drawing. scales & taps.
4.2 Acceptance Test.
Acceptance Tests are carried out as per IS 2486 –P-1-1993.& as per GETCO norms.

For Gayatri Metalic Foundry.