HBL POWER SYSTEMS LIMITED

RECTIFIER DIVISION
QUALITY ASSURANCE PLAN

Customer M/S BHUSHAN ENERGY LIMITED Ref.No.: 89298-04

PSQ/P119A
Project 2 X 150 MERAMANDALI THERMAL POWER PLANT Rev.No.: 0
P.O.No. 8-4006-BEL-86 DT: 29.12.07 Date : :5/11/2003
16.08.03
PE Job No. TP-08-2-2603 Sheet : 1 of 12
Type of Unit 220 TP 400 FC & FCBC
220 TP 150 FC & FCBC
220 TP 75 FC & FCBC
24 TP 40 FC & FCBC

I. INWARD MATERIAL INSPECTION

1. Console 4. Thyristor 7. Capacitor 10. Rotary Switch

2. Transformer 5. Power Diode 8. Meters 11. Fuses
3. Choke 6. MCCB/MCB 9. Contactor

II. SUB ASSEMBLY

1. Magnetics 3. Capacitor Bank 5. Populated PCB

2. Rectifier 4. Mounting Plates & Cutout Plates 6. Wiring

III. PERFORMANCE TESTS :

IV. PACKING /DESPATCH :

Abbreviations Used : P – Actual/Perform, R – Review, W - Witness of Inspection, A-Approve

TI - Test Instruction. MPI - Manufacturing Process Instruction, BOM - Bill of Material,
MTR- Manufacturer Test Report, AQL - Accepted Quality Level, HPS-HBL Power systems Ltd
PO - Purchase Order
 QUALITY PLAN BC Q.P 02 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

1 CONSOLE 1. Material Major Visual 100% Engineering Engineering No.: PSQ/07A P R

Conformance Inspection Drawings Drawings

2. Dimensional Major Measurement 100% Engineering Engg. Drawing No.: PSQ/07A P R

Conformance Drawings

3. Paint Shade & Major Visual 100% IS - 5 / RAL IS - 5 / RAL No.: PSQ/07A P R
Finish Inspection

4. Paint Thickness Major Measurement 100% Engineering Engg. Drawing No.: PSQ/07A P R
Drawing

5. Adhesion of Major Tape Test 100% TI - 101 Paint should No.: PSQ/07A P R
Paint not peel off
 QUALITY PLAN BC Q.P 03 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

2 TRANSFORMER 1. Rating Plate Major Visual 100% Tech.Spec. Tech. Spec. No.:PSQ/23A/27A A R
& Termination & IS - 2026 89352-01
IS:11171

2. Electrical Critical a) Winding 100% TI - 102 " " P R

Performance Resistance

b) Voltage 100% TI - 103 " " P R

Ratio

c) No load test 100% TI - 104 " " P R

d) Copper 100% TI - 105 " " P R

losses

e) Insulation 100% TI - 106 " " P R

Resistance

f) H.V. Test 100% TI - 107 " " P R

g) Temperature Type test TI - 108 " " P R

Rise test
 QUALITY PLAN BC Q.P 04 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

3 CHOKE 1. Rating Plate & Major Visual 100% HBL HBL No.: PSQ/31 A R
Terminations inspection Tech.Spec. Tech.Spec.
89353-01 89353-01

2. Electrical Critical a) Inductance 100% TI - 109 " " P R

Performance measurement

b) Insulation 100% TI - 106 " " P R

Resistance

c) H.V. Test 100% TI - 107 " " P R

d) Temperature Type test TI - 110 " " P R

Rise test

4 THYRISTOR 1. Type & Rating Major Visual 100% BOM / P.O BOM / P.O No.: PSQ/09 A R
verification IS 3715 Mnfrs. IS 3715 Mnfrs.
catalogue catalogue

2. Electrical Critical a) Triggering 100% IS 3700 Manufacturer's " P R

performance current TI - 113 catalogue

b) Voltage Drop 100% TI - 113 Manufacturer's " P R

catalogue

c) Latching 100% TI - 114 Manufacturer's " P R

current catalogue
 QUALITY PLAN BC Q.P 05 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

d) Holding 100% TI - 115 Manufacturer's No.: PSQ/09 P R

current catalogue

e) Insulation IS-2500-I TI - 106 > 100 M ohms No.: PSQ/09 P R

Resistance 2.5% AQL

5 POWER DIODE 1. Type & Rating Major Visual 100% BOM / P.O / BOM / P.O No.: PSQ/17 A R
Verification IS 3700 Mfrs.
catalogue

2. Electrical Critical a) Forward 100% TI - 112 Manufacturer's No.: PSQ/17 P R

performance voltage drop catalogue

b) Insulation IS - 2500-1 TI - 106 >/= 100 M ohms " P R

Resistance 2.5% AQL

6 MCCB / MCB 1. Type and Rating Major Marking 100% BOM / P.O BOM / P.O No.: PSQ/11 A R
verification Manufacturer's
catalogue

2. Functional Check Critical Tripping 100% IS 13118 /1991 IS 13118 /1991 " P R
Mechanism TI 124 TI 124

3. Electrical Critical a) H.V. Test 100% TI - 107 Should with- No.: PSQ/11 P R
performance stand

b) Insulation 100% TI - 106 > 100 ohms " P R

Resistance
 QUALITY PLAN BC Q.P 06 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

7 C A P A C I T O R 1. Rating & Type Major Visual IS - 2500-1 BOM / P.O / BOM / P.O No.: PSQ/16 A R
verification 2.5% AQL Manufacturer's IS 7305
catalogue

2. Electrical Major Capacitance IS-2500-2 TI - 121 Must be with " P R

performance measurement 0.65% AQL in Tolerance

8 METERS 1. Type & Range Major Marking 100% BOM / P.O / BOM / P.O No.: PSQ/06/35 A R
verification IS 1248 IS 1248

2. Accuracy & Critical Electrical 100% BOM / P.O / BOM / P.O " P R
Calibration comparision IS 1248 IS 1248
with standard
meter
9 CONTACTOR 1. Type & Rating Major Visual 100% BOM / P.O BOM / P.O No.: PSQ/14 A R
verification IS - 13947 IS - 13947
PT.IV SEC.I PT.IV SEC.I

2. Electrical Critical a) Pick up 100% TI - 120 Manufacturer's " P R

performance voltage catalogue

b) Release 100% TI - 120 Manufacturer's " P R

Voltage catalogue

c) H.V. Test IS-2500-I TI - 107 Should " P R

2.5% AQL withstand H.V

d) IR Test " TI -106 >100 M ohms " P R

 QUALITY PLAN BC Q.P 07 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM
SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

10 ROTARY 1. Type & Rating Major Visual 100% BOM / P.O BOM / P.O No.: PSQ/10 A R
SWITCHES verification BS EN 60947-3

2. Operating Major Mechanical 100% BOM / P.O Should be " P R

mechanism operation smooth P

3. Electrical Critical a) Continuity 100% TI - 123 Should have " P R

Performance check continuity in
on state

b) H.V. Test 100% TI - 106 Should No.: PSQ/10 P R

withstand H.V

c) I.R Test 100% TI - 107 > 100 M ohms " P R

11 FUSES 1. Type & Rating Major Visual 100% BOM / P.O / BOM / P.O / No.: PSQ/00 A R
verification Manufacturer's Manufacturer's (LOG BOOK)
catalogue catalogue

2. Electrical Critical Continuity 100% " Should have " P R

performance test continuity
 QUALITY PLAN BC Q.P 08 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER
II SUB ASSEMBLY

1 MAGNETICS 1. Component Major Visual 100% BOM BOM No.: PSQ/39 A R

specification verification

2. Layout Major Visual 100% Engineering Approved Engg. " A R

verification Drawing Drawing

3. Method of Major Verification 100% MPI MPI " A R

mounting as per MPI

4. Firmness Major Check for 100% MPI MPI " A R

of fixing mechanical
tightness

2 RECTIFIER 1. Component Major Visual 100% MPI BOM / MPI " A R

MODULE Specification verification
as per BOM

2. Layout Major Visual 100% Engineering Engineering " A R

inspection drawing drawing

3. Method of Major Verification 100% MPI MPI " A R

mounting & as per MPI
firmness of fixing
 QUALITY PLAN BC Q.P 09 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

3 CAPACITOR 1. Component Major Visual 100% BOM BOM No.: PSQ/39 A R

BANK specification verification
as per BOM

2. Method of Major Verification 100% MPI MPI " A R

mounting & as per MPI
firmness of fixing

4 MOUNTING 1. Component Major Visual 100% BOM BOM " A R

PLATES & specification verification
CUTOUT PLATES as per BOM

2. Lay out Major Visual 100% Engineering Engineering " A R

verification drawing drawing

3. Method of Major Verification 100% MPI MPI " A R

mounting & as per MPI
firmness of fixing

5 POPULATED 1. Correctness Major a) Verification 100% BOM BOM / MPI No.: PSQ/39 A R
PCB of assembly as per BOM TI - 118

b) Mounting 100% PCB Layout & PCB Layout & " A R

as per leg- TI - 118 TI - 118
end printing
 QUALITY PLAN BC Q.P 10 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

2. Soldering Major Visual inspect- 100% TI -118 BOM No.: PSQ/P19A A R

Quality ion with
magnifier.x 5

3. Electrical Major Functional 100% PCB Test PCB Test No.: PSQ/P20A A R
performance checks Report Report

6 WIRING 1. Cable Size Major Verification 100% BOM & Wiring BOM & Wiring No.: PSQ/39 A R
diagram diagram

2. Crimping Major Visual IS 2500 MPI MPI " A R

inspection pt.I
10% AQL

3. Terminal Major Ferrule No. 100% Wiring Wiring " A R

identification check Diagram Diagram

4. Correctness Major Visual 100% MPI MPI

of Routing verification " A R
 QUALITY PLAN BC Q.P 11 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

III PERFORMANCE 1. Physical Major Visual 100% BOM/Approved BOM/Approved No.: PSQ/P22A A W
TESTS verification Drawing Drawing

2. Insulation Major Insulation 100% HBLNIFE >/= 10 M ohms No.: PSQ/P22A A W

Resistance test resistance Test Proced-
measurement ure/cust.spec.

3. H.V. Test Major H.V. Test 100% Tech.spec. Should with- No.: PSQ/P22A A W
stand 2 KV/min

4. Efficiency Major Efficiency Type Test Tech.Spec. Tech.Spec. No.: PSQ/P22A A W One of each
Measurement Measurement type

5. Ripple Major Ripple 100% Tech.Spec. Tech.Spec. No.: PSQ/P22A A W

measurement Measurement

6. Voltage Major Voltage 100% Tech.Spec. Tech.Spec. No.: PSQ/P22A A W

Regulation Regulation
measurement Measurement

7. Heat Run Test Major Heat Run Type Test Mfrs standard No failure No.: PSQ/P22A A R
Test Till stabili- (HBL)
zation

8. Functional Test Major Annunciation 100% Tech.Spec Tech.Spec. No.: PSQ/P22A A W

& Check&Feature
System Details Check
 QUALITY PLAN BC Q.P 12 OF 12
FOR REF.NO.: PSQ/P119A
DC SYSTEM

SL COMPONENTS QUALITY CHARAC- CLASSIFI- TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. TERISTICS CATION CHECK OF CHECK DOCUMENT NORMS RECORDS HBL CUSTOMER

IV PACKING & 1. Pre-Packing Major a) Tightness 100% As per Spec. Packing spec. No.: WI/P/PI/11 A -
DESPATCH checks of all the 89397 89397
fastners and
cable
connections

b) Overall 100% " " " A -

appearance

c) Paint Finish 100% " No scratches " A -

2. Conformance Critical Verification of 100% Packing Spec. Packing Spec. " A -

to packing packing mater- 89397 89397
specification ials and method
of packing

3. Packing of Critical Verification as 100% Production Packing list No.: WI/P/PI/11 A -

accessories per BOM and indent & 89280
spares, Manual packing list packing Spec.
etc. list 89397