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RAW MATERIAL INSPECTION

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PART OF TRANSMISSION LINE TOWERSECTION - ARAW MATERIAL INSPECTION

SR. NO.

COMPONENT /OPERATION AND DESCRIPTION OF TEST

SAMPLING PLAN WITH BASIS

REFERANCE DOCUMENT& ACCEPTANCE NORM

TESTING AGENCY / FORMAT OF RECORD

REMARKS

1.0

1.1

1.1.1

RAW MATERIALS PROCUREMENT

STRUCTURAL STEEL (ANGLE SECTIONS & PLATES)

PHYSICAL PROPERTIES

A) TEST FOR ULTIMATETENSILE STRENGTH

B) TEST FOR YIELD STRESS

One sample for 20MT/Lot or part thereof


a) Mild SteelBS EN 10025 -2:2004(Gr. S-275 JR I JO)or equivalent410 – 560 N/mm2

b) High Tensile SteelBS EN 10025 -2:2004(Gr. S-355 JR IJO)470 - 630 N I mm2

or equivalent

a) Mild SteelBS EN 10025 -2:2004(Gr. S-275 JR IJO)or equivalent-275 N I mm2

(min.)(upto 16 mm thick)-265 N I mm2

(min.)(above 16 mm thick)

CONFIDENCESTEEL LTD/TPL


Raw materials to be procured from reputed vendors from China/India/Turkey/Ukraine

CWP (CustomerWitness Point)Verification of manufacturer'sTestCertificates & CONFIDENCERecord, duly correlatedat the time ofFinal Inspection.

Verification of manufacturer'sTestCertificates & CONFIDENCERecords, duly correlatedat the time ofFinal Inspection.

P a g e 2 | 53

SR. NO.



REFERANCE DOCUMENT&ACCEPTANCE NORM


REMARKS

C)PERCENTAGE ELONGATION TEST

D) IMPACT TEST (CHARPY ‘V’ Notch)



b) High Tensile Steel BS EN 10025-2:2004(Gr. S-355 JR IJO-355 N I mm2

(min.)(upto 16 mm thick) -345 N Imm2(min.)(Above 16 mm thick) or equivalent.

a) BS EN 10025 -2:2004(Gr. S-275 JR IJOor equivalent23 % min.for 3< t < 40 mmb) BS EN 10025 -2:2004(Gr.- S355 JR/JOfor 3< t < 40 mmOf equivalent22 % min.

BS EN 10025-2:2004(Gr.S355 JR/JO) or equivalentMinimum Energy for S275JR/S355JR=27Joules at 200C for Thickness 6mm & aboveAnd Minimum Energy for S275JO/S355JO=27Joules at 00C for Thickness 6mm & above



Verification of manufacture’s TestCertificates & CONFIDENCERecords, duly correlatedat the time ofFinal Inspection.


P a g e 3 | 53

SR. NO.



REFERANCE DOCUMENT&ACCEPTANCE NORM


REMARKS

1.1.2

1.1.3

1.1.4

CHEMICAL COMPOSITION

VISUAL CHECKS FORSURFACE FINISH

DIMENSIONAL CHECKS




BS EN 10025-2 : 2004(Gr. S-355 JR / JO) OR (Gr. S-275 JR / JO)Table-4 (Annexure-V)

Material to be free from the lot surface defects likeLaminations. rough Ijagged and imperfectedges, cracks, roundedapex. deep roll marks,pipy and any harmfuldefects (Removal ofminor surface defectsas per BS EN 10025-2:2004clause 7.5.2/7.5.3 acceptable)BS EN 10163 P-1 & P-3

BS EN 10056-2:1993

CSL/ TPL

CONFIDENCESTEEL LTD

CONFIDENCESTEEL LTD


Record Review atthe time of FinalInspection, duly correlatedat the time ofFinal Inspection.


SR. NO.



REFERANCE DOCUMENT & ACCEPTANCE NORM


REMARKS

1.1.4(A)

TOLERANCES FOR LEG

P a g e 4 | 53

1.1.4(B)

LENGTH OF ANGLES

(a) EQUAL ANGLES1) Upto 50 mm Leg Length2) Over 50 to 100 mm3) Over 100 to 150 mm4) Over 150 to 200 mm5) Over 200 mm

(b) UNEQUAL ANGLES

TOLERANCES FORTHICKNESS (a) Section Thickness

1)t ≤ 5mm2) 5<t≤10mm3)10<t≤15mm4) 15 ≤t mm




BS EN 10056-2:1993

± 1.0 mm

± 2.0 mm

± 3.0 mm

± 4.0 mm

+6mm, -4mm

For unequal anglestake the longer leg length as the reference as per BS EN 10056-2:1993

BS EN 10056-2:1993

± 0.5 mm± 0.75 mm±1.0 mm±1.2 mm

CONFIDENCESTEEL LTD

CONFIDENCESTEEL LTD

CONFIDENCESTEEL LTD




SR. NO.





REMARKS

1.1.4(C)

OUT OF SQUARENESS

One sample for 20MT/Lot

BS EN 10056-2:1993Table 1 Deviation in mm

CONFIDENCESTEEL LTD

Record Review atthe time of Final

P a g e 5 | 53

1.1.4(D)

1.1.4(E)

1.1.4(F)

1.1.4(G)

1) Upto100 mm Leg Length2) Over 100 to 150 mm3) Over 150 to 200 mm4) Over 200mmCAMBER for full bar length (For Leg Length)1) Up to 150 mm2) Over 150 to 200 mm3) Over 200 mmWEIGHT TOLERANCE FOR ANGLE SECTIONS1) Over 4 mm Thickness2) for t≤ 4 mm

WEIGHT TOLERANCE FOR PLATES

THICKNESS TOLERANCEFOR PLATES1) ≥ 3 < 52) ≥ 5 < 83) ≥ 8 < 154) ≥ 15 < 255) ≥ 25 < 40

or part thereof



(max.)± 1.0 mm

± 1.5 mm

± 2.0 mm

± 3.0 mm

BS EN 10056-2:1993

0.4% of length

0.2% of length

0.1% of length

BS EN 10056-2:1993

±4%

±6%

BS EN 10029:1991

(Maxm Thickness difference shall be as per Table-1)

±0.6mm±0.75mm±0.85mm±0.95mm±1.1mm

CONFIDENCESTEEL LTD

CONFIDENCESTEEL LTD

CONFIDENCESTEEL LTD

CONFIDENCESTEEL LTD

Inspection, duly correlatedat the time ofFinal Inspection.




SR. NO.





REMARKS

1.2 ZINC To be procured fromAbroad (Imported from Korea/Japan/Australia/India

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1.2.1 CHEMICAL COMPOSITON

One sample for50 MT or part thereof

One sample from Galvanizing bath once in a month.

ISO 752:1981 (E)a) Gr.Zn 99.99%b) Gr. Zn 99.95%

The molten metal in theGalvanizing bath shall not contain less than 98.5% by mass of Zinc.

CSL/ Third party Independent Certified lab

/ Iran)

Verification of manufacturer'sTestCertificates &CSLThird party Records.

P a g e 7 | 53

INPROCESS INSPECTION

PART OF TRANSMISSION LINE TOWERSECTION - BINPROCESS INSPECTION

SR.NO.

COMPONENT OPERATIONAND DESCRIPTION OFTEST

WITH BASIS SAMPLING PLAN

REFERANCE DOC. & ACCEPTANCE NORM

TESTING AGENCY / FORMAT OF

REMARKS

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RECORD

2.0

2.1

2.2

2.2.1

2.3

IN PROCESS INSPECTIONFABRICATION OF TOWERPARTS

STRAIGHTENING

CUTTING (CROPPINGLength)

a) up to 16 mm thick angle/Plateb) above 16 mm thick angle/Plate

STAMPINGWithin 600mm of the end but clear of holes




Approved Drag., Shop Sketches

BSEN 10056-2 : 1993

Cutting LengthTolerances ± 2.0 mm

Shearing cutting

Hack-saw cutting(The cut surface to be clear square and free from distortion)

Letter size as per CSL specification. (Letter height- 12mm) Visually Legible

CONFIDENCE STEEL LTD.





Record review at the time of Final Inspection.




SR.NO.





REMARKS

P a g e 9 | 53

2.4 PUNCHING I DRILLING

Punching of full sized holes will be permitted up to andincluding the thickness andMaterial quality specified.

A) i) Hole Diameterii) Taper on punched holeB) Hole to Hole Dimension (Punching/ drilling)

C) Edge Security

For 13.5 mm dia. hole




D) Back Mark


Quality- Thickness275 JR- 16mm355 JO 20mm

(No hole to be punchedwhere the thickness ofthe material exceeds the finished dia. of the hole)

+ 0.5 mm, - 0.0 mm+ 1.00 mm (on die side)

Dimensional Tolerances± 2.0 mm for longdistance holes± 1.0 mm for consecutiveHoles

Sheared 20 mm Min.Rolled 16 mm MinSheared 23 mm Min.Rolled 20 mm Min.Sheared 28 mm Min.Rolled 25 mm Min.Sheared 35 mm Min.Rolled 35 mm Min.

± 1.0 mm



SR.NO.





REMARKS

P a g e 10 | 53

2.5

2.6

2.7

NOTCHING ( Flange Cut I Corner Cut/ Bevel Cut)

HEEL GRINDING

BENDINGi)HT sections (Angles/Plates)

ii) MS Sections (Angles)

iii) MS Plates

iv) Temperature Range for Hot Bending



100 %

PROCESSColdColdHotHotPROCESSColdHot

+ 5 mm on specifiedLength of cut.a) Operation by shearingup to 12 mm or less thickb) by gas cutting formaterial 12 mm or larger thickFor Notching by gas cutting,cut edges to be cut oversize& ground smooth to remove notchesApproved drags. I Shop Sketches>8 mm gas cutting to be adopted followed by grinding/ machine cutting.Tolerance on heel cutting. -0, +10 on length & -0, +2 on depth.

All Sections & platesto be hot bent.

SECTIONupto75 x6upto100x8above 75 x 6above 100 x 8SECTIONup to 10 mm thickAbove 10 mm thick

850 - 1000°C




ANGLEup to 100

up to 50

above100

above 50

ANGLEup to 150

above 150




SR.NO.





REMARKS

P a g e 11 | 53

2.8

3.0

FINAL INSPECTION OFFABRICATED PARTS

PROTO MODEL ASSEMBLY

To be assembled andchecked for (dimensions, angle size, by this, to verify interchangeabilityOf members etc.


One structure of each type of all tower/extensions

All parameters frompt 2.1 to 2.7 above arechecked and recordsmaintained beforereleasing the materialsfor galvanizing

Approved structureAssembly drawingsa) Determine if errorfabrication or work ·shop drawingb) List all conforming Itemsc) Present information toDesign for action,Assembly, work-shopDrawing revision etc.

CONFIDENCE STEEL LTD

CONFIDENCE STEEL LTD


CWP(Customer Witness Point)

CWP(Customer Witness Point)CHP(Customer Hold Point)

SR.NO.





REMARKS

P a g e 12 | 53

4.0

4.1

GALVANIZING

PROCESS CONTROL

A) DEGREASING Alkali based Degreasing to be followed byrinsing of water

B) PICKLING( HCl Acid)i)Specific Gravity

ii)Acid Content

iii) Iron Content

iv) Inhibitor to be added to prevent over pickling

C) RINSING(in continuous tap water)

D) PRE FLUXINGIn Zinc Chloride andAmmonium Chloride Soln.i) Tempii)Specific Gravityiii) pH Valueiv) Iron Content

One sample daily

One sample dailyOne sample dailyOne sample daily

One sample daily

One sample daily

BSEN ISO 1461:2009

a) Sp. Gravity 1.01 ~ 1.03

b) PH 10 ~ 12

1.07 to 1.26

180 gm/ Lit to 60gm/ Lit120 gm/Lit (Maxm)

PH value 4 to 7

Vendor Norms

Room to 80oC1.08 ~ 1.164 to 5.5 pH

Maximum 5 gm/Ltr







Rinsing with water


SR.NO.





REMARKS

P a g e 13 | 53

4.2 DIPPING (GALVANIZATION)

A) Zinc bath temperature is continuously recorded and auto controllers are set so as to receive the desired Temp. range

B) Immersion time and withdrawal Time

C) Quenching in RunningWater

D) Dichromating

Hourlychecks

Once daily

BSEN ISO 1461:2009

Range:i) At Idle - 4350C to 4400Cji) At working -4500C to 4600C

Articles to be immersedtill reaction takes place which is indicated byStoppage of bubbling.Withdrawal to beControlled so that Zinc drains freely.

(BS EN ISO 1461:2009Prepare the solution by adding 1% SodiumDichromate and 0.5%Sulphuric Acid in Water.Keep strength of thesolution in between1% to 0.2% at temperature less than 65oC











SR.NO.





REMARKS

4.3

4.3.1

GALVANIZING CHECKINGVISUAL CHECKING 100 % BSEN ISO 1461:2009 CONFIDENCE Record review at the

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4.3.2 GALVANIZING TESTINGA) Thickness of Zinc Coating (For Member Thickness)T > 6mm6mm≥ T >3mm

B) Weight of Zinc CoatingT > 6mm6mm≥ T >3mm

C) Uniformity of Zinc Coating Immersion of testspecimen in the Copper Sulphate solution(Sp. Gr. 1.186) at atemperature of 160 to 200

D) ADHESION TEST(Pivoted Hammer Test IKnife Test)

8 sample/shift

3 sample/shift

3 sample/shift

3 sample/shift

Surface to be free from defects like Bare/ Black spots (except when small & suitable for patching) heavy ash/ flux inclusions/ lumps/ pimples/ Drips & Runs etc.BS EN ISO 1461:2009

Mean coating thickness (µm) min.

8570

Mean coating mass (g/m²) min.610505

BS EN ISO 1461:2009Material to withstand4 dips of one minuteeach without showingSigns of Copper deposits.

BS EN ISO 1461:2009No removal of liftingof coating in areasbetween hammerimpressions I coatingshould not peel off.

STEEL LTD.


timeof Final Inspection


SR.NO.





REMARKS

P a g e 15 | 53

5.0 PACKING, STORING,BUNDLING, HANDLING

100% Bundling to be carried out as per customer’s requirement

(BS 1133Section 1 to 3-1989)

Bundle. Weight as perCustomer's requirement.

Packing List to besubmitted along withDispatch documents.


Plates and smallparts to be packedInto boxes.All sections to besecurely bundled.

Stacking to haveProper ventilation and kept inclined.Damage to Galvanization coating to be avoided while handling.CONFIDENCE STEEL LTD to ensureSequential supplies.

P a g e 16 | 53

FINAL ACCEPTANCE AND TESTING

(FAT)

PART OF TRANSMISSION LINE TOWERSECTION - CFINAL ACCEPTANCE AND TESTING

P a g e 17 | 53

(CUSTOMER WITNESS POINT)

SR.NO.



ACCEPTANCE DOC. & REFERANCE NORM


REMARKS

6.0

6.1

6.2

6.3

FINAL INSPECTIONAND TESTING(Inspection Engineer toCheck I ensure complianceto notes I GeneralRequirement given in thisPlan)

PHYSICAL PROPERTIES i) UTS TEST II) YIELD STRESS TEST III) PERCENTAGE ELONGATION TESTIV) IMPACT TEST

CHEMICAL COMPOSITION

VISUAL INSPECTION For Fabrication and Galvanization




Please Refer Clauses No. 1.1.1(A), 1.1.1(B), 1.1.1(C)

Please Refer 1.1.1(D)

BS EN 10025:2004Table-4(Annexure-V)

BS EN 10025:2004





Customer Witness Point




SR.NO.

COMPONENT OPERATIONAND

WITH BASIS SAMPLING

ACCEPTANCE DOC. & REFERANCE

TESTING AGENCY /

REMARKS

P a g e 18 | 53

DESCRIPTION OFTEST

PLAN NORM FORMAT OF RECORD

6.4 GALVANIZING TESTS

i) Thickness of Zinc coating ii) Weight of Zinc coatingiii) Uniformity of Zinc coatingiv) Adhesion of Zn coating


BSEN ISO 1461:2009 CONFIDENCE STEEL LTD.


SECTION-FINAL INSPECTION & TESTING (Bolt/Nut/Washer)

P a g e 19 | 53

SRL NO.

COMPONENT/OPERATION AND DESCRIPTION OF LIST

SAMPLING PLAN WITH BASIS REFERANCE DOC. & ACCEPTANCE NORM

TESTING AGENCY REMARKS

1.0

2.0

2.1

2.2

2.3

MATERIALS

Batch Certificates for Bolts & Nuts , Spring Washers, Step Bolts from approved Sub contractors to be supplied.

M12 Bolts (4.6 Grade)

VISUAL

DIMENSIONAL

a) Bolt Length

b) Body Diameter (Ds)

c) Width across flats (s)

d) Width across corners ( . e)

e) Height of Head (k)

f) Pitch (p)

g) Thread Length (b)

PHYSICAL PROPERTIES

a) Tensile strength under wedge (Minimum ultimate tensile load)

)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness

OR Rockwell Hardness

P=4; n<500

P=4+1.5n/1000;

n>500,maximum 50 pieces

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:2009 (. E)

ISO 6157-1 Bolts shall be cleanly finished , sound and free from surface defects

DIN 7990

as specified

11.3-12.7 mm

17.57/18 mm

19.85 mm min.

7.55- 8.45 mm

1.75 mm

17.75/23 mm

24.75/30 mm (For Anti-theft

Bolt)

ISO 898-1:2009 (. E)

33700 N (3438 kg) (Table 4)

19000N (1938 kg) (Table 5)

120 HV to 220 HV

CSL/Supplier T.C./

CSL/Supplier T.C./ Third

Party Certified Lab


Party Certified Lab

To be procured from reputed vendor of China/India.

CWP (Customer witness point)




P a g e 20 | 53

SRL NO.




3.0

3.1

3.2

3.3

3.4

12 mm NUTS (Grade 4)

VISUAL

DIMENSIONAL

a) Height of Nut (m)

b) Width across flats (s)

c) Width across corners ( . e)

d) Diameter of Bearing Face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 6157-2, Nuts shall be cleanly finished , sound and free from surface defects

ISO 4034

10.4/12.20 mm

17.57/18 mm

19.85 mm min.

16.47 mm min.

1.75 mm

ISO 898- Part II:2012 ( . E)

. -

BSEN ISO 1461: 2009,Refer Point no. 2.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.

Third Party Certified

Lab

CSL/Supplier T.C.




WP (Customer witness point)


P a g e 21 | 53

SRL NO.




4.0

4.1

4.2

4.3

SPRING WASHER (M12)

VISUAL

DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)

a) Section width (b)

b) Section Thickness (s)

PHYSICAL PROPERTIES

a)Hardness

b) Twist Test

c) Permanent Set Test

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127

Surface shall be free from cracks

, burrs pits and loose scale.

The flat face shall be free from knurling, scratches, die marks etc.

DIN 127

Table 1

12.2 to 12.7 mm max.

21.1 mm (max.)

3.8/4.2

2.35/2.65 mm

BS 4464

440 / 550 HV or

45/52 HRC

Washer should not be cracked or broken after twisting through

90°.

Washer shall be completely closed between hardened and ground plates . After releasing, free height of the washer should not be less than 1.66 times sectional thickness.

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C./Third

Party Certified Lab





P a g e 22 | 53

SRL NO.




5.0

5.1

5.2

5.3

PACK WASHER (For M12

Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


Free from cracks, bun pits, no sharp edges and other defects.

As per approved drawing

13.5 mm to 13.93 mm

22.7 to 24 mm

As per Specification

5 mm thick

6 mm thick

8 mm thick


CSL

CSL

CSL





P a g e 23 | 53

SRL NO.




6.0

6.1

6.2

6.3

M16 Bolts (5.6

Grade) VISUAL

DIMENSIONAL

a) Bolt Length



d) Width across corners (.e)


f) Pitch (p)


PHYSICAL PROPERTIES


b)Proof load

Test c)Hardness

Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST

a) Zinc Coating Thickness

b) Uniformity of Zinc Coating

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:2009 (. E)

ISO 6157-1,

Bolts shall be cleanly finished , sound and free from surface defects

DIN 7990

as specified

15.3-16.7 mm

23.16/24 mm

26.17 mm min.

9.25- 10.75 mm

2 mm

21/27 mm

28/34 mm (For Anti-theft

Bolt) ISO 898-1:2009 (.E)

78500 N (8010 kg) (Table 4)

44000N (4490 kg) (Table 5)

155 HV to 220 HV

147 HB to 209 HB

79 HRB to 95 HRB

BSEN ISO 1461: 2009,Table 4

50 microns min. I.e. 360

g/m² Should withstand 6

dips of 1

minute duration in Copper Sulphate

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab






P a g e 24 | 53

SECTION-FINAL INSPECTION & TESTINGSRL NO.




7.0

7.1

7.2

7.3

7.4


VISUAL

DIMENSIONAL




d) Diameter of bearing face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,

Nuts shall be cleanly finished , sound and free from surface defects.

ISO 4034

14.1/15.90 mm

23.16/24 mm

26.17 mm min.

22 mm min.

2 mm

ISO 898- Part II

130-302 HV

95800N (9775 Kg)


CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.






P a g e 25 | 53





8.0

8.1

8.2

8.3


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)

g) Thread Length (lg)

PHYSICAL PROPERTIES

a) Tensile strength under

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:2009 (. E)

ISO 6157-1,


DIN 7990

as specified

15.3-16.7 mm

23.16/24 mm

26.17 mm min.

9.25- 10.75 mm

2 mm

21/27 mm

28/34 mm (For Anti-theft Bolt)

ISO 898-1:2009 (.E)

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab





BSEN ISO 1461:2009 ( Table 4) BS 729

50 microns min. I.e. 360 g/m²

Should withstand 6 dips of 1

minute duration in Copper

Sulphate

The coating shall be sufficiently adherent to withstand normal handling condition without peelin



c) Adhesion of Zinc Coating

P a g e 26 | 53

SRL NO.




9.0

9.1

9.2

9.3

9.4


VISUAL

DIMENSIONAL




d) Diameter of bearing face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

a)Hardness

b)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034,

Nuts shall be cleanly finished , sound and free from surface defects

ISO 4034

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.






ISO 898- Part II:2012

Maximum 30 HRC

138200N (14102 Kg)

BSEN ISO 1461,BS 729 Refer

Point no. 2.4

P a g e 27 | 53

SRL NO.




10.0

10.1

10.2

10.3

10.4

SPRING WASHER (M16)

VISUAL

DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)



PHYSICAL PROPERTIES

a)Hardness

b) Twist Test


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127


, burrs pits and loose scale.The flat face shall be free from knurling, scratches, die marks etc.

DIN 127

Table 1

16.2 to 17 mm

27.4 mm (max.)

4.8-5.2 mm

3.3-3.7 mm

BS- 4464

440 / 550 HV or

45/52 HRC


90◦Washer shall be completely closed between hardened and ground plates . After releasing, free height of the washer should not be less than 1.66 times sectional thickness.

BSEN ISO 1461: 2009, Refer Point no. 6.4

CSL/Supplier T.C./

CSL/Supplier T.C.


Party Certified Lab

CSL/Supplier T.C.






P a g e 28 | 53

SRL NO.




11.0

11.1

11.2

11.3


Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;




17.50 to 17.93 mm

28.7 to 30 mm

As per specification

5 mm thick

6 mm thick

8 mm thick

10 mm thick


CSL

CSL

CSL





P a g e 29 | 53

SRL NO.




12.0

12.1

12.2

12.3

12.4


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES


b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST




P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 (. E)

ISO 6157-1,


DIN 7990

as specified

19.16/20.84 mm

29.16/30 mm

32.95 mm min.

11.6/13.4 mm

2.5 mm

23.5/31 mm

32.5/40 mm (For Anti-theft Bolt)

ISO 898-1:1999 (.E)

122000 N (12448 kg) (Table 4)

68600N (7000 kg) (Table 5)

155 HV to 220 HV

147 HB to 209 HB

79 HRB to 95 HRB

BSEN ISO 1461: 2009, Table 4




Sulphate

The coating shall be sufficiently adherent to withstand normal handling condition without peeling.

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.






P a g e 30 | 53

SRL NO.




13.0

13.1

13.2

13.3

13.4


VISUAL

DIMENSIONAL




d) Diameter of Bearing face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,


ISO 4034

16.90/19 mm

29.16/30 mm

32.95 mm min.

27.7 mm min.

2.5 mm


146/302 HV

154400N (15755 Kg)


CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.






P a g e 31 | 53





14.0

14.1

14.2

14.3


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES


b)Proof load Test

c)Hardness Test

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 (. E)

ISO 6157-1,


DIN 7990

as specified

19.16/20.84 mm

29.16/30 mm

32.95 mm min.

12.1/13.9 mm

2.5 mm

23.5/31 mm

32.5/40 mm (For Anti-theft Bolt)

ISO 898-1:1999 (.E)

203000 N (20714 kg) (Table 4)

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab





BSEN ISO 1461:2009 ( Table 4) BS 729




Sulphate

he coating shall be sufficiently adherent to withstand normal handling condition without peeling.




P a g e 32 | 53

SRL NO.




15.0

15.1

15.2

15.3

15.4


VISUAL

DIMENSIONAL





(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,


ISO 4034

16.90/19 mm

29.16/30 mm

32.95 mm min.

27.7 mm min.

2.5 mm


233/353 HV

225400N (23000 Kg)

BSEN ISO 1461: 2009, Refer

Point no. 10.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.






P a g e 33 | 53

SRL NO.




16.0

16.1

16.2

16.3

SPRING WASHER (M20)

VISUAL

DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)



PHYSICAL PROPERTIES

a)Hardness

b) Twist Test


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127


, burrs, pits and loose scale. The flat face shall be free from knurling, scratches, die marks etc.

DIN 127

Table 1

20.2/21.2 mm

33.6 mm max.

5.8/6.2 mm

3.8/4.2 mm

BS 4464

440 / 550 HV or

45/52 HRC


90◦

Washer shall be completely closed between hardened and ground plates . After releasing, free height of the washer should not be less than 1.66 times sectional thickness

CSL/Supplier T.C./

CSL/Supplier T.C.


Party Certified Lab





P a g e 34 | 53

SRL NO.




17.0

17.1

17.2

17.3


Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;




22 mm (+0.5 mm)

37 mm (± 0.5 mm)


5 mm thick

6 mm thick

8 mm thick

10 mm thick


CSL

CSL

CSL/Supplier T.C.





P a g e 35 | 53





18.0

18.1

18.2

18.3

18.4


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES


b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST




P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 (. E)

ISO 6157-1,


DIN 7990

as specified

23.16/24.84 mm

35/36 mm

39.55 mm min.

14.1-15.9 mm

3 mm

26/36 mm


ISO 898-1:1999 (.E)

176000 N (17960 kg) (Table 4)

98800N (10082 kg) (Table 5)

155 HV to 220 HV

147 HB to 209 HB

79 HRB to 95 HRB

BSEN ISO 1461: 2009, Table 4




Sulphate

The coating shall be sufficiently adherent to withstand normal handling condition without peeling.

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.






P a g e 36 | 53

SRL NO.




19.0

19.1

19.2

19.3

19.4


VISUAL

DIMENSIONAL





(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,


ISO 4034

20.2/22.3 mm

35/36 mm

39.55 mm min.

33 mm min.

3 mm


146 HV to 302 HV

222400N (22693 Kg)


CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.






P a g e 37 | 53





20.0

20.1

20.2

20.3

20.4


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES


b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 (. E)

ISO 6157-1,


DIN 7990

as specified

23.16/24.84 mm

35/36 mm

39.55 mm min.

14.1-15.9 mm

3 mm

26/36 mm


ISO 898-1:1999 (.E)

293000 N (29897 kg) (Table 4)

212000N (21632 kg) (Table 5)

255 HV to 335 HV

242 HB to 318 HB

23 HRC to 34 HRC

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.






P a g e 38 | 53

BSEN ISO 1461:2009 ( Table 4) BS 729




Sulphate

The coating shall be sufficiently adherent to withstand normal handling condition without peelin




SRL NO.




21.0

21.1

21.2


VISUAL

DIMENSIONAL

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

ISO 4034

ISO 6157-2,


ISO 4034

CSL/Supplier T.C./

CSL/Supplier T.C.





P a g e 39 | 53

21.3

21.4





(Dw)

e) Pitch

PHYSICAL PROPERTIES

a)Hardness

b)Proof Load

GALVANIZING TEST

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


CSL/Supplier T.C.


Lab

CSL/Supplier T.C.



Maximum 36 HRC

324800N (33142 Kg)

BSEN ISO 1461: 2009, Refer

Point no. 18.4

SRL NO.




P a g e 40 | 53

22.0

22.1

22.2

22.3

SPRING WASHER (M24)

VISUAL

DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)



PHYSICAL PROPERTIES

a)Hardness

b) Twist Test


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127


, burrs, pits and loose scale. The flat face shall be free from knurling, scratches, die marks etc.

DIN 127

Table 1

24.5/25.5 mm

40 mm max.

6.75/7.25 mm

4.8/5 mm

BS 4464

440 / 550 HV or

45/52 HRC


90◦

Washer shall be completely closed between hardened and ground plates . After releasing, free height of the washer should not be less than 1.66 times sectional thickness

CSL/Supplier T.C./

CSL/Supplier T.C.


Party Certified Lab





P a g e 41 | 53

SRL NO.




23.0

23.1

23.2

23.3

24.0


Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

STEP BOLT

(As Per Approved Drawing)

DIMENSIONAL

PHYSICAL PROPERTIES

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 126A



26 mm (+0.5 mm)

40 mm (± 0.5 mm)


5 mm thick

6 mm thick

8 mm thick

10 mm thick


CSL

CSL

CSL

CSL/Supplier T.C./






P a g e 42 | 53

P a g e 43 | 53

Prototype Assembly Test (PAT)

P r o t o t y p e A s s emb l y T e s t Re po r t

Project Name Design, Supply, Erection, Testing & Commissioning of Ashuganj - Bhulta 400 kV Transmission Line on Turnkey Basis.

FOR POWER GRID COMPANY OF BANGLADESH LTD (PGCB)

(Name) (Name)

(Position) (Position)

FOR CONTRACTOR

(Name) (Name)


FOR SUPPLIER

(Name) (Name)


P a g e 44 | 53

Q.F.-DES-100

1. Refer ence Dr aw i ngs, BOM & Shop Sketch Suppli ed by PGCB:-

Sl. No. DESCRIPTION

DRG. NO. BOM NO.

P a g e 45 | 53

2. Design Dimension:- Q.F.-DES-100

The following dimensions has been checked as per the erection drawing so as to ensure the overall dimension of Tower geometry and electrical clearances.

Values as per Tower drawing

(mm)

Observed Value (mm)

1. Width

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

2. Arm

GW

TC

MC

BC

3.Height

H1

H2

H3

H5

4.Length

L1

L3

L4

L6

L7

L8

P a g e 46 | 53

Q.F.-DES-100

3. Id en tifi ca tio n o f Dum my Se cti on s:-

During Proto assembly, it is generally observed that due to non-availability of few sections, Dummy Sections are used. These Dummies may be either replacing High Tensile (H.T.) material by Mild Tensile (M.T.) or any Particular Sections by other sections. These dummies need to be identified and marked in such a way that it does not become a part of mass supply anyway.

Section as per drawing

Dummy section used

Corrective action:

Corrective action may include:-

a) Cut the Dummy Sections by Gas Cut flame

OR

b) Mark with Red Paint at Regular Interval on All Sides

P a g e 47 | 53

4. INSULATOR/EARTH WIRE ATTACHMENT DETAILS :-

Q.F.-DES-100

Strain Plate details such as hole size,thickness, Grade of material etc to suit to the Insulator/Earth

Wire assembly needs to be checked, as it is one of the most important parameters.

Name of Conductor :- Configuration of Conductors :- Insulator Hardware Drawing No. :-

Thickness of 'D'

Shackle/Dia of hanger

Hole size in Length of Eye of "D" Shackle

EdgeRemarks Change in

Drg./Bom/Shop Sketch Required if any

Bottom Cross Arm

Middle Cross Arm

Ground Earthware

5. SMOO T H FI TT INGS OF JOI N T S / MEMBERS :-

To check thy smooth fittings of Joints/Members, few members at those joints where more members are bend and joined should be checked for tightening of bolts. Few bolts should be untighten, memers at that particular joint under review shall be removed and then assemble these again as

per drawing. The same procedure shall be followed for two-Three(2-3) joints and should be recorded in tabular form as per following.

SI No. Drawing No.Mark No of members disassemble and

assembled again Observation Remarks

P a g e 48 | 53

P a g e 49 | 53

6 . M E A S U R E M E NT O F DIMEN S I O NS O F SE C T I O NS : -

The measurement such as width of flanges, Thickness, length of angle sections and plates should be taken and matched with Bill of material(BOM)/Shop

Section Size as per drg. Section Size as per proto assembly

With in tolerance Limit

as per MQP

Leg

7. HOLE OF ACC ESSORIES ATTACHM ENT :-

Hole for Danger Plate

Hole for Phase plates

Hole for Number plate

Hole for Bird Guard

Hole for Step bolts

Hole for Brackets bolt

Hole for Anti Climbing Device (ACD)

Hole for Earthing

8. D ETAILS TO B E ADD ED IN DR AWIN G/B OM/SH OP SK ETC H :-

Detail to be added (Notching, Cutting, Bending etc)

9. D E V I A T IO N W . R . T . P R O T O D O N E B E FORE A T A N Y F A C T O R Y O R A P PR O V E D B O M :-

Drawing

Dimension As per

Previous Proto report/app. BOM

Dimension As per Proto

10. L EN G T H SIZ E S O F BOL T S : -

Adequeacy of Length or/and Size of Bolts should be checked for all leg Jionts, Joints at Bends and if some changes found that should be recorded in Drawing and BOM.

Drawing No. BOM Joint Details & Bolts Sizes as per Drawing

Reviesed Bolt Sizes as per

Proto assemblyChanges to be incorporated in

drawing and BOM

51

Q.F.-DES-100

11 . SAGG ING OF MEMBERS DUE TO SELF W EIG HT : -

Sagging of members due to self weight if found should be examined and measures such as any modification required in drawing, Bom and shop sketch. The modification if found necessary shall be fabricated, assembled and inspected for deflection, fittings etc.

Mark No. Drawing No. Observed Limiting CorrectiveChange to be

incorporated in Drawing

Bom/Shop

12 . LI S T OF RE J ECTED M E M BERS : -

Depending upon the nature of defect as mentioned below should by identified and rejected. These rejected material should be red painted or gas cut.

LengthWrong

febrication

13 . RECTIFICATION PROPOS ED : -

52

Q.F.-DES-100

14. PRE-ASSEMBLING INSPECTION - Photos

53

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