S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
QUALITY ASSURANCE PLAN
ITEM : MOTOR CONTROL CENTER, POWER CONTROL CENTRE , DISTRIBUTION BOARD, AMF PANEL , LT PANEL ETC.
1A
MATERIAL
INSPECTION
MILD STEEL FOR
FABRICATION (SHEET
STEEL & CHANNEL
CRCA '0' GRADE)
A) Surface Finish
B ) Sheet Metal
Thickness
C) Dimensions
1B
1C
Busbar Support SMC/
DMC
BUSBAR
Main Busbar (Ver. &
Hor.) Al / Cu
Control Busbar Al/ Cu
1D
1
Hardware
Bolt / Nuts / Plain
Washer / Spring
Washer
A) Type Of
Support
Major
- do - do Major
IS:513/1973
Measurement
Apprd Drgs
IS:513/1973
- do -
- do Visual
B) Dimensions
C) Surface Finish
D) H.V. Test
A) Size & Cross
Section
-
B) Resistivity /
Conductivity
C) Tensile
Strength
- do -
A) Dimensional
Confirmity
do
do
do
do
Visual
-
- do -
Major
Page 1 of 11
Measurement
Visual
Electrical
Measurement
- do Mechanical
Measurement
Krypton
Inspection
Record
- do -
- do -
- do -
- do -
As per
Application
Drgs
Krypton
- do - do - do Apprd. Drwgs
&
Specifications
IS : 5082/
1897
- do -
- do - do - do Krypton
Inspection
Record
- do -
IS :
1364/3063
Krypton
- do - do -
Krypton
Inspection
Record
Krypton
- do - do - do Krypton
Krypton
- do -
Krypton
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
1E
1F
Drawout Contact
Assembly (Power &
Aux. Contacts)
Paint
1G
Neoprene Rubber
Gasket
1H
Conductor / Wire
B) Plating : Zinc /
Cd
A) Surface Finish
- do - do -
Visual
B) Rating Size
A) Finish (Shade )
Viscosity
- do - do -
Measurement
Visual
- do IS : 101/ IS :
5 & Shade
no.631
- do Krypton
Inspection
Record
B ) Routine Test
C) Tape Test
A) Dimensional
Confirmity
- do - do - do -
- do Putting Tape
- do -
- do - do Internal Std.
- do - do Krypton
Inspection
Record
A) Verification of
Cross Section
make, Colour
Code , Grade etc.
B) Thickness of
Insulation
1I
Air Ckt Breaker (ACB)
A) Verification of
Current rating
B) Verification of
Voltage Grade
C) Mounting
Arrangement &
Dimensions
D) Setting Of
Releases
Major
- do -
Major
- do -
- do -
Physical
Verification /
Measurement
Physical
Verification /
Measurement
Visual
- do -
- do -
- do -
- do -
- do -
- do -
- do - do -
- do Krypton
- do - do Krypton
- do -
- do -
IS : 694
- do -
- do -
Approved Drg
- do -
- do -
- do -
- do -
- do -
- do -
Measurement
- do -
- do -
- do -
- do -
Electrical
- do -
- do -
- do -
Page 2 of 11
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
1J
1K
Terminal for Power &
Control
Air Break Switch
E) Voltage Rating
of Closing Coil /
Shunt / Trip /
Under Voltage
- do -
Visual
- do -
- do -
- do -
F) Anti Pumping
/ Trip Free
Feature
- do -
Electrical
- do -
- do -
- do -
G) Slow Costing
H) Routine / Type
Test
A) Size / Current
rating
- do - do -
- do Electrical /
Mechanical
Visual
- do As per IS :
2516
Approved
Drg.
B ) Connecting
Arrangement
A) Verification Of
Voltage Grade
B) Current Rating
C) Operating &
Interlocking
Arrangement
Major
- do Major
- do - do -
- do Verification
- do - do -
- do IS : 4064
Approved Drg
- do Manufacturer
TC
Krypton
Inspection
Record
- do Krypton
Inspection
Record
- do - do -
- do - do -
- do Manufacturer
Krypton
- do Krypton
- do - do -
1L
HRC Fuses
A) Verification of
Make , current
rating, rupturing
current
Major
Verification
IS : 9224
Krypton
Inspection
Record
Krypton
1M
Protective Relays
A) Mounting
Detail Setting
range Aux.
Contact Pos.
Major
Physical
verification
Approved Drg
Krypton
Inspection
Record
Krypton
B) Operation
Critical
Page 3 of 11
Test
- do -
- do -
- do -
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
1N
Air Break Contactors /
Timers / Time
switches
Approved Drg
/ IS : 2959
Krypton
Inspection
Record
Krypton
1O
1P
1Q
Current Transformer
Indicating
Instruments(Voltmeter,
Ammeter, Frequency,
KW, KWH, Meter etc.)
Control Switch
A) Mounting
Detail &
Mechanical
operation
B) Current Rating
/ Make
C) No. Of
Contacts
A) Mounting
Detail &
Dimensions
Major
Physical
verification
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
Minor
Physical
Verification
Approved Drg
Krypton
Inspection
Record
Krypton
Manufacturer
TC
Manufacturer
Manufacturer
TC
Manufacturer
B) CT Ratio ,
Class Of
Accuracy
Critical
A) Mounting
Detail &
Dimensions
Minor
Physical
Verification
Approved Drg
B) Accuracy Class
Major
Visual
Approved drg
IS : 1248
IS : 2419
C) Routine / Type
Test
A) Visual
Major
Electrical
Minor
Physical
verification
Approved drg
IS : 6875
Approved Drg
Major
Visual
- do -
- do -
- do -
Functional
test
- do -
- do -
- do -
B) Contact Rating
AC / DC
C) Operational
Test
- do -
Page 4 of 11
Test
- do -
- do -
Manufacturer
TC
Krypton
Inspection
Record
- do -
Manufacturer
Krypton
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
Approved Drg
Krypton
Inspection
Record
Krypton
1R
1S
Space Heater
Indicating Light
A) Mounting
Detail
Minor
Visual /
Physical
inspection
B) Verification of
Volt / Watt
Rating
Major
TEDT
A) Verification Of
Voltage Grade
Major
Verification
B) Series
Resistance Value
/ TRF, ratio
1T
1U
Voltage Transformer
Thermal Overload
Relay
A) Mounting
Detail &
Dimensions
B) PT Ratio, Class
of Accuracy
C) Verification of
polarity
D) Routine / Type
test
A) Verification of
Rating & Contact
Arrangement
B) Current
Setting
C) Mounting
Arrangement
D) Re Setting
arrangement
- do -
Major
- do -
Measurement
- do -
Approved Drg
/ IS : 4795
- do -
Manufacturer
Std
- do -
Krypton
Inspection
Record
- do -
Krypton
Inspection
Record
- do -
Krypton
- do -
Krypton
- do -
Visual
- do -
- do -
- do -
- do -
Electrical
- do -
- do -
- do -
- do Major
- do Electrical
- do Approved drg
Manufacturer
TC
Krypton
Inspection
Record
Manufacturer
Krypton
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
Page 5 of 11
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
1V
MCB / MCCB
A) Verification of
rating & Make
Major
Electrical
Approved drg
Krypton
Inspection
Record
Krypton
1W
Push Button
A) Verification of
Rating & Contact
Arrangement
Major
Electrical
Approved drg
Krypton
Inspection
Record
Krypton
B) Mounting
Arrangement
C) Operational /
Functional
2A
INPROCESS
INSPECTION
PANEL FABRICATION
A) Visual check
for weld,
dressing,
deburing,
straightness &
dimensional
control
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
Minor
B) Checking of
Frame with Std.
Trolley
- do -
C) Checking of
Trollies with
standard fixtures
- do -
D) Dimensions
- do -
E) Lifting
Facilities
F) Cable Entry
- do - do -
Page 6 of 11
Physical
Verification
Physical
Internal Std.
Internal
Inspection
record
Krypton
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
Process (
Physical
check before
assembly)
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
2B
PRE- TREATMENT /
PAINTING
G) Waviness
H) Gasket
Arrangement
A) Pre- Treatment
of sheet steel
B) Final Painting
- Paint
Thickness
- Adhesiveness
2C
Assembly
- Finish
A) Alignment of
Panel & Busbar
b) Check for
Busbar Mounting
1) Tightness of
Busbar Joints
- do - do Minor
- do - do Physical
Visual
- do - do Internal Std./
IS : 6005
- do - do Krypton
Inspection
Record
- do - do Krypton
- do - do -
- do Measurement
- do - do -
- do - do -
- do - do -
- do -
Physical
- do -
- do -
- do -
- do Major
- do -
Visual
Physical
verification
Physical test
by Torque
Wrench
- do IS : 101
Internal Std.
- do Internal
Inspection
record
- do Krypton
- do -
- do -
2) Busbar
Mounting on
Insulators
- do -
- do -
- do -
- do -
- do -
3) Busbar jointing
Arrangement &
Overlapping
- do -
- do -
- do -
- do -
- do -
4) Busbar
bending &
Drilling
- do -
- do -
- do -
- do -
- do -
- do -
- do -
- do -
5) Phase
Identification &
Clearance
Critical
Page 7 of 11
Physical
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
6) Busbar
Sleeving & Colour
Bends
C) Check for CT
Mounting
1) Mounting &
Adequate
Supports of CT
Minor
Visual Check
- do -
- do -
- do -
Major
Physical
verification
- do -
- do -
- do -
2) Provision for
Shorting link on
CT terminal
- do -
- do -
- do -
- do -
- do -
D) Mechanical
Interlocking
Arrangement
- do -
Functional
check
- do -
- do -
- do -
E) Check for
Arrangement of
Gasketing &
Sealing by torch
test
- do -
test
- do -
- do -
- do -
F) Arrangement of
Components &
Terminations
- do -
Physical
Verification
- do -
- do -
- do -
G) Check for
Interchangeability
- do -
Functional
check
- do -
- do -
- do -
H) Check for
Smooth
Movement of
Trolley During
Withdrawal /
Insertion
operation
Major
Page 8 of 11
Functional
Check
Internal Std
Internal
Inspection
record
Krypton
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
I) Check Trollies
for isolate test
service position
2D
Wiring
A) Proper Wire
Clamping
B) Continuity &
Ferruling as per
wiring diagram
C) Proper
crimping of lugs /
connections
tightening at
terminals &
components
3A
Final Inspection
A) Verification of
Component,
Rating,
Arrangement as
per GA Drg make
- do -
Minor
- do -
- do -
Major
Physical
Visual
Visual / test
- do -
Physical
Verification
- do -
- do -
- do -
Krypton
- do -
Internal
records
- do -
- do -
- do -
- do -
Internal
records
Krypton
Internal Std
Approved Drg
IS : 8625/ IS
: 4237/ IS :
2127
- do -
B) Mounting
Arrangement of
name plate covers
interchangeability
of Modules
- do -
- do -
- do -
- do -
- do -
C) Wiring Cubicle
& Ckt. Function
test , operation of
indicating
instruments
wiring
completeness
- do -
- do -
- do -
- do -
- do -
D) Continuity test
- do -
- do -
- do -
- do -
Page 9 of 11
Routine test
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
E) HV / IR Test
on both Power /
Control Ckt
F) Phase
Indication
Critical
Major
- do -
Visual
- do -
Approved Drg
IS : 8623 / IS
: 4237 / IS :
2127
- do -
- do -
Internal
Records
Krypton
G ) Check for
Busbar clearance
, Tightness pf
electrical /
mechanical
interlock
- do -
Visual /
Physical
verification of
torque
wrench
- do -
- do -
- do -
H ) Degree of
protection by
insertion of thin
paper / light test
- do -
Test
- do -
- do -
- do -
Visual
- do Physical
Verification
- do -
- do - do - do -
- do - do - do -
- do - do - do -
- do -
- do -
- do -
I ) Final Painting
1) Shade
2) Surface Finish
3) Thickness
4) Adhesion
J) Space Heater
1) Function
- do Minor
Major
- do Major
2) HV / IR test
3) Contact
Resistance of
D/O Components
- do - do -
Physical
verification
Routine test
Visual
K ) Degree of
protection
- do -
Mechanical
Page 10 of 11
Internal
Specs
- do - do -
- do -
Inspection
Record
- do - do -
- do -
Krypton
- do - do -
- do -
S.No.
Component /
Operation
Characteristics
Checked
Classification
Method /
Type of Check
Acceptance
Norm
Format of
Record
Agency
1
2
3
4
5
6
7
8
L) Temp. Rise
Test
M) Short Circuit
Test
- do -
Electrical
- do -
- do -
Visual
- do -
Page 11 of 11
Test
Certificate
- do -
- do - do -