THIS QAP IS READ IN CONJUNCTION WITH THE ATTACHED
COMPLIANCE.
[Link] Motor
QP. No : LA80386701-QVE
REV. 3
Doc no KSL / SYS- DE-power-1107/E02/05
DATE : 2013.04.04
ITEM : 4600kW 18P 6.6kV VSTC1250
HYOSUNG CORPORATION
KOREA
PROJECT : 1040 MW Vizag Thermal Power Project
CUSTOMER : Hinduja National Power Corporation
Limited
CONSULTANT : Mott
MacDonald
CONTRACTOR : KBL PUNE
MANUFACTURING QUALITY PLAN
MANUFACTURER'S NAME & ADDRESS
PAGE : 1 of 5
SL No
COMPONENTS &
OPERATIONS
CHARACTERISTICS
2.
3.
1.
CLASS
TYPE OF
CHECK
4.
QUANTUM
M
OF CHECK
S/C
ACCEPTANCE
NORMS
8.
6.
5.
REFERENCE
DOCUMENT
FORMAT OF
REPORT
9.
AGENCY
M
D*
REMARKS
C
** 10.
11.
1.0 SUPPLIED MATERIALS (Major)
1.1
SHAFT
1.1.1
Dimensional & visual check
Major
Dimn.
Drawing
Drawing
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
TC
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
TC
ASME A 388
ASME A 388
TC
Chemical analysis
Major
Record verfication
1.1.3
Mechanical properties, Tensile,
Yield, Elongation ,
Heat treatment, Finish and hardness
Major
Record verfication
1 Sample
/ Lot
1 Sample
/ Lot
Major
Record verfication
100%
100%
Ultrasonic Examination
1.2
100%
1 Sample
/ Lot
1.1.2
1.1.4
QCR
100%
1 Sample
/ Lot
MAGNETIC SHEET STEEL
1.2.1
Dimensional & visual check
(straightness / edge camber, waveiness,
freedom from loose scale, dents, etc)
Major
Record verfication
1 Sample
/ Lot
1 Sample
/ Lot
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
1.2.2
All test as per Maker ST`
Major
Record verfication
1 Sample
/ Lot
1 Sample
/ Lot
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
TC
Final dimensional check
Major
Dimn
100%
100%
Drawing
Drawing
QCR
Final dimensional check for bearing
seating dia, coupling seating dia, run out
(eccentricity)
Major
Dimn
100%
100%
Drawing
Drawing
QCR
2.0
INPROCESS INSPECTION - MACHINING
2.1
STATOR FRAME
2.1.1
2.2
R1
SHAFT
2.2.1
Hyosung corporation LTD.
[Link]
LEGEND * RECORDS, IDENTIFIED WITH "TICK" () SHALL BE ESSENTIALLY
INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M : MANUFACTURER/SUB-SUPPLIER, S : MAIN SUPPLIER, APPROVED
C : CUSTOMER
/
AS INDICATED
BY
CONSULTANT,
CATEGORY I APPROVED
P : PERFORM, W : WITNESS AND V : VERIFICATION.
BELOW
APPROVED BY
CATEGORY II APPROVED;SUBJECT TO COMMENTS TO BE
INCORPORATED
CATEGORY III NOT APPROVED, TO BE REVISED
CATEGORY IV FOR INFORMATION ONLY
CATEGORY IV-R FOR INFORMATION WITH COMMENTS
1/5
Contractor is responsible for Design, coordination, dimensions, quantities
etc. Approval does not relieve the contractor of his responsibility for design
and performance of the equipment / system / overall plant in accordance with
the contract document.
______________________________________________________________
MOTT MACDONALD PVT. LTD.
Job No. .
Checked by . Date
18.04.2013
MS/AK
APPROVAL SEAL
[Link] Motor
QP. No : LA80386701-QVE
REV. 3
Doc no KSL / SYS- DE-power-1107/E02/05
DATE : 2013.04.04
ITEM : 4600kW 18P 6.6kV VSTC1250
HYOSUNG CORPORATION
KOREA
PROJECT : 1040 MW Vizag Thermal Power Project
CUSTOMER : Hinduja National Power Corporation
Limited
CONSULTANT : Mott
MacDonald
CONTRACTOR : KBL PUNE
MANUFACTURING QUALITY PLAN
MANUFACTURER'S NAME & ADDRESS
PAGE : 2 of 5
SL No
COMPONENTS &
OPERATIONS
CHARACTERISTICS
2.
3.
1.
3.0
ROTOR/STATOR - CORE PUNCHING
3.1
ROTOR / STATOR CORE PUNCHING
CLASS
TYPE OF
CHECK
5.
4.
3.1.1
Dimensional & visual check
Major
Dimn
3.1.2
Burr checking
Major
Dimn
3.2
QUANTUM
OF CHECK
S/C
REFERENCE
DOCUMENT
ACCEPTANCE
NORMS
8.
6.
1 Sample
/ Lot
1 Sample
/ Lot
1 Sample
/ Lot
1 Sample
/ Lot
FORMAT OF
REPORT
9.
AGENCY
M
D*
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
11.
ROTOR CORE ASSEMBLY
Dimensional & visual check including
slot size with gauge
Major
Dimn
1 Sample
/ Lot
1 Sample
/ Lot
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
3.2.2
Check locking of
1) Both end of core
2) Shaft with core
Major
Visual
100%
100%
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
ROTOR COMPLETE INCLUDING BRAZING OF S. C. RING
3.3.1
Check records of approved brazing
proces and qualified brazers
Major
Process
100%
100%
BPS / PQR ASME
BPS / PQR ASME
QCR
3.3.2
Preparatory checks befor brazing
Major
Visual
100%
100%
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
3.3.3
Visual inspection of brazed joints
and procees control
Major
Visual
100%
100%
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
3.3.4
Dynamic balancing
Major
Mech.
100%
100%
ISO 1940
ISO 1940 grade 2.5
3.4
REMARKS
C
** 10.
3.2.1
3.3
Report
STATOR CORE ASSEMBLY
3.4.1
Dimensional & visual check
(including cleanliness)
Major
Dimn.
100%
100%
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
3.4.2
Check by gauge
Major
Dimn.
100%
100%
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
Check locking of stator core with frame
Major
Visual
100%
100%
Drawing or Mfg. ST`.
Drawing or Mfg. ST`.
QCR
3.4.3
Hyosung corporation LTD.
[Link]
LEGEND * RECORDS, IDENTIFIED WITH "TICK" () SHALL BE ESSENTIALLY
INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M : MANUFACTURER/SUB-SUPPLIER, S : MAIN SUPPLIER, C : CUSTOMER /
CONSULTANT,
P : PERFORM, W : WITNESS AND V : VERIFICATION.
2/5
APPROVED BY
APPROVAL SEAL
[Link] Motor
QP. No : LA80386701-QVE
REV. 3
Doc no KSL / SYS- DE-power-1107/E02/05
DATE : 2013.04.04
ITEM : 4600kW 18P 6.6kV VSTC1250
HYOSUNG CORPORATION
KOREA
PROJECT : 1040 MW Vizag Thermal Power Project
CUSTOMER : Hinduja National Power Corporation
Limited
CONSULTANT : Mott
MacDonald
CONTRACTOR : KBL PUNE
MANUFACTURING QUALITY PLAN
MANUFACTURER'S NAME & ADDRESS
PAGE : 3 of 5
SL No
COMPONENTS &
OPERATIONS
CHARACTERISTICS
2.
3.
1.
TYPE OF
CHECK
CLASS
4.
QUANTUM
M
5.
OF CHECK
S/C
REFERENCE
DOCUMENT
ACCEPTANCE
NORMS
8.
6.
4.0
INSPECTION ON THE COILS AND WOUND STATOR --> HYOSUNG inprocess standard application
4.1
COIL - Befor Connection
4.1.1
Dimensional & visual check
Major
Dimn.
100%
1 Sample
/ Lot
4.1.2
Surge Test
Major
Test
100%
4.2
FORMAT OF
REPORT
9.
AGENCY
M
D*
REMARKS
C
** 10.
Drawing / electrical
specification
Drawing / electrical
specification
QCR
100%
IEC60034-15 or
Mfg. ST`.
IEC60034-15 or
Mfg. ST`.
QCR
100%
Drawing / electrical
specification
Drawing / electrical
specification
QCR
11.
WOUND STATOR - After connection and Befor Impregnation
4.2.1
Dimensional & visual check
Major
Dimn.
100%
4.2.2
Ohmic Resistance
Major
Test
100%
100%
IEC 60034
IEEE 112 or IEC 60034
QCR
4.2.3
Insulation Resistance
Major
Test
100%
100%
IEEE 43-12.3
IEEE 43-12.3
QCR
4.2.4
High Voltage Test - AC
Major
Elec.
100%
100%
IEC 60034-15
IEC 60034-15
QCR
4.2.5
Ohmic Resistance fo RTDs
Major
Elec.
100%
100%
IEC 60034-1
20% of Deviation
QCR
Major
Elec.
100%
100%
IEC 60894-App.B - fig. 1
IEC 60894
QCR
4.3
WOUND STATOR - After Impregnation
4.3.1
Tan Delta
5.0
ASSEMBLED MOTOR
5.1
FINISHED ASSEMBLED MOTOR
5.1.1
Visual check including size of lugs and
quality of joints(crimping)
Major
Measurement
100%
100%
Approved Dwg. &
Mfg. Dwg.
Approved Dwg. &
Mfg. Dwg.
TC
5.1.2
Check for identity & completeness of
components and accessories & clearing
Major
Measurement
100%
100%
IEEE 112 or IEC 60034
IEEE 112 or IEC 60034
TC
Hyosung corporation LTD.
[Link]
LEGEND * RECORDS, IDENTIFIED WITH "TICK" () SHALL BE ESSENTIALLY
INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M : MANUFACTURER/SUB-SUPPLIER, S : MAIN SUPPLIER, C : CUSTOMER /
CONSULTANT,
P : PERFORM, W : WITNESS AND V : VERIFICATION.
3/5
APPROVED BY
APPROVAL SEAL
[Link] Motor
QP. No : LA80386701-QVE
REV. 3
Doc no KSL / SYS- DE-power-1107/E02/05
DATE : 2013.04.04
ITEM : 4600kW 18P 6.6kV VSTC1250
HYOSUNG CORPORATION
KOREA
PROJECT : 1040 MW Vizag Thermal Power Project
CUSTOMER : Hinduja National Power Corporation
Limited
CONSULTANT : Mott
MacDonald
CONTRACTOR : KBL PUNE
MANUFACTURING QUALITY PLAN
MANUFACTURER'S NAME & ADDRESS
PAGE : 4 of 5
SL No
COMPONENTS &
OPERATIONS
2.
1.
5.2
CHARACTERISTICS
CLASS
3.
4.
TYPE OF
CHECK
QUANTUM
M
5.
OF CHECK
REFERENCE
DOCUMENT
S/C
6.
ACCEPTANCE
NORMS
8.
FORMAT OF
REPORT
AGENCY
M
9.
REMARKS
C
** 10.
11.
PAINTING & PRESERVATION
Visual check & check for paint coat
thickness
Major
Measurement
100%
100%
Approved Dwg. &
Mfg. Dwg.
Approved Dwg. &
Mfg. Dwg.
TC
5.3.1.
Dimensional check as per drawing
Major
Measurement
100%
100%
Approved Dwg. &
Mfg. Dwg.
Approved Dwg. &
Mfg. Dwg.
TC
5.3.2
Resistance measurement of Winding,
RTD, BTD and Space Heater before
start of the machine
Major
Measurement
100%
100%
IEEE 112 or IEC 60034
IEEE 112 or IEC 60034
TC
5.3.3
Reduced voltage running test actual
direction of rotation
ajor
Measurement
100%
100%
IEEE 112 or IEC 60034
IEEE 112 or IEC 60034
TC
5.3.4
Measurement of IR on stator winding and
ajor
Space heater before & after HV test
Measurement
100%
100%
IEEE 43
IEEE 43
TC
5.3.5
IR value for BTD, RTD
Measurement
100%
100%
IEEE 43
IEEE 43
TC
5.3.6
Polorization Index
Major
Measurement
100%
100%
IEEE 43
IEEE 43
TC
5.3.7
HV as on stator winding & space heater
Major
Measurement
100%
100%
IEEE 112 or IEC 60034
IEEE 112 or IEC 60034
TC
5.3.8
No Load Run Test
measure current, voltage, power,
speed
Major
Measurement
100%
100%
IEEE 112 or IEC 60034
IEEE 112 or IEC 60034
TC
5.3.9
Locked Rotor
reading at voltage, current,
power input at suitable reduce voltage
Major
Measurement
100%
100%
IEEE 112 or JEC2137
IEEE 112 or JEC2137
TC
5.3.10
Shaft Voltage measurment
Major
Measurement
100%
100%
IEEE 112 or Eq.
IEEE 112 or Eq.
TC
5.2.1
5.3
ROUTINE TESTS
ajor
Hyosung corporation LTD.
[Link]
LEGEND * RECORDS, IDENTIFIED WITH "TICK" () SHALL BE ESSENTIALLY
INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M : MANUFACTURER/SUB-SUPPLIER, S : MAIN SUPPLIER, C : CUSTOMER /
CONSULTANT,
P : PERFORM, W : WITNESS AND V : VERIFICATION.
4/5
APPROVED BY
APPROVAL SEAL
MANUFACTURING QUALITY PLAN
MANUFACTURER'S NAME & ADDRESS
[Link] Motor
QP. No : LA80386701-QVE
REV. 3
Doc no KSL / SYS- DE-power-1107/E02/05
DATE : 2013.04.04
ITEM : 4600kW 18P 6.6kV VSTC1250
HYOSUNG CORPORATION
KOREA
PROJECT : 1040 MW Vizag Thermal Power Project
CUSTOMER : Hinduja National Power Corporation
Limited
CONSULTANT : Mott
MacDonald
CONTRACTOR : KBL PUNE
PAGE : 5 of 5
SL No
5.4
COMPONENTS &
OPERATIONS
CHARACTERISTICS
CLASS
TYPE OF
CHECK
QUANTUM
OF CHECK
S/C
REFERENCE
DOCUMENT
ACCEPTANCE
NORMS
FORMAT OF
REPORT
AGENCY
REMARKS
TYPE TEST
5.4.1
Vibration measurement
Major
Measurement
100%
100%
NEMA MG1 or Eq.
NEMA MG1 or IEC
60034
TC
R1
5.4.2
Noise level measurement
Major
Measurement
100%
100%
IEC60034-9 or
Specification
IEC60034-9 or
Specification
TC
R1
5.4.3
Momentory overload test
Major
Measurement
1 Sample
/ Type
1 Sample
/ Type
NEMA MG1 or IEC
60034
NEMA MG1 or IEC
60034
TC
5.4.4
Over Speed test At 120% of Rated Speed
Major
Measurement
1 Sample
/ Type
1 Sample
/ Type
NEMA MG1 or IEC
60034
NEMA MG1 or IEC
60034
TC
5.4.5
Temperature rise test
Major
Measurement
1 Sample
/ Type
1 Sample
/ Type
IEEE 112 or IEC 60034
NEMA MG1 or IEC
60034
TC
5.4.6
Full load test to determine Efficiency,
Power factor & Slip.
Major
Measurement
1 Sample
/ Type
1 Sample
/ Type
IEEE112 Method F1 /
JEC2137
Approved Spec`.
& IEC60034-1
TC
5.5
Tan Delta test on assembled motor and
indivdual phases
Major
Measurement
100%
100%
IEC 60894
IEC 60894
TC
5.6
Dieelectric Test on sample coil (Internal
test records)
Major
Measurement
100%
1 Sample
/ Type
IEC 60034-15
IEC 60034-15
TC
IP55 certificate II neumeral
(Internal - similar design) &
Fault Level Certificate review.
R2/R3
Hyosung corporation LTD.
[Link]
LEGEND * RECORDS, IDENTIFIED WITH "TICK" () SHALL BE ESSENTIALLY
INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M : MANUFACTURER/SUB-SUPPLIER, S : MAIN SUPPLIER, C : CUSTOMER /
CONSULTANT,
P : PERFORM, W : WITNESS AND V : VERIFICATION.
5/5
APPROVED BY
APPROVAL SEAL
DRAWING/DOCUMENT TRANSMITTAL DT 04.07.2012 - FOR VENDOR DOCUMENTS - QAP FOR
MOTOR (DRG NO KSL/SYS-DE-POW-1107/E02/05 REV 00) & TEST PROCEDURE FOR
INDUCTION MOTOR (DRG NO KSL/SYS-DE-POW-1107/E02/06 REV 00)
REPLY / CLARIFICATIONS_ R2
COMMENTS :
1. TEST TO DIAGNOSE ROTOR BAR FAILURE DURING MANUFACTURE SHALL BE
CONDUCTED ON THIS MOTOR. THE RPM OF THIS MOTOR IS 325. THEREFORE KBL TO
REMOVE THE CONDITION OF 1500 RPM ORABOVE.
HYOSUNG REPLY : 1.1.4 - ULTRASONIC EXAMINATION OF SHAFT WILL BE DONE.
SAME INCORPORATED IN QAP.
2. THE TEST CERTIFICATES FOR ALL BOUGHT OUT ITEMS SHALL BE FURNISHED BY
KBL.
HYOSUNG REPLY : TEST CERTIFICATE FOR BROUGHTOUT VIZ DIAL GAUGES & CTS
SHALL BE SUBMITTED FOR REVIEW DURING TESTING.
3. KBL TO CORRECT THE SERIAL NUMBER OF THE ITEM. ALSO KBL TO NOTE THAT THE
PAINTING SHALL BE AS PER THE APPROVED PAINTING SCHEDULE BY MM.
HYOSUNG REPLY : SN CORRECTED, WE HAVE NOTED PAINTING SHALL BE AS PER
APPROVED PAINTING PROCEDURE BY MM.
4. KBL TO ALSO CONDUCT TAN DELTA, CHARGING CURRENT AND DIELECTRIC LOSS
MEASUREMENTS ON EACH PHASE OF MOTOR STATOR WINDING AS ROUTINE TEST.
HYOSUNG REPLY : TAN DELTA IS CARRIED OUT ON WOUND STATOR, PLEASE REFER
SN 4.3.1. WE WILL OFFER TAN DELTA TEST ON ASSEMBLED MOTOR AND INDIVDUAL
PHASES FOR WITNESS THIS TEST ADDED IN QAP SN 5.5.
R1
5. THESE TESTS SHALL ALSO BE THE PART OF ROUTINE TESTS AS PER THE
SPECIFICATIONS VIBRATION & NOISE LEVEL MEASUREMENT.
HYOSUNG REPLY : PLEASE NOTE THESE ARE TYPE TEST AS PER STANDARD. WE
WILL OFFER THESE TEST DURING TESTING. QUANTUM OF CHECK MADE 100%
INSTEAD 1 SAMPLE / TYPE
6. THE TYPE TEST CERTIFICATE FOR FIRST NUMERAL SHALL BE ACCEPTABLE,
PROVIDED THE TEST MOTOR IS IDENTICAL TO MOTOR BEING SUPPLIED. HOWEVER
THE SECOND NUMERAL TEST SHALL BE CARRIED OUT ON MOTORS AS ROUTINE
TEST.
HYOSUNG REPLY : IP55 - THE TYPE TEST CERTIFICATE FOR FIRST NUMERAL IS NOT
AVAILABLE WE WILL GIVE COMPLIANCE. ALSO PLEASE NOTE TESTING AUTHORITY
IN INDIA & ABROD DO NOT HAVE FACILITY FOR SUCH BIG MOTORS (WEIGHT 46
TONS). AS REGARD THE SECOND NUMERAL TEST WE ATTACHED WITNESS TEST
REPORT OF SIMILAR DESIGN, WE REQUEST YOU TO WAIVE OFF THIS WITNESS
TEST. T BOX FAULT LEVEL CERTIFICATE ATTACHED FOR YOUR REFERENCE WHICH
WILL BE FURNISHED AS PART OF DOCUMENTS DURING TESTING.
R1
WE CONFIRM MOTOR FULFIL REQUIRNMENT OF IP55. DECLARATION OF CONFIRMITY
IN THIS REGARD WILL BE SUBMITTED DURING TESTING.
R2
PROJECT No.
LA80386701
Page 1 of 2
DRAWING/DOCUMENT TRANSMITTAL DT 04.07.2012 - FOR VENDOR DOCUMENTS - QAP FOR
MOTOR (DRG NO KSL/SYS-DE-POW-1107/E02/05 REV 00) & TEST PROCEDURE FOR
INDUCTION MOTOR (DRG NO KSL/SYS-DE-POW-1107/E02/06 REV 00)
REPLY / CLARIFICATIONS_ R2
REPLY / CLARIFICATIONS_ R2
7. KBL TO NOTE THAT THE MANUFACTURE TO CARRY OUT IMPULSE TEST BY 1.2/50
MICRO-SECOND ON ONE SAMPLE COIL OF STATOR WINDING AS TYPE TEST AS PER
IEC60034-15 TO CUSTOMER DURING FINAL INSPECTION KBL TO ALSO PERFORM
DIELECTRIC TEST (CAPACITANCE & DESSIPATION FACTOR)
HYOSUNG REPLY : WE WILL CARRY OUT DIEELECTRIC TEST ON ONE SAMPLE COIL
OF ORDERED MOTOR & REPORT WILL BE FURNISHED FOR REVIEW DURING
TESTING. IMPULSE TEST CARRIED OUT ON ALL STATOR COILS BEFORE
PLACEMENT IN STATOR PLEASE REFER SN 4.1.2 (SURGE TEST).
R1
8. KBL TO INCORPORATE THE CHANGES AS PER THE COMMENTS ON QAP IN TEST
PROCEDURE.
HYOSUNG REPLY : NO CHANGE IN THREE PHASE INDUCTION MOTOR TEST
PROCEDURE
PROJECT No.
LA80386701
Page 2 of 2
