MANUFACTURING QUALITY PLAN MQP NO: 399042020

ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 1 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

A. Raw Materials & Bought Out Items

Panels
1. Sheet Steel, CRCA Dimensional Conformity Major Measurement Sample Approved APPSIL Supplier Ö 3 _ 2
Chemical compositions Drawing Plant Test
standard/ Report
IS 513

2. Fabrication Dimensional conformity Major Measurement Sample Approved APPSIL -- 3 _ 2

Drawing Plant
standard Activities
under direct
3. Surface Preparation/ Pre- Titration test Major Measurement Sample Approved APPSIL -- 3 _ 2 supervision
Treatment Process Drawing / Plant by ABB
standard/
IS 3618
4. Powder Coating Surface Finish/ shade/ Major Visual & Random Approved APPSIL Test Ö 3 _ 2
Scratch hatch test/coating Measurement Drawing/ Plant Report
thickness standard/
IS 5 Shade
/RAL shade

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 2 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

5. GASKET Material Type Major Visual Sample Approved APPSIL Supplier 3 - 2

Hardness Measurement Drawing Plant Test
standard/ Report
IS 11149

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 3 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

6 Cable 1. Type of cable Major Visual / Sample Approved APPSIL Supplier Ö 3 - 2

2. Color check Drawing Plant Test
3. Conductor Resistance Measurement standard / Report
4. No. of Strands
5. Shielding (if called) Electrical IS 694
6. Construction Diameter Tests
7. Dimensional conformity
Check
8. High voltage Spark test
(during mfg. process)
9. Elongation
10. Smoke density test
11. Flammability test
12. Oxygen Index test

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 4 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

7 Assembled panel with 1. Position of component Major Visual 100% Approved APPSIL --- 3 2 - Relays are
manufacture
associated components assembly. Drawing Plant
d at ABB
(Door Switch, Space 2. Type, make & Quantity standard in-house &
Heater, Thermostats, 3 Pin of components associated
Socket and Switch, Relays, assembled. components
and Panel
Compact Fluo / Indicating 3. Aesthetic
wiring
Lamp, Toggle switch for carried out
Heater, terminal block. in our
fuses, Links & fittings) Approved
vendor
premises
under direct
supervision
by ABB

Various Other Components & Bought Out Items

8 Push buttons, Switches, Type & Make Major Visual Sample Approved APPSIL --- 3 - 2
Annunciators, Semaphore, , Range Drawing Plant
Fuses, MCB, Indication Rating standard
Lamps, Relays, Test terminal Functional Check
blocks, Sync. Socket,
Electronic Bell, Hooter. etc.

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 5 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

9 GPS Receiver Type & Make Major Electrical 100% Approved APPSIL Supplier Ö 3 - 2
Functional Check Drawing Plant Test
standard Report
10 Transducer Type & Make Major Electrical 100% Approved APPSIL Supplier Ö 3 - 2
Range Drawing Plant Test
Functional Check standard/ Report
IEC 60688
11 Inverter & UPS Type & Make Major Electrical 100% Approved APPSIL Supplier Ö 3 - 2
Range Drawing Plant Test
Functional Check standard Report
12 Aux CT's & VT's Type & Make Major Electrical Sample Approved APPSIL Supplier Ö 3 - 2
(CT- Current transformer Rating Drawing Plant Test
VT-Voltage transformer) Functional Check standard/ Report
IS 2705/
IS 3156
13 Protection relays Make, Type & Rating Major Visual 100% Approved APPSIL Supplier Ö 3 - 2
Functional Check Electrical Drawing Plant Test
standard/ Report

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 6 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

14 Indicating meters (Analog/ Type & Make Major Electrical 100% Approved APPSIL Supplier Ö 3 - 2
Digital) Range Drawing Plant test
Functional Check standard// report
IS 1248/
IS 2419
15 Computer peripherals & Visual Check Major Visual 100% Approved APPSIL -- 3 - 2
Ethernet switch /configurations / Make Power on Drawing Plant
Functional Check check / Test standard
Operating system Check Page Print
Out

B. ABB INPROCESS INSPECTION

16 Numerical Protection Relays Type Major Visual 100% Approved APPSIL ABB Ö 2 - 2
Rating, Electrical Drawing Plant Test
Functional Check Test standard/ Report
HV test IEC60255-5

17 Test Switches Type, Rating, Major Visual 100% Approved APPSIL -- 2 - 2

Electrical Drawing Plant
Test standard

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 7 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

18 Combiflex relays Type Major Visual Approved APPSIL -- 2 - 2

Rating, Electrical 100% Drawing Plant
Functional Check Test standard/
HV test IS 3231
19 Complete Assembled, IR Value Test (Before Major 100% Approved APPSIL -- 2 - 2
Wired Panel -IR Value Test H.V. Test) Electrical Drawing Plant
Test standard

20 Complete Assembled, High Voltage Test 2KV Major Electrical 100% Approved APPSIL RTC 2 - 2
Wired Panel -High Voltage for 1min between all Test Drawing Plant
Test terminals and earth standard

21 Complete Assembled, IR Value Test (After Major 100% Approved APPSIL -- 2 - 2

Wired Panel -IR Value Test H.V. Test) Electrical Drawing Plant
Test standard

C. Final Testing

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 8 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

22 Complete Assembled, Visual Check for Basic Major Visual * Approved APPSIL RTC Ö 2 1 1 RTC-
Wired Panel - Control, assembly and Dimension Measurement Drawing Plant Routine
Relay & SAS like, Height, Width, Depth standard Test
Workman ship Report
Paint shade, Surface finish Major Visual Random Approved APPSIL RTC Ö 2 1 1
& Coating Thickness Measurement Drawing Plant
standard/
IS 5 Shade
/RAL
shade
Visual Check for Major Visual * Approved APPSIL RTC Ö 2 1 1
Mounting of all equipment Drawing Plant
WRT BOM, Rating, Type, standard
Make of components
Degree of Protection Major Test - Approved APPSIL IP Ö 3 - 2,
Drawing Plant Report 1
standard/
IS/IEC60529
Verification of Wiring, Major Visual * Approved APPSIL RTC Ö 2 1 1
Ferruling /Continuity Electrical Test Drawing Plant
Check/color standard
coding/earthling

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 9 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

Operational and scheme Major Electrical * Approved APPSIL RTC Ö 2 1 1

test for all Relays Test Drawing Plant
standard/
IEC60255-6
Operational test (elect. Major Electrical Approved APPSIL RTC Ö 2 1 1
Control Interlock and Test * Drawing Plant
Sequential Operation) standard/
IEC60255-6
Secondary current Major Electrical Approved APPSIL RTC Ö 2 1 1
Injection tests on relays & Test * Drawing Plant
Meters standard/
IEC60255-6
Continuity Check for Major Electrical * Approved APPSIL RTC Ö 2 1 1
earthing Test Drawing Plant
standard/
IEC60255-6
Functional check for Time Major Communication * Approved APPSIL RTC Ö 2 1 1
synchronization, Ethernet & Real Time Drawing Plant
switch & Gateway Data standard/
Approved
FAT
Procedure

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 10 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

Quantum of Check

* For APPSIL Testing: 100%,

* Customer/ EPC/ Third party inspection agencies: 10 % of the offered lot.

Note: MQP Column "D"- (Tick) Bought out material-Supplier test report will be made available during customer factory acceptance test.

D. Packing

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer
 MANUFACTURING QUALITY PLAN MQP NO: 399042020
ABB
ABB Power Products & System India Ltd. Customer: TSGENCO Rev: 00 DATE: 30.04.2020
Plot No:4A,5&6, II Phase,
Peenya industrial area, Substation Ref:Pochampad powerhouse/
Bangalore-560058 Jurala powerhouse/ Nagarjunasagar powerhouse Page 11 of 11
Package Items: Control Panel, Relay Panel &Substation
Automation System
Sl Components Characteristics Class Type of Quantum Reference Acceptance Format ** Agency Remarks
No Check of Check Document Norms of D
Record P W V#

23 Pre-dispatch checks Verification of Major Visual 100% ABB Plant APPSIL Delivery 2 - 2
completeness of all items standard Plant Challan
- Dressing, Routing, as per contract standard
Bunching & proper
fastening all items
- Packing worthiness
- Identification marks on
packed casing
- Dispatch Destination
mark
- Storage instructions
- Encloser of applicable
documents

Legend: P-Perform, W-Witness, And V-Verification. Indicate

1 - For Customer / Contractor/ EPC/ Third party inspection agencies, Prepared by
2 – Supplier (APPSIL), 3 – Sub Vendor, As Appropriate Against Each
Component/ Characteristic Under P, W & V Columns
V# For Items Marked- Verification of record only
** For Items Marked Ö (Tick) In Column ‘D’, Test Certificates Shall Be CUSTOMER SIGNATURE AND STAMP
Submitted To Customer