We follow a comprehensive Quality Assurance Plan (QAP) for wires and cables which involves raw material inspection, in-process monitoring, and final testing according to standards like IS/IEC. Key checks include conductor resistance, insulation thickness, spark tests, and sheath integrity, ensuring compliance with specifications such as tensile strength, elongation, and flame resistance.
| QUALITY ASSURANCE PLAN | |||||
|---|---|---|---|---|---|
| Material / Process | Characteristic Tests | Method of check / Test Equipment | Sampling Plan | Requirement / Ref. Document | Internal Acceptances Norms |
| I. RAW MATERIAL | |||||
| A. CONDUCTOR (COPPER) | 1) Diameter | Vernier caliper / Micrometer | Each bobbin / Drum | As per IS - 8130 | As per IS - 8130 |
| 2) Surface finish | Visual | Each Drum | The conductor should be smooth. | Conforms to the requirement | |
| 3) Annealing Test (for copper) | Tensile Testing M/c | Random Drum | As per IS - 8130 | As per IS - 8130 | |
| 4) Conductor Resistance at 20°C | Digital micro ohm Meter | Each Drum | As per IS - 8130 | As per IS - 8130 | |
| B. PVC COMPOUND INSULATION / SHEATH | 1) Type of compound | Visual check | Random Lot | Material grade as per Requirement | As per Manufacturer specification |
| 2) Tensile strength Before and After Ageing | Review M.T.C | Each Lot | As per IS - 5831 | As per IS - 5831 | |
| 3) Elongation Before and After Ageing | Review M.T.C | Each Lot | As per IS - 5831 | As per IS - 5831 | |
| 4) Thermal Stability | Thermal stability oven | Random Lot | As per IS - 5831 | As per IS - 5831 | |
| II. INPROCESS (SEMI FINISHED CABLES / WIRES) INSPECTION | |||||
| A. BUNCHING / STRANDING | 1) No of wires / Strand | Self Device | Measurement at the start of each job | As per IS - 8130 | As per IS - 8130 |
| 2) Diameter of Wire / Strand | Vernier caliper / Micrometer | Measurement at the start of each job | As per IS - 8130 | As per IS - 8130 | |
| 3) Direction of Lay | Visual | Measurement at the start of each job | As per requirement | Conforms to the requirement | |
| 4) Overall Dimensions | Vernier caliper / Micrometer | Measurement at the start of each job | As per requirement | Conforms to the requirement | |
| 5) Conductor resistance | Digital micro ohm Meter | Measurement at the start of each job | As per IS - 8130 | As per IS - 8130 | |
| B. CORE EXTRUSION | 1) Type of Compound | Visual check of grade | Once when the new bag is opened for use | As per requirement | Conforms to the requirement |
| 2) Thickness of Insulation | Vernier caliper / Micrometer | Each setting & twice in a shift | As per IS - 694 | As per IS - 694 | |
| 3) Core Identification | Visual | Each setting & twice in a shift | As per IS - 694 | As per IS - 694 | |
| 4) Diameter Check | Vernier caliper / Micrometer | Each setting & twice in a shift | As per requirement | Conforms to the requirement | |
| 5) Surface finish | Visual | Start and end of each setting & twice during the processing for that setting | Should be smooth & free from porosity | Should be smooth & free from porosity | |
| 6) Concentricity of PVC | Visual | Start and end of each setting | As per IS - 694 | Conforms to the requirement | |
| 7) Printing / marking (For single core) | Visual | Continuous monitoring | As per requirement | Conforms to the requirement | |
| C. TEST ON CORE IN LABORATORY | 1) Thickness of Insulation | Vernier caliper / Micrometer | Random check for each size & colour | As per IS - 694 | As per IS - 694 |
| 2) Concentricity of PVC | Vernier caliper / Micrometer | One for each size & colour (if changed) | As per IS - 694 | As per IS - 694 | |
| 3) Tensile strength & Elongation | Tensile testing m/c | One sample for each size | As per IS - 694 | As per IS - 5831 | |
| 4) Insulation resistance & Volume resistivity | Million mega ohm Meter | One sample for each size | As per IS - 694 | As per IS - 5831 | |
| D. LAYING UP (FOR MULTICORE FLEXIBLE) | 1) Number / Sequence of cores | Visual | Each setting | As per IS - 694 | As per IS - 694 |
| 2) Identification Of Cores | Visual | Each setting | As per IS - 694 | As per IS - 694 | |
| 3) Lay Direction | Visual | Each setting | As per IS - 694 | As per IS - 694 | |
| 4) Lay Length | Meter Scale | Each setting | As per requirement | Conforms to the requirement | |
| E. INNER SHEATH (FOR SIZE ABOVE 10.0 SQMM) | 1) Type of PVC/Tape | Visual check | Random | As per requirement | Conforms to the requirement |
| 2) Thickness of Inner Sheath | Vernier caliper / Micrometer | Each setting | As per IS - 694 | As per IS - 694 | |
| 3) Surface finish | Visual | Each Drum | Smooth surface | Smooth surface | |
| F. OUTER SHEATH | 1) Type of PVC | Visual check of grade used | Once when the new bag is opened for use | As per requirement | Conforms to the requirement |
| 2) Thickness of Outer sheath | Vernier caliper / microscope | Each setting | As per IS - 694 | As per IS - 694 | |
| 3) Overall Diameter | Vernier caliper | Each setting | As per IS - 694 | As per IS - 694 | |
| 4) Colour of sheath | Visual | Check on each Drum | As per IS - 694 | As per IS - 694 | |
| 5) Embossing / Sequential Marking | Visual | Check on each Drum | As per IS - 694 | As per IS - 694 | |
| 6) Cable Length | Visual | Check on each Drum | As per requirement | Conforms to the requirement | |
| 7) Surface Quality | Visual | Check on each Drum | Smooth surface Finishing | Smooth surface Finishing | |
| 8) — | |||||
| 9) High Voltage Test | High voltage tester | 100% | As per IS - 694 | Withstood all connection | |
| III. FINISHED CABLE INSPECTION | |||||
| A. ROUTINE TEST | 1) Conductor Resistance | Digital micro ohm Meter | As per IS - 694 | As per IS - 8130 | As per IS - 8130 |
| 2) High Voltage Test | High voltage tester | As per IS - 694 | As per IS - 694 | As per IS - 694 | |
| B. ACCEPTANCE TESTS | 1) Annealing test on Copper | Tensile testing m/c | As per IS - 694 | As per IS - 8130 | As per IS - 8130 |
| 2) Conductor resistance | Digital micro ohm Meter | As per IS - 694 | As per IS - 8130 | As per IS - 8130 | |
| 3) Thickness of Insulation / Sheath | Vernier caliper / Micrometer | As per IS - 694 | As per IS - 5831 | As per IS - 5831 | |
| 4) Tensile strength of insulation / sheath | Tensile testing m/c | As per IS - 694 | As per IS - 5831 | As per IS - 5831 | |
| 5) Elongation of insulation / sheath | Tensile testing m/c | As per IS - 694 | As per IS - 5831 | As per IS - 5831 | |
| 6) Insulation Resistance Test / Volume resistivity | Million mega ohm Meter | As per IS - 694 | As per IS - 5831 | As per IS - 5831 | |
| 7) High Voltage Test at room temp | High voltage tester | As per IS - 694 | As per IS - 694 | As per IS - 694 | |
| 8) Flammability Test | Flammability Chamber | As per IS - 694 | As per IS - 694 | As per IS - 694 | |
| C. TYPE TEST | 1) Annealing test on Copper | Tensile testing m/c | One Sample Per Lot | As per IS - 8130 | As per IS - 8130 |
| 2) Conductor At 20°C resistance | Digital micro ohm Meter | One Sample Per Lot | As per IS - 8130 | As per IS - 8130 | |
| 3) Thickness of Insulation / sheath | Vernier caliper | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 4) Tensile strength of insulation / sheath | Tensile testing m/c | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 5) Elongation of insulation / sheath | Tensile testing m/c | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 6) Ageing in air oven | Ageing oven | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 7) Shrinkage test on insulation / sheath | Hot air oven | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 8) Hot deformation test for insulation / sheath | Hot air oven | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 9) Loss of mass test for sheath | Weighting balance | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 10) Heat shock test for sheath | Hot air oven | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 11) Thermal Stability Test for sheath | Thermal Stability Oven | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 12) Insulation resistance and Volume resistivity | Million mega ohm Meter | As per IS - 7098 (PT-1) | As per IS - 5831 | As per IS - 5831 | |
| 13) High Voltage Test at room Temperature | HV tester | One Sample Per Lot | As per IS - 694 | As per IS - 694 | |
| 14) Cold bend / Cold Impact test | Cold chamber | One Sample Per Lot | As per IS - 5831 | As per IS - 5831 | |
| 15) Flammability Test | Flammability Chamber | One Sample Per Lot | As per IS - 694 | As per IS - 694 | |