BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

INSTRUCTIONS FOR CODE ALLOCATION

Code 1 Indicates place where testing is planned to be performed i.e. Inspection Code 2 Indicates who has to perform the tests i.e. Testing Agency
location

A At Equipment Manufacturer's works (Fabricator) J The Equipment Manufacturer

B At Component Manufacturer's works (Re-roller) K The Component Manufacturer

C At Authorized Distributor's place L The Third Party
D At Independent Lab M The Turnkey Contractor
E At Turn Key Contractor's location
F Not specified

Code 4 Review of Test Reports/Certificates

Code 3 Indicates who shall witness the tests i.e. Witnessing Agency

P Component Manufacturer itself W By Equipment manufacturer during raw material / bought out component inspection
Q Component Manufacturer and Equipment Manufacturer X By Contractor during product/process inspection
R Y By BSPTCL during product/process inspection
Component Manufacturer, Equipment Manufacturer and Contractor
S Equipment Manufacturer itself
Z By Contractor and/or BSPTCL during product/process inspection
T Equipment Manufacturer and Contractor
U Equipment Manufacturer, Contractor and BSPTCL
V Third Party itself

Code 5 Whether specific approval of sub-vendor / Component make is Code 6 Whether test records required to be submitted after final inspection for issuance of
envisaged? Dispatch Clearances / Instructions ?
E Envisaged Y Yes
N Not Envisaged N No

Page 1 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

A. Raw Material Inspection (Indigenous)

Components/ Reference
Sr. Type of Quantum of Check / Acceptance Format of Applicable Codes
Operation & document Remarks
No. Check Sampling with basis Norms Record
Description of Test for Testing
1 2 3 4 5 6
1.1 Structural Steel E Structural Steel to be procured from
(Sections and Plates) BSPTCL approved Sources. For re-
rollers specific approval of BSPTCL is
to be ensured and Dispatch Instruction
for every lot at re-roller’s works.
1.1.1 Mechanical Properties
(a) Test For 2 - Samples for IS: 410 N/mm² BSPTCL A J S Z N
Ultimate cast/heat size up to 2062:2011 (Min.) REPORT
Tensile 100 MT Grade E250A
Strength BSPTCL
3 - Samples for cast Specn.
/heat size between
100-200 MT
IS:
4 - Samples for 2062:2011 490 N/mm²
cast/heat size over Grade E350A (Min)
200 MT

(b) Yield Stress 2 - Samples for IS: i) <20mm thick BSPTCL A J S Z N

cast/heat size up to 2062:2011 250 N/mm² min REPORT
100 MT Grade E250 ii) 20to40 mm
3 - Samples for A& thick
cast/heat size BSPTCL 240 N/mm² Min.
between 100-200 Specn. iii) >40mm thick
MT 230 N/mm² min.
4 - Samples for
cast/heat size over
200 MT as per
IS 2062:2011

Page 2 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

Components/
Reference Applicable Codes
Sr. Operation & Type of Quantum of Check / Format of
document for Acceptance Norms Remarks
No. Description of Check Sampling with basis Record
Testing
Test
1 2 3 4 5 6
IS: 2062:2011 below 20 mm min
Grade E 350 A 350 N/mm²
& 20-40 mm
BSPTCL Specn. min 330 N/mm²
above 40 mm
min 320 N/mm²

(c) Percentage 2 - Samples for cast/heat size IS: 2062:2011 23% Min. BSPTCL A J S Z N
Elongation at up to 100 MT Grade E250 A REPORT
5.65√Area 3 - Samples for cast/heat size &
between 100-200 MT BSPTCL Specn.
4 - Samples for cast/heat size
over 200 MT as per
IS 2062:2011
IS: 2062:2011 22% min.
Grade E 350 A
BSPTCL Specn.

(d) Bend Test 1 Sample for 50 MT per IS: 2062:2011 Piece at room temp. BSPTCL A J S Z N
Section per cast or Part thereof Grade E250 A shall with stand REPORT
as per IS 2062-2011 BSPTCL Specn. bending through
180 degree to an
internal dia

i) not greater 2t for

25 mm,
ii) 3t for > 25 mm,

with both side parallel,

without cracking.

Page 3 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

Components/ Applicable Codes Remarks

Reference
Sr. Operation & Type of Quantum of Check / Sampling Format of
document for Acceptance Norms
No. Description of Check with basis Record
Testing
Test
1 2 3 4 5 6

IS: 2062:2011 Piece at room temp.

Grade E350A shall withstand
BSPTCL bending through
Specn. 180° to an internal
dia not greater than
2t

1.1.2 Chemical Chemical 2 - Samples for cast size up to 100 As per As per Chemistry BSPTCL A J S Z - N
Composition Analysis MT Chemistry enclosed for each REPORT / / /
3 - Samples for cast size between enclosed for source D L V
100-200 MT each source
4 - Samples for cast size over 200
MT as per IS 2062 :2006

1.1.3 Visual Visual One sample IS 2062:2011 Material to be free BSPTCL A J S Z N

Inspection for 50 MT / BSPTCL from surface defects REPORT
Section or specn. like laminations,
Part Thereof rough/jagged and
imperfect edges,
cracks, rounded
apex, deep roll
marks, pipe and any
harmful defects

Page 4 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

Components/
Reference Applicable Codes Remarks
Sr. Operation & Quantum of Check / Format of
Type of Check document for Acceptance Norms
No. Description of Sampling with basis Record
Testing
Test
1 2 3 4 5 6
1.1.4 Dimensional Measurement One sample IS 808/ BSPTCL A J S Z N
Inspection for 50 MT / IS 1730 / REPORT
Section or IS 1852 &
Part Thereof BSPTCL Specn.

Angle section

a) Tolerances For One sample IS 1852/ Equal: BSPTCL A J S Z N

Leg Length of for 50 MT / IS 808 (i) Up to 45 mm Leg REPORT
Angles Equal / Un Section or Length
Equal Part Thereof ± 1.5 mm
(ii) > 45 to 100 mm Leg
Length
± 2.0 mm

(iii) >100 mm Leg

Length
± 2.0 % of leg length

Difference between Leg

Length of Equal Angles
shall be limited to 75 %
of Total Tolerance
(Plus & Minus)

Unequal: tolerance as per

IS

b) Out of Measurement One sample IS 1852 ±1° BSPTCL A J S Z N

Square ness for 50 MT / BSPTCL REPORT
Section or Specn.
Part Thereof

Page 5 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

Components/ Reference Applicable Codes

Sr. Quantum of Check / Format of
Operation & Type of Check document for Acceptance Norms Remarks
No. Sampling with basis Record
Description of Test Testing
1 2 3 4 5 6
c) Camber Measurement One sample IS 1852 (i) For Flange Less (BSPTCL A J S Z N
for 50 MT / than 100 mm REPORT)
Section or Reasonably Straight
Part Thereof
(ii) For Flange
100 mm & above
Max 0.2% of length

d) Root radius Measurement -do- IS 808 IS 808 Test Report A J S W - N

e) Weight Tolerance Unit Weight Test One sample IS 1852 / i) Up to 3 mm thick (BSPTCL A J S Z N
For Angle Sections for 50 MT / IS 808 ±5% REPORT)
Section or ii) > 3 mm thick
Part Thereof + 5%, - 3 %
over weights specified
in IS 808

Plate
a) Weight Unit Weight Test One sample for IS 1852 / +5%, -2.5% over (BSPTCL B K * Z - Y *P/U as per
Tolerances 50 MT / Section or part IS 1730 weights specified in REPORT) BSPTCL approval
thereof IS 1730

b)Thickness Measurement One sample IS < 8 mm thick (BSPTCL B K * Z - Y *P/U as per

Tolerance for 50 MT / 2062:2006IS + 12.5 %, - 5 % REPORT) BSPTCL approval
Section or 1730 / 8 mm - 12 mm
Part Thereof IS 1852 + 7.5 %, - 5 %
over 12 mm ± 5 %

Page 6 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

Quantum of Format
Components/ Operation Type of Reference document Applicable Codes
Sr. No. Check / Sampling Acceptance Norms of Remarks
& Description of Test Check for Testing
with basis Record
1 2 3 4 5 6
1.2 Zinc E
To be procured from
BSPTCL approved
sources or Imported LME
registered source

Chemical Composition Chemical Every IS 209/IS 13229 IS 209/IS 13229 Zinc B K P W N

Analysis Consignment Manufact
urer TC

Chemical Composition Chemical One sample for IS 209/IS 13229 IS 209/IS 13229 TPL D L V W N
Analysis 100MT or Reports
Part thereof

Chemical Composition Chemical One sample of IS 209/IS 13229 Min Zinc purity 98.5% TPL D L V W N
Analysis molten zinc taken Reports
from bath per
quarter

Page 7 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

ANNEXURE – I
Chemical Composition

A) RINL billet/bloom - All values as below are including Tolerance

Element C18HMn-For HT (E350) C20 MMn-For MS (E250)

C 0.15- 0.22 0.17- 0.25
Mn 1.1- 1.45 0.6- 1.05
Si 0.10- 0.37 0.10- 0.37
P 0.045 max 0.05 max
S 0.045 max 0.05 max
Cr 0.08 max 0.08 max
Ni 0.03 max 0.03 max
Cu 0.03 max 0.03 max
B 0.004 max 0.004 max
Mo 0.005 max 0.005 max
V 0.025- 0.060 0.005 max
Al 0.015 min 0.015 min
CE 0.45 max 0.28- 0.42

Note: For Blooms size 150x150 mm and above Al and Si shall be read as follows:

Al- 0.015 max

Si- 0.10 to 0.45

Page 8 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B) SAIL (BSP/DSP)- All values as below are including Tolerance

Element SAIL Tower Grade VI For HT (E350) C20 MMn-For MS (E250)

C 0.15- 0.22 0.16 -0.25
1.25- 1.60 for blooms size 350x150mm
Mn 1.20-1.60 for other sizes of blooms & billets 0.6-1.05
0.15- 0.30 for DSP
Si 0.15- 0.30 0.10 max for BSP
P 0.047 max 0.047 max
S 0.047 max 0.047 max
S+P 0.090 max 0.090 max
Cr 0.20 max 0.20 max
Ni 0.05 max 0.05 max
Cu 0.10 max 0.10 max
B 0.005 max 0.005 max
Mo 0.05 max 0.05 max
0.03 min for blooms of 160 mm and above
V 0.025 min for billets and blooms upto 150 mm As per Test Certificate
Nb Actual, 0.015 min if added alone -
0.36 -0.45 for BSP & 125x125 mm billet of
DSP
CE 0.38-0.47 for DSP billet above 125x125 mm 0.28- 0.42

Page 9 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

C. Jindal: Chemistry of billets (Laddle):

Element C18 HMn-HT (E350) C20 MMn-For MS (E250) C18 MMn-For MS (E250)
C 0.15- 0.20 0.17- 0.23 0.15- 0.21
Mn 1.20- 1.50 0.6-1.0 0.6-1.0
Si 0.15- 0.30 0.10- 0.40 0.10-0.40
P 0.03 max 0.040 max 0.040 max
S 0.03 max 0.040 max 0.040 max
Cr 0.07 max 0.07 max 0.07 max
Al 0.015 min 0.010 min 0.010 min
Ni 0.07 max 0.07 max 0.07 max
Cu 0.10 max 0.10 max 0.10 max
Mo 0.07 max 0.07 max 0.07 max
V 0.030 min - -
V+Nb+Ti ≤0.25 ≤0.25 ≤0.25
CE 0.45 max 0.42 max 0.42 max

Permissible variation in Jindal Chemistry in angles specified max or under min limits-

C-0.02, Mn-0.03, S-0.005, P-0.005

Page 10 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

D. Adhunik Metaliks: Chemistry of billets:

Element C18 HMn-HT (E350) C20 MMn-For MS (E250)

C 0.15- 0.20 0.17- 0.23
Mn 1.20- 1.50 0.6-1.0
Si 0.15- 0.30 0.10- 0.40
P 0.04 max 0.04 max
S 0.04 max 0.04 max
Cr 0.06 max 0.06 max
Al 0.020 min -
Ni 0.08 max 0.08 max
Cu 0.07 max 0.07 max
Mo 0.03 max 0.03 max
V 0.030 min -
Ti 0.01 max 0.01 max
Sn 0.015 max 0.015 max
CE 0.43 max 0.39 max

Permissible variation in Adhunik Metaliks Chemistry in angles specified max or under min limits-

C-0.02, Mn-0.03, S-0.005, P-0.005, Si-0.03

Page 11 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

E. Jayaswal Neco Industries Ltd Chemistry

Element C18 HMn-HT (E350) C20 HMn-HT (E350) C18 MMn MS (E250) C20 MMn- MS (E250)
C 0.15- 0.20 0.15- 0.20 0.15- 0.20 0.17- 0.23
Mn 1.20- 1.50 1.20-1.50 0.6-1.0 0.6-1.0
Si 0.15- 0.35 0.15- 0.35 0.15-0.35 0.15-0.35
P 0.035 max 0.035 max 0.035 max 0.035 max
S 0.035 max 0.035 max 0.035 max 0.035 max
V 0.030 min 0.030 min - -
Al 0.015 -0.035 0.015 -0.035 0.010-0.035 0.010-0.035
CE 0.38-0.42 max 0.38-0.42 max 0.41 max 0.41 max

Permissible variation in Jayaswal Neco Industries Ltd Chemistry in angles specified max or under min limits-

C- 0.02, Mn- 0.05

Max value of Trace Elements-

Cu- 0.10, Sn- 0.10, Cr- 0.05, Ni- 0.05, Mo- 0.05

Page 12 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

F) Visa Steel Limited : Chemical Composition

C20 MMn-For MS
Element (%) C18 HMn-HT (E350) C20 HMn-HT (E350) C18 MMn-For MS (E250)
(E250)
C 0.15 - 0.20 0.17 - 0.20 0.15 - 0.20 0.17 - 0.21
Mn 1.20 - 1.50 1.20 - 1.50 0.60 -1.00 0.60 -1.00
Si 0.15 - 0.35 0.15 - 0.35 0.15 - 0.30 0.15 - 0.30
P 0.035 max 0.035 max 0.035 max 0.035 max
S 0.035 max 0.035 max 0.035 max 0.035 max
Cr 0.05 max 0.05 max 0.05 max 0.05 max
Al 0.020 min 0.020 min 0.025 max 0.025 max
Ni 0.05 max 0.05 max 0.05 max 0.05 max
Cu 0.05 max 0.05 max 0.05 max 0.05 max
Mo 0.05 max 0.05 max 0.05 max 0.05 max
V 0.030 min 0.030 min - -
Ti 0.010 max 0.010 max 0.010 max 0.010 max
V+Nb+Ti 0.15 max 0.15 max 0.15 max 0.15 max
CE 0.44 max 0.44 max 0.39 max 0.39 max

Page 13 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

Permissible variation in Visa Steel Limited in angles specified max or under min limits-

C - 0.02, Mn - 0.03, S - 0.005, P-0.005, Si – 0.03

G. Usha Martin Ltd: Chemistry of MS & HT billets excluding tolerance

Element C18HMn-For HT (E350) C20 MMn-For MS (E250) C18 MMn for MS (E250)
C 0.15- 0.20 0.17- 0.23 0.15- 0.21
Mn 1.20- 1.50 0.6- 1.00 0.6- 1.00
Si 0.15- 0.30 0.10-0.40 0.10-0.40
P 0.03 max 0.04 max 0.04 max
S 0.03 max 0.04 max 0.04 max
Cr 0.07 max 0.07 max 0.07 max
Ni 0.10 max 0.07 max 0.07 max
Cu 0.10 max 0.10 max 0.10 max
Al 0.015 min 0.002 min 0.002 min
Mo 0.010 max 0.010 max 0.010 max
V 0.030 min - -
V+Nb+Ti ≤0.25 ≤0.25 ≤0.25
CE 0.45 max 0.42 max 0.42 max

Page 14 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

H.Electrosteel Steels Ltd: Chemistry of MS & HT billets including tolerance

Element C18HMn-For HT (E350) C20 MMn-For MS (E250)

C 0.15- 0.22 0.17- 0.25
Mn 1.2- 1.50 0.6- 1.00
Si 0.10- 0.35 0.10- 0.35
P 0.045 max 0.045 max
S 0.045 max 0.045 max
Cr 0.08 max 0.08 max
Ni 0.03 max 0.03 max
Cu 0.03 max 0.03 max
B 0.004 max 0.004 max
Mo 0.005 max 0.005 max
V 0.030- 0.060 0.005 max
CE 0.36 to 0.45 0.28- 0.42

Page 15 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

I.Monnet Ispat & Energy Ltd: Chemistry of MS & HT billets including tolerance

Element C18HMn-For HT (E350) C20 MMn-For MS (E250) C18 MMn for MS (E250)
C 0.17- 0.21 0.18- 0.22 0.16- 0.20
Mn 1.20- 1.35 0.6- 0.8 0.6- 0.8
Si 0.15- 0.30 0.15-0.30 0.15-0.30
P 0.03 max 0.04 max 0.04 max
S 0.03 max 0.04 max 0.04 max
Cr 0.05 max 0.05 max 0.05 max
Ni 0.05 max 0.05 max 0.05 max
Cu 0.05 max 0.05 max 0.05 max
Mo 0.05 max 0.05 max 0.05 max
V 0.025 min - -
V+Nb+Ti ≤0.15 ≤0.15 ≤0.15
CE 0.45 max 0.42 max 0.42 max

For Al killed- 0.02% Al is maintained

Page 16 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

J.JSW Steel Ltd: Chemistry of MS & HT billets including tolerance

C18 HMn-HT C20 MMn-For MS C18 MMn-For MS

Element
(E350) (E250) (E250)
C 0.15- 0.20 0.17- 0.23 0.15- 0.21
Mn 1.20- 1.50 0.6-1.0 0.6-1.0
Si 0.15- 0.30 0.10- 0.35 0.10-0.35
P 0.03 max 0.040 max 0.040 max
S 0.03 max 0.040 max 0.040 max
Cr 0.07 max 0.07 max 0.07 max
Al 0.015 min 0.010 min 0.010 min
Ni 0.07 max 0.07 max 0.07 max
Cu 0.10 max 0.10 max 0.10 max
Mo 0.07 max 0.07 max 0.07 max
V 0.030 min - -
V+Nb+Ti ≤0.25 ≤0.25 ≤0.25
CE 0.45 max 0.42 max 0.42 max

Page 17 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B. In Process Inspection
Quantum of
Components/ Reference
Type of Check / Format of Applicable Codes
Sr. No. Operation & document for Acceptance Norms Remarks
Check Sampling with Record
Description of Test Testing
basis
1 2 3 4 5 6
2.0 INPROCESS
INSPECTION
Fabrication of Tower IS 802 Part II/
Parts IS 7215/
BSPTCL approved
Drwg., Shop
Sketches
(a) Straightening Visual 100%

(b) Cropping (Cutting) Dime- 1st Piece and Length Tolerance BSPTCL A J S Z - N
nsional every 50th Piece ± 2 mm REPORT
The cut surface
to be clean, reasonable square & free
from distortion
(c) Stamping Visual 1st Piece and Letter size as per -do- A J S Z - N
every 50th Piece BSPTCL Specn. /
TPL norms

Page 18 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

(d) Punching / Drilling Dime- 1st Piece and Holes for bolts shall be drilled -do- A J S Z - N
nsional every 50th Piece or punched with a jig but
drilled holes shall be preferred.
The punching may be adopted
for thickness up to 12 mm.
Tolerances regarding punch
holes should be as follows:
a)Holes must be perfectly
circular and no tolerances in
this respect are possible.
b)The maximum allowable
difference in diameter of the
holes on the two sides of plates
or angle is 0.8mm,i.e the
allowable taper in a punched
hole should not exceed 0.8mm
on diameter.
c)Holes must be square with
the plates or angles and have
their walls parallel.

Page 19 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B. In Process Inspection

Components/ Quantum of
Reference document for Format of Applicable Codes
Sr. No. Operation & Type of Check Check / Sampling Acceptance Norms Remarks
Testing Record
Description of Test with basis
1 2 3 4 5 6
(e) Edge Security Dimensional 1st Piece and every IS 802 Part II/ -do- A J S Z - N
50th Piece IS 7215/
BSPTCL approved Drwg.,
Shop Sketches
(i) For 13.5 mm dia Sheared 20mm Min.
Hole Rolled 16mm Min.

(ii) For 17.5 mm dia Sheared 23mm Min.

Hole Rolled 20mm Min.

(iii) For 21.5 mm dia Sheared 28mm Min.

Hole Rolled 25mm Min.

(iv) For 25 mm & 25.5 As per approved

mm dia Hole Drawing

(f) Drilling & Punching 1st Piece and Tolerance cumulative and -do- A J S Z - N
Hole To Hole every 50th Piece between consecutive hole
Distance shall be within
± 2 mm and ± 1mm
respectively

(g) Notching 1st Piece and + 5mm on specified length -do- A J S Z - N

Flange Cut every of cut operationally
Corner Cut 50th Piece shearing up to 12 mm
Bevel Cut thick
by gas cutting for
material above
12 mm thick

Page 20 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B. In Process Inspection

Components/
Type of Quantum of Check / Reference document Format of Applicable Codes
Sr. No. Operation & Acceptance Norms Remarks
Check Sampling with basis for Testing Record
Description of Test
1 2 3 4 5 6
(h) Heel Cutting Dimensi- 1st Piece and every BSPTCL for members -do- A J S Z - N
onal 50th Piece Approved Drwgs./ > 12mm thick
Shop Sketches gas cutting to be adopted
followed
By grinding/Machine cutting.
Tolerance on heel cutting length
+10mm
(i) Bending 100% Pieces IS 802( Part II)/ (1) HT Sections / Plates -do- A J S Z - N
IS 7215/ BSPTCL All Sections & all plates to be
Approved Drawing / hot bent.
Shop Sketches

(2) MS Section -do-

i) Cold – Section upto
75X75X6 - Angle upto 10°
ii) Cold – Section upto
100X100X8 – Angle upto 5°
iii) Hot - Section above
75X75X6 – Angle Above 10°
iv) Hot - Section above
100X100X8 – Angle Above 5°

(3) M. S. Plates -do-

i) Cold Upto 12 mm thick
Upto 15°
ii) Hot - Others

Page 21 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B. In Process Inspection
Quantum of
Components/
Check / Acceptance Format of Applicable Codes
Sr. No. Operation & Type of Check Reference document for Testing Remarks
Sampling with Norms Record
Description of Test
basis
1 2 3 4 5 6
(j) Welding (a) WPS As per BSPTCL Technical -do- WPS approval
Approval specn./approved by BSPTCL
(Welding Drg./BSPTCL approved Welding
procedure procedure & Welder`s qualification
specification)
(b) PQR/WQR Dispatch
Approval A J U Y - N Instructions at
(Procedure black stage for
/Welder welded
qualification members
record)

Welding (1) DP Test Random Basis -- do --- -do- A J U Z - N Dispatch

(2) Dimensional Instructions
& visual for
welded tower
parts
(k) Final Inspection of Random Basis All parameters from (a) to (j) -do- A J S Z - N
Fabricated Parts above are checked and record
maintained before releasing the
materials for galvanizing.
(l) Foundation Physical 1st piece & IS 802/BSPTCL technical BSPTCL A J S Z N
Bolts every 50th spec./approved drawing REPORT
i) Cutting & piece
Shearing
ii) Chamfering
iii) Threading

Page 22 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B. In Process Inspection

Quantum of Reference
Components/ Operation & Type of Acceptance Format of Applicable Codes
Sr. No. Check / Sampling document for Remarks
Description of Test Check Norms Record
with basis Testing
1 2 3 4 5 6
3.0 GALVANIZING
(Surface Preparation Procedure)
3.1 Degreasing Chemical One sample IS 2629 Manufacturer’s -do- A J S Z - N
daily plant standard/IS
3.2 Pickling Chemical One sample IS 2629 Manufacturer’s -do- A J S Z - N
daily plant standard/IS
Iron contents 100
to 120 gram/litre.
Max
3.3 Rinsing Chemical One sample IS 2629 Manufacturer’s -do- A J S Z - N
daily plant standard/IS

Page 23 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B. In Process Inspection
Quantum of
Reference
Components/ Operation & Description of Type of Check / Format of Applicable Codes
Sr. No. document for Acceptance Norms Remarks
Test Check Sampling with Record
Testing
basis
1 2 3 4 5 6
3.4 Pre Fluxing Chemical One sample IS 2629 IS 2629 -do- A J S Z - N
daily

3.5 Pre-heating Measure- One check IS 2629 IS 2629 -do- A J S Z - N

ment per day

3.6 Dipping -do- A J S Z - N

After drying is over the material is dipped in
molten zinc. Following parameters are controlled

a) Zinc bath temperature Hourly check IS 2629 450+/-10° C. -do- A J S Z - N

Recording is done by graphical manner OR
sensors with digital display

b) Immersion & IS 2629 IS 2629 -do- A J S Z - N

Withdrawal time.
Degree of immersion and withdrawal time is
decided based on thickness and length of
material.

3.7 Quenching in Running Water: IS 2629 IS 2629 -do- A J S Z - N

After dipping the material is quenched in running
water

3.8 Dichromating : One Sample IS 2629 IS 2629 -do- A J S Z - N

After quenching, material is dipped in sodium daily
dichromatic solution to avoid the white rust.
(Proprietary Chemicals.)

Page 24 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

B. In Process Inspection
Quantum of
Components/ Reference
Check / Format of Applicable Codes
Sr. No. Operation & Type of Check document for Acceptance Norms Remarks
Sampling Record
Description of Test Testing
with basis
1 2 3 4 5 6
4.0 Galvanizing
Checking
(a) Visual Checking Visual 100% IS 2629 Surface to be free from defects like bare / -do- A J S Z - N
black spots, (except when small and
suitable for patching) heavy ash & flux
inclusions, lumps, pimples, runs etc
(b) Thickness of Measurement 8 samples / IS 4759 The minimum average zinc coating for all -do- A J S Z - N *For marine
Zinc coating shift section shall be 87 microns for thickness ≥ mentioned
5 mm & 65 microns for thickness < 5mm in BPS,
and for plates ≥5mm=127
micron,
<5mm &
plate=87
micron
(c) Weight of Zinc Measurement 3 samples / IS 4759 / IS (a) For thickness below 5mm, but not less -do- A J S Z - N *For
coating shift 6745 then 2 mm and for plates- Average Mass of marine,
Coating -460gm/m² ≥5mm=900
(b) For thickness 5mm & above – Average gm/ m²,
Mass of Coating - 610 gm/m² <5mm &
plate=610
gm/ m²
(d) Uniformity Measurement 3 samples / IS 2633 Material to withstand -do- A J S Z - N
of Zinc coating shift 4 dips of one minute each without showing
signs of copper deposits

(e) Adhesion Tests of Pivoted 3 samples / IS 2629 No removal or lifting of coating in areas -do- A J S Z - N
Zinc coating Hammer Test shift between hammer impressions

Page 25 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

C. Final Inspection & Testing

Quantum of
Sr. Components/ Operation Reference document for Format Applicable Codes
Type of Check Check / Sampling Acceptance Norms Remarks
No. & Description of Test Testing of Record
with basis
1 2 3 4 5 6
5.0 FINAL INSPECTION &
TESTING
(Inspection Engineer to
Check/ensure compliance
to notes/General
Requirements given on
Notes of MQP.

(a) VISUAL & One sample for Please refer Please refer Test A J U Z Y Dispatch
DIMENSIONAL Visual & Measurement Every 50 MT/ Sr. No 2(a) Sr. No 2(a) Report Instructions
INSPECTION section/Lot or part to 2(j) to 2(j)
For Fabrication (as per thereof & Cl. No. & Cl. No.
approved dwg.) & 4.3 (a) 4.3 (a)
Galvanizing

(b) MECHANICAL (i) UTS Test One sample for Please Refer (for test Please Refer (for Test A J U Z - Y Dispatch
PROPERTIES (ii) Yield Stress Test Every 50 MT/ values) Sr. No. test values) Sr. No. Report Instructions
(iii) Percentage section/Lot or part 1.1.1(a), (b) (c), (d) 1.1.1(a), (b) (c),
Elongation Test thereof (d)
(iv) Bend Test

(c ) Chemical Properties Spectro Analysis -do- IS 2062:2011 Chemistry needs to Test A J/ U Z Y

(only applicable for black be comparable with Report / L / Dispatch
angle sections procured TC of primary D V Instructions
from primary sources sources approved
without stage Dispatch by BSPTCL
Instructions by BSPTCL at
source place)

Page 26 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

C. Final Inspection & Testing

Quantum of
Components/ Reference
Check / Acceptance Format of Applicable Codes
Sr. No. Operation & Type of Check document for Remarks
Sampling Norms Record
Description of Test Testing
with basis
1 2 3 4 5 6
(c) GALVANIZING i) Thickness of Zinc Coating One sample IS 2629/IS Please refer Cl. Test Report A J U Z - Y Dispatch Instructions
TESTS ii) Weight of Zinc Coating for 4759/IS 4.0
iii) Uniformity of Zinc Every 50 MT/ 6745/IS 2633/
Coating section
iv) Adhesion Test of Zinc and part
Coating thereof
For Foundation bolt- A J U Z - Y Dispatch Instructions
a) Dimensional test Measurement Sampling as BSPTCL BSPTCL Test Report
per IS Drawing Drawing
1367/2500

b) Mechanical Test Mechanical 2 sample per As per IS As per IS

UTS, Yield & heat/cast/lot 2062/SAE 1018 2062/SAE 1018
Elongation of 100MT

c)Chemical Test Spectro Analysis 2 sample -do- Chemistry TPL Report

/heat/cast/lot needs to be
or part thereof comparable
with raw
material
supplier TC
6.0 Packing, Storing, 100 % IS802/BSPTCL Tower Pieces of light sections
Bundling and specn./Packing manufacturer’ to be wire bundled and
Handling list to be s Log heavy sections to be
submitted along Book/Format supplied loose. Stacking
with dispatch No to have proper
documents ventilation and kept
inclined. Damage to
galvanization coating to
be avoided while
handling. to ensure
sequential supplies and
other details as per
BSPTCL technical
specification.

Page 27 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

NOTES/GENERAL REQUIREMENTS TO BE CHECKED/ENSURED

(1) The manufacturer if purchasing the steel sections directly from the re-rollers, the BSPTCL approved re-roller MQP to be ensured.

(2) Nuts & Bolts and Step Bolts & Nuts & other bought out items to be procured from BSPTCL approved sources and inspection at sub-vendor’s works.

(3) Welding procedure and Welder’s performance qualification approval by BSPTCL is required in case welding is involved at any stage of fabrication/erection.

(4) All bent pieces shall be checked at the process of bending by a bend gauge made as per bend ratio/degree shown in the sketch of the item/mark no. On the stand one
piece is thoroughly checked with bend gauge and all other pieces are checked by comparison method and pieces are cleared for further process. If the holes are to be
made near the bend line the same shall be done after bending.

(5) The sample pieces consumed in a testing shall be replenished by the manufacturer at the time of dispatch. If the offered material meets the quality requirements, Dispatch
Instructions shall be issued for total quantity offered without deducting the weight of materials consumed in testing.

(6) BSPTCL Specification means BSPTCL Technical Specification, Approved Drawing, Approved Technical data sheet and LOA provisions applicable for the specific
contract.

(7) Grades of steel used and the standards to which they conform shall be as approved by BSPTCL Engineering for the specific contract and shall be indicated in
approved Drawings/ BOM/offer list at the time of inspection.

(8) Steel plates below 6 mm used for packing plates/Packing washers shall be as per BSPTCL specification/ approved drawings BSPTCL, Produced as per IS 1079 1994
(Grade-O) are also acceptable however if below 6 mm thickness plates are used as load bearing plates viz. gusset plates, Joint splices etc. same shall confirm to IS 2062
or equivalent standard.

(10) The manufacturer shall maintain proper co-relation of test certificate with respect to the material from raw material stage to finished material stage (whether procured
from main producer or BSPTCL approved re-rollers)

(11) The manufacturer shall strip off galvanizing of rejected material before re-galvanizing in case rejection is due to galvanizing defects.

(12) The manufacturer shall dispose off entire section rejected in physical testing by gas cutting or by machine cutting from any end of rejected mark number.

(13) In case of any contradiction between Technical Specification / Approved Drawing and MQP, the details mentioned in the Technical Specification / Approved Drawing
shall be final.

(14) The manufacturer should progressively align their Quality System and sub-vendors Quality System to the requirements of ISO 9000 series Quality Standards and in due
course of time should get their quality system certified to ISO 9001.

(15) The manufacturer to ensure that all measuring & testing equipments is having valid calibration certificate issued by NABL accredited testing agency only.

Page 28 of 29
 BIHAR STATE POWER TRANSMISSION COMPANY LIMITED

MANUFACTURING QUALITY PLAN : GALVANIZED TOWER STRUCTURES/PARTS

Manufacturer’s Details :- Customer : Vendor’s Item : Galvanized M.Q.P.No.: 37 Valid From: 15-01-16
BSPTCL Code : Tower Structures / Rev. No. : 00 Valid Up to: till revision
Parts Date:06.01.2016

(16) Inspection of angle sections at black stage for galvanized tower structures/parts, irrespective of specific contract can be followed as detailed hereunder.

(a) The manufacturer may raise inspection call for angle section at black stage at re-roller`s work against any one of the ongoing Contract.
(b) The manufacturer may fabricate the raw material cleared Dispatch Instructions for a particular contractor, for any of your projects under execution. Your fabricator may do
so against specific instruction from you in this regard.
(c) The fabricator (i.e. you) will maintain a separate register indicating splitting and swapping of material between different Projects awarded to same contractor, which can be
reviewed by BSPTCL inspection engineer, separate register for each Contractor is to be maintained if the fabricator is executing jobs for different contractor.
(d) The fabricator as a contractor on whom BSPTCL has placed the contract, will only be allowed to split and swap materials in black stage only between your different
ongoing contracts with BSPTCL, without any obligation to BSPTCL.
(e) The final inspection after fabrication and galvanizing, however, will continue to be contract wise and Dispatch Instructions will be issued for each contract only.

(17) Pieces of light sections to be wire bundled & of heavy sections to be supplied loose. Stacking to have proper ventilation and kept inclined. Damage to galvanization coating
to be avoided while handling. The fabricator to ensure sequential supplies and other details as per BSPTCL Technical Specification

(18) Prior approval of BSPTCL is required to be taken for any activity or process that is out sourced.

(19) In case tower part to be used at sub zero temperature, we may carry out Impact testing at -20° C during final inspection in line with IS/ BSPTCL TS.

(20) All relevant IS standards shall be read along with the latest amendments.

(21) Dispatch of the inspected towers shall be done with each tower / panel wise bundling in order to ensure availability of
complete tower parts without missing of any member at site.

Page 29 of 29