POLARIS CABLES & WIRES PVT. LTD.

(An IS & ISO 9001 :2000 Certified Company)

Factory : Plot 35, Genesis Indl Complex, Kolgaon, PALGHAR, Dist :Thane, Maharashtra.

MANUFACTURER'S QUALITY ASSURANCE PLAN (Q.A.P for IS - 694)

Component / Method of Check / Test Requirement / Ref. Doc Internal acceptances

Characteristics Tests Sampling plan
Process equipment (if any) Norms
I. R A W M A T E R I A L S - PVC Wires / Cables
A. CONDUCTOR 1) Diameter Vernier / Micrometer 10% As per IS - 8130 As per IS - 8130

(Cu / Alu) 2) Tensile Test (for Alu) Tensile Testing M/c 10% As per IS - 8130 As per IS - 8130

3) Wrapping Test (for Alu) Self Device 10% As per IS - 8130 As per IS - 8130
The conductor should be Confirms to the
4) Surface finish Visual 10%
smooth. requirement

5) Annealing Test (for copper) Tensile Testing M/c 10% As per IS - 8130 As per IS - 8130

Electrical /Digital micro ohm

6) Conductor Resistance at 20°C 10% As per IS - 8130 As per IS - 8130
Meter
Confirms to the
7) Visual check Visual 10% Bright Colour, No dents
requirement
8) Physical & Chemical properties Review M.T.C 100% As per IS - 8130 As per IS - 8130
B. PVC As per Manufacturer As per Manufacturer
1) Specific Gravity By Weight on Weighing m/c One sample Per Lot
COMPOUND specification specification

2) Tensile strength & Elongation Review M.T.C 100% As per IS - 5831 As per IS - 5831

Before and After Ageing

3) Loss of mass Review M.T.C 100% As per IS - 5831 As per IS - 5831

II. INPROCESS (SEMI FINISHED CABLES / WIRES) INSPECTION

A. Bunching / Measurement at the start of
1) No of wires/ Strand Self Device As per IS - 8130 As per IS - 8130
Stranding each job
Measurement at the start of
2) Diameter of Wire/Strand Vernier calliper / Micrometer As per IS - 8130 As per IS - 8130
each job
Measurement at the start of Confirms to the
3) Direction of Lay Visual As per requirement
each job requirement
Confirms to the
4) Lay length Meter Scale Two Samples per Lot As per requirement
requirement
Measurement at the start of
5) Overall Dimensions Vernier calliper / Micrometer As per IS - 8130 As per IS - 8130
each job
Electrical /Digital micro ohm Measurement at the start of
6) Conductor resistance As per IS - 8130 As per IS - 8130
Meter each job
Once when the new bag is Confirms to the
B. Core Extrusion 1) Type of Compound Visual check of grade used As per requirement
opened for use requirement
Each setting & twice in a
2) Thickness of Insulation Vernier Calliper As per IS - 694 As per IS - 694
shift
Each setting & twice in a
3) Core Identification Visual As per IS - 694 As per IS - 694
shift
4) Void test Visual 5% As per Plants std No voids

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 5) Spark test ( On Line) On line sparke tester 100% As per IS - 694 As per IS - 694
Each setting & twice in a
6) Diameter Check Vernier Calliper As per IS - 694 As per IS - 694
shift
Start and end of each
Should be smooth & free from Should be smooth & free
7) Surface finish Visual setting & twice during the
porosity from porosity
processing for that setting
Conductor should show Conductor should show
8) Continuity of Conductor Continuity tester 100%
continuity continuity
C. Tests on cores Random check for each
1) Thickness of Insulation Vernier Calliper As per IS - 694 As per IS - 694
in Laboratory size & colour

One for each size &

2) Concentricity of PVC Vernier Calliper As per IS - 694 As per IS - 694
colour(if changes)

3) Tensile strength & Elongation Tensile testing m/c - Do - As per IS - 694 As per IS - 694
4) Insulation resistance & Volume One for each size &
Insulation tester As per IS - 694 As per IS - 694
resistivity colour(if changes)
D. Printing /
Visual Check Visual 100% As per IS - 694 As per IS - 694
Embossing
E. Laying up 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

Confirms to the
4) Lay Length Meter Scale Each setting As per requirement
requirement
Conductor should show Conductor should show
5) Continuity of conductors Continuity tester 100%
continuity continuity
F. Outer Sheath Confirms to the
1) Type of PVC Visual check of grade Random As per requirement
Extrusion requirement

2) Thichness of Outer sheath Vernier calliper / microscope Each setting As per IS - 694 As per IS - 694

3) Overall Diameter Vernier calliper 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

Confirms to the
6) Cable Length Visual Check on each Drum As per requirement
requirement

7) Surface Quality Visual Check on each Drum Smooth surface Smooth surface

Conductor should show Conductor should show

8) Continuity test Continuity tester 100%
continuity continuity

9) High Voltage Test High voltage tester 100% As per IS - 694 As per IS - 694

G. DRUMS 1) Marking on Drum Visual 100% As per IS - 694 As per IS - 694

Confirms to the
2) Checking of length Visual 100% As per requirement
requirement

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III. FINISHED CABLE INSPECTION
Electrical /Digital micro ohm
A. Routine Tests 1) Conductor Resistance As per IS - 694 As per IS - 694 As per IS - 694
Meter
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 - 694 As per IS - 694

Electrical /Digital micro ohm

2) Conductor resistance As per IS - 694 As per IS - 694 As per IS - 694
Meter
3) Tensile test for Aluminium Tensile testing m/c As per IS - 694 As per IS - 694 As per IS - 694

4) Wrapping test for Aluminium Self Device As per IS - 694 As per IS - 694 As per IS - 694

5)Thickness of Insulation / Shesth measurment As per IS - 694 As per IS - 694 As per IS - 694

6) Tensile strength of PVC insulation

Tensile testing m/c As per IS - 694 As per IS - 694 As per IS - 694
/ Sheath
7) Elongation of PVC insulation /
Tensile testing m/c As per IS - 694 As per IS - 694 As per IS - 694
Sheath
8) Insuation Resistance Test I.R.Tester As per IS - 694 As per IS - 694 As per IS - 694

9) High Voltage Test at room temp High voltage tester As per IS - 694 As per IS - 694 As per IS - 694

10) Flammability Test Flammability Chamber As per IS - 694 As per IS - 694 As per IS - 694

C. Type Tests 1) Annealing test on Copper Tensile testing m/c One Sample Per Lot As per IS - 694 As per IS - 694

2) Tensile test for Aluminium Tensile testing m/c One Sample Per Lot As per IS - 694 As per IS - 694

3) Wrapping test for Aluminium Self Device One Sample Per Lot As per IS - 694 As per IS - 694

Electrical /Digital micro ohm

4) Conductor resistance One Sample Per Lot As per IS - 694 As per IS - 694
Meter

5) Thickness of Insulation / Sheath measurment One Sample Per Lot As per IS - 694 As per IS - 694

6) Tensile strength of PVC insulation

Tensile testing m/c One Sample Per Lot As per IS - 694 As per IS - 694
/ Sheath
7) Elongation of PVC insulation /
Tensile testing m/c One Sample Per Lot As per IS - 694 As per IS - 694
Sheath
8) Ageing in air oven Oven, tensile testing m/c One Sample Per Lot As per IS - 694 As per IS - 694
9) Shrinkage test on PVC insulation
Oven Scales One Sample Per Lot As per IS - 694 As per IS - 694
/ Sheath
10) Hot deformation test for
Oven Scales One Sample Per Lot As per IS - 694 As per IS - 694
insulation /Sheath
11) Loss of mass test for insulation/
oven, weighing One Sample Per Lot As per IS - 694 As per IS - 694
Sheath
12) Heat shock test for insulation
Oven Scales One Sample Per Lot As per IS - 694 As per IS - 694
/Sheath
13) Insul.resistance Test I.R.Tester One Sample Per Lot As per IS - 694 As per IS - 694

14) High Voltage Test at room

Water tank,HV tester One Sample Per Lot As per IS - 694 As per IS - 694
Temperatue & water Immersion test

15) Flammability Test Flammability Chamber One Sample Per Lot As per IS - 694 As per IS - 694

Note: All Routine and Acceptance Tests can be carried out in the presence of Inspection agencies. Type tests can however only be reviewed..

Submitted By:
M/S POLARIS CABLES & WIRES PVT. LTD