MINISTRY OF DEFENCE (DGQA)

STANDARD QUALITY ASSURANCE PLAN

ANCHOR CAPSTAN

STANDARD QAP NO. DGQA/DQA(WP)/ANCHOR CAPSTAN/16/2022/REV 0

14 FEB 22

Total Nos. of Pages :- 24

ISSUING AUTHORITY

DIRECTORATE OF QUALITY ASSURANCE (WARSHIP PROJECT)

MINISTRY OF DEFENCE (DGQA)
TH
6 FLOOR, ‘B’ BLOCK, DEFENCE OFFICE COMPLEX
NETAJI NAGAR PO, NEW DELHI – 110 023

Page 1 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 02
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

RECORD OF AMENDMENTS

Sl. Date of Amendments Authority Remarks

No. Amendment

Page 2 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 03
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

MINISTRY OF DEFENCE (DGQA)

STANDARD QUALITY ASSURANCE PLAN

FOR ANCHOR CAPSTAN

STANDARD QAP NO.

DGQA/DQA(WP)/ANCHOR CAPSTAN/16/2022/REV 0
14 FEB 2022

(SN Alamanda)
Rear Admiral
ADGQA (WP)

Promulgated by:-

DIRECTORATE OF QUALITY ASSURANCE (WARSHIP PROJECT)

MINISTRY OF DEFENCE (DGQA)
TH
6 FLOOR, ‘B’ BLOCK, DEFENCE OFFICE COMPLEX
SAROJINI NAGAR PO, NEW DELHI – 110 023

Page 3 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 04
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

CONDITION OF RELEASE

1. This standard QAP has been prepared for use of the Indian Navy and of its contractors to
follow the specified Quality Assurance procedure during the execution of the contracts. No alteration
is to be made to this Standard QAP except by the issue of authorised amendment by DQA (WP).

2. It is to be applied as required in the Quality Assurance procedures covering manufacture of

Anchor Capstan for IN Ships.

3. The website htpp://www.dgqadefence.gov.in may also be referred for other QA

requirements.

4. The Standard QAP has been prepared on the basis of decisions made in consultations with
leading manufacturers of Anchor Capstan, representatives of professional directorates and
inspection agencies. Any user of this Standard QAP either within DGQA / Indian Navy or in industry
may propose an amendment to it with valid justification. Proposals not applicable to particular
contract can be sent directly to DQA (WP), New Delhi, and those directly applicable to a particular
contract are to be dealt with using contract procedures.

5. DQA(WP) reserves the right to amend or modify the contents of this Standard QAP without
consulting or informing any holder of this document.

6. When this Standard QAP is incorporated into contracts, users are responsible for their correct
application and for complying with contractual and other statutory requirements. Compliance with
Standard QAP does not of itself confer immunity from legal obligations.

7. Enquiries in connection to these requirements may be made from:

Directorate of Quality Assurance (Warship Projects)

Ministry of Defence
6th Floor, ‘B’ Block,
Defence Office Complex
Sarojini Nagar P.O.
New Delhi – 110 023

Page 4 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 05
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

TABLE OF CONTENTS

S.No. DESCRIPTION PAGE

1. Standards Invoked
06
2. Specific Requirements
07
3. Abbreviations
09
4. Scope
10
5. System Description
11
6. SQAP Part-I: General Information
12
7. SQAP Part-II : Technical Inspection/Trials
12
APP Standard QAP of Anchor Capstan for Naval Projects
13-22
'A'

LIST OF ANNEXURES

Ser. Annexure No. Topic

1. Annexure – I DQA(N) Policy No. 66301/POLICY/DQA(N)/SG dated

14 Nov 17 regarding inspection of imported items
2. Annexure – II DQA(N) Policy No. 12575//POLICY/DGQA/WP-TC
dated 12 Oct 20 regarding Qualification of NDT
Personnel through ASNT
3. Annexure – III DQA(WP) Policy letter 12575/POLICY/DGQA/WP-TC
dated 28 Sep 20 regarding Guidelines for approval of
SQAPs/QAPs.
4. Annexure – IV DQA(WP) Policy letter 12575/POLICY/DGQA/WP-TC
dated 14 Jun 21regarding use of approved QAP for
replenishment order.
5. Annexure – V DQA(WP) Policy letter 29814/MISC/DGQA/WP-TC
dated 24 Feb 21 regarding SOP for Remote
Inspection.

Page 5 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 06
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

STANDARDS INVOKED

S. No. Specification No. Description

1. IS 7937:2012(Ref 2017) Shipbuilding-Sea-going Vessels –Windlasses and

Anchor Capstan
2. BR 3021,Vol I & II Shock Manual
3. EED-Q-071(R 4) Motors and Starters for Naval Ships
4. MIL-STD-461E Control of Electromagnetic Interference
Characteristics of sub systems & equipment
5. NES 514 and Requirement for Cable Glands
DGS/EED/VI/1535/R6
6. DEFSTAN 02-636(NES Requirement for AC & DC starting & Control Gear
636)
7. NCD 3901 Guideline Technical Specifications Electrically
Operated Anchor Capstan
8. IS 2062 Specification for Structure Steel
9. NES 723 Tally Diagram Plates

Note: - The Standards given are indicative only. The specifications / standards and parameters
given in the SOTR / Technical Specification (TSP) / MoM of TNC / Approved drawings will be final
and binding.

Page 6 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 07
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

SPECIFIC REQUIREMENTS
1. Testing of physical, chemical properties and specific tests (wherever mentioned) has to be
done by NABL accredited lab (including firm’s NABL accredited lab).
2. If casting is being poured without integral test bar, then the pouring is to be witnessed by
Inspector. No repair of casting whatsoever is to be undertaken without approval by QAE.
3 All castings are to be subjected to RT and / or UT, as applicable, to qualify the same in
accordance with the approved class of casting, unless otherwise specified in P.O. & SOTR / TSP.
The extent of RT will be as per the approved drawing. The class of casting is to be invariably
mentioned in the drawing / DBOM
4. All forgings are to undergo UT for soundness and integrity checks.
5. Motors are to be procured only from IHQ, MoD (N) approved vendors.
6. Make of the outsourced Items should be as per approved PIL/Detailed Bill of Material
(DBOM) or Naval approved sources
7. Imported items will be inspected i.a.w DQA(N) Policy No. 66301/Policy/DQA(N)/SG dated 14
Nov 17 (Annexure-I), as amended from time to time. Normally, following documents are inspected: -

(a) Bill of Lading / Shipping Bill / Airway bill.

(b) Invoice by OEM or Country of Origin Certificate with Packing List
(c) Bill of entry to warehousing
(d) OEM confirmation Certificate
(e) Firm’s Guarantee Certificate as per PO

8. All NDT to be performed in accordance with DQA(WP) Policy No.

12575/Policy/DGQA/WP-TC dated 12 Oct 20 (Annexure-II) and subsequent amendments as
applicable.
9. All NDT procedures are to be approved by ASNT (ACCP) / ISNT Level III qualified NDT
personnel based on standards and acceptance criteria specified in SOTR / TSP / Applicable
Standards.
10. Type Test, EMI/EMC test and ETT will be done at Government/PSU test centers or NABL
accredited labs.
11. If Type Testing, EMI/EMC and ETT have already been done in earlier projects on identical
units, it will not be done again & the original reports of earlier tested units will have to be provided for
review of Inspection Agency.
12. Guidelines for approval of SQAPs/QAPs, DQA(WP) policy letter 12575/POLICY/DGQA/WP-
TC dated 28 Sep 20 (Annexure-III) is relevant.

13. For replenishment order, DQA(WP) policy letter 12575/POLICY/DGQA/WP-TC dated 14 Jun
21 (Annexure- IV) is relevant.

Page 7 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 08
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

14. Post promulgation of this SQAP. The manufacturer shall be required to submit confirmation to
concerned QA Agency and OPA towards acceptance of SQAP either in totality or with some design
specific inclusions and/or exclusions, if any, along with the following details.
(a) Equipment name.
(b) Equipment technical details (as applicable).
(c) Purchase Order reference.
(d) Sub/Sub-Sub Orders reference (as applicable).
(e) Name of Main Indenter/ Ordering Authority.
(f) Name of end user, if available.
(g) Name of firm / manufacturer.
(h) SOTRs reference, if available.
(j) Yard No./ Name of ship where to be fitted (if available)/ End user.
(k) References of relevant drawings.
(l) QAP No. & Date (as indicated by the firm).
(m) Contractual delivery date.
(n) Inspection Authority.
(p) Inspection Agency.
(q) Quantity (as applicable).
(r) Inclusions, if any.
(s) Exclusions, if any.

15. The SQAP along with the proposed inclusions/ exclusions approved by DQA(WP) shall be
deemed as the approved QAP for the particular PO.

16. SOP for Remote Inspection, DQA(WP) policy letter 29814/MISC/DGQA/WP-TC dated 24 Feb
21 (Annexure- V) is relevant.

Page 8 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 09
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

ABBREVIATIONS

ABN Air Borne Noise

ACCP ASNT Central Certificate Program
ASME American Society of Mechanical Engineers
ASNT American Society of Non-destructive Testing
ATP Approved Test Procedure
CHP Customer Hold Point
CoC Certificate of Conformance
COTS Commercial-off-the-shelf
DBOM Detailed Bill of Material
DFT Dry Film Thickness
DI Dimensional Inspection
DPT Dye Penetrant Test
EMC Electro Magnetic Conduction
EMI Electro Magnetic Induction
ESS Environment Stress Screening
ETT Environmental Type Testing
FATs Factory Acceptance Trials
GA General Arrangement
HT Heat Treatment
I-Note Inspection Note
IFATs Integrated Factory Acceptance Trials
IR Inspection Report by Vendor
ITC Inspection and Test Certificate
ISNT Indian Society of Non-destructive Testing
MO Material Organisation
MoM Minutes of Meeting
MPT Magnetic Particle Test
MTC Manufacture Test Certificate
NABL National Accreditation Board for Testing and Calibration Laboratories
NDE Non Destructive Evaluation
NDT Non-destructive Testing
NSTL Naval Science and Technological Laboratory
OEM Original Equipment Manufacturer
OPA Order Placing Authority
P Perform by
PIL Parts Identification List
PO Purchase Order
PQR Procedure Qualification Record
QA Quality Assurance
QAE Quality Assurance Establishment
QAO Quality Assurance Officer
QAP Quality Assurance Plan
Page 9 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 10
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

ABBREVIATIONS

R Review by
RT Radiography Testing
SBN Structure Borne Noise
SOTR Statement of Technical Requirement
SQAP Standard Quality Assurance Plan
STC Supplier Test Certificate
TC Test Certificate
TEC Technical Evaluation Committee
TNC Technical Negotiation Committee
TSP Technical Specification Particulars
TT Type Test
UT Ultrasonic Testing
VI Visual Inspection
W Witness by QA Rep.
WPQ Welder Performance Qualification
WPS Welding Procedure Specification

Page 10 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 11
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

SCOPE
Scope of Quality Assurance. The scope of Quality Assurance will cover witness and review of
all manufacturing activities during all stages viz. raw material stage inspection including, bought out
items, in-process stage inspection and final inspection stage. The scope also covers the review and
witness of Type Test of equipment, wherever applicable.

This Standard Quality Assurance Plan contains comprehensive list of inspections and/or trials
that is to be applicable for quality assurance of the equipment. In addition, quality assurance of
equipment will also be governed by specific conditions laid down in SOTRs and ‘Approved
Drawings’. The inspections/ trials must be contemporary to latest technology/ techniques available
in the industry at the time of placement of orders

The following quality assurance activities will be carried out during the quality assurance of
equipment:

(a) Visual Inspection.

(b) Dimensional Inspection.
(c) Witness of Pouring in absence of integral test bar.
(d) Review of Lab Test Certificates.
(e) Witness of in-house Lab Testing, if applicable.
(f) Witness of Non-destructive testing viz. UT, DPT & MPT
(g) Review of RT films and reports.
(h) Review of Heat Treatment Charts
(j) Review of ETT, EMI/EMC and ESS reports, in addition to Pre and Post ETT Post
inspection, as applicable.
(k) Functional Checks as per approved ATP
(l) Review of draft documentation and witness/ stamping of final documentation, as
applicable.
(m) Issue of CHP clearance.
(n) Issue of I-Note/ Form-IV or Dispatch Clearance as applicable.

Page 11 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 12
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

SYSTEM DESCRIPTION
An anchor capstan is a machine that restrains and manipulates the anchor chain on a ship,
as required, allowing the anchor to be raised and lowered by means of chain cable. A notched
wheel engages the link of the chain.

An anchor capstan consists of a capstan head/ warping barrel and a cable lifter capable of
being driven in both directions by an electrical motor through a slipping clutch and a gear box. The
warping barrel is fitted at the upper end of the vertical shaft and moves along with it under the
control of electrical drive and gear box. The cable lifter can either run freely under the control of a
hand wheel operated brake or positive driving force of the warping barrel which can be engaged by
means of a hand wheel at the top of the warping head.

The electric motor is controlled by the drum type controller with the help of ‘T’ handle. An
emergency stop foot switch is also provided near ‘T’ handle position.

Page 12 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 13
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

STANDARD QUALITY ASSURANCE PLAN

Part – I: General Information

1. The following generic information must generally be indicated on each QAP as its identity:-

(a) Equipment Name

(b) Equipment Technical Details (as applicable)
(c) Purchase Order Reference
(d) Sub/Sub-Sub Orders reference (as applicable)
(e) Name of Main Indenter/ Ordering Authority
(f) Name of End User
(g) Name of Firm / Manufacturer
(h) SOTRs Reference
(j) Yard No./ Name of Ship where to be fitted (if available)/End User
(k) References of Relevant Drawings
(l) QAP No. & Date (as indicated by the firm)
(m) Contractual Delivery Date
(n) Inspection Authority
(p) Inspection Agency
(q) Quantity (as applicable)

Page 13 of 24
 MINISTRY OF DEFENCE / ANCHOR CAPSTAN PAGE 14
DGQA
DIRECTORATE OF QUALITY STANDARD QAP NO. DGQA/DQA(WP)/ REV. NO. 0
ASSURANCE (WP) ANCHOR CAPSTAN /16/2022/ REV-0 DATE 14 FEB 22
NEW DELHI – 110 023

STANDARD QUALITY ASSURANCE PLAN

Part – II: Technical Inspection / Trials

Standard QAP of Anchor Capstan Appendix "A"

Page 14 of 24
 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
MINISTRY OF DEFENCE / DGQA ANCHOR CAPSTAN PAGE 15
DIRECTORATE OF QUALITY ASSURANCE STANDARD QAP NO. DGQA/DQA(WP)/ANCHOR CAPSTAN/16/2022/ REV-0 REV. NO. 0
(WP),NEW DELHI – 110 023
APPENDIX-A DATE 14 FEB 22
Technical Inspection / Trials in form of SQAP Part II (Refers to Page No. 14)

S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS

NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
1.00 DRAWINGS/DOCUMENTS/TYPE TEST
1.01 GA Drawings of all Check for availability of 100% As per PO/ SOTR/ All approved List of Approved P R CHP
Assemblies & sub approved drawings and TNC Minutes drawings along with Binding Drawings Approved binding
assemblies along with DBOM & Binding data DBOM & Binding data data/drawing to be
DBOM & Binding Data are available. verified
1.02 Type Test/ETT/ EMI/EMC Verification of Type Test / 100% Purchase Order, GA Equipment should Type Test/ P R CHP
reports* Qualification test reports. drawings, have successfully Qualification Test Shipyard Orders.
Component undergone Type Test, reports Type / Qualification
drawings& EMI/EMC and ETT test are to be
SOTR/TNC Minutes/ (as applicable) conducted if not
JSS 55555 undertaken earlier or
test certificate not
held or equipment has
undergone changes.
MO Orders. Type /
qualification tests
undertaken only, if
mentioned in PO.
*EMI/EMC test
mandatory for Motors,
Starter & Control
panel.
Decision of IHQ
MoD(N) is final for all
tests.

Page 15 of 24
 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
2.00 RAW MATERIALS INSPECTION/ IDENTIFICATION
2.01 Plates/Sheets/sections for
(i) Motor Base Frame, (i) Chemical, Physical 01 sample As per approved Approved Drawing NABL TC P R CHP
(ii) Gear Boxes, per heat/ drawing Sample to be drawn in
(iii) Top Cover of Gear thickness presence of QA Rep
and Report to be
Boxes, etc (ii) UT (for Plates) 100% As per approved Approved Drawing NDE Report / IR P W reviewed. UT to be
drawing witnessed by QA Reps.
2.02 Forged Bars/ Blanks/ Round Bars
(i) Shafts/ Pinions, (i) Chemical, Physical 01 sample / As per approved Approved Drawing NABL TC P R CHP
(ii) Brake Spindle for Band heat drawing Sample to be drawn in
Brake, presence of QA Rep and
(iii) Coupling / Coupling (ii) UT 100% As per approved Approved Drawing NDE Report / IR P W tested at NABL lab. UT
Clutch, drawing to be performed by
(iv) Gears ISNT/ ASNT level II/III.
UT to be witnessed by
QA Reps. Heat
treatment charts &
report review by QA
agency for all forged
components. If no
reference standard for
UT is specified in the
approved drawings then
NES 729 Part-V to be
referred.
2.03 Castings
(i) Worm Wheel (i) Chemical, Physical 01 sample / As per approved Approved Drawing NABL TC P R CHP
(ii) Cable Lifter (Gypsy) heat drawing Test sample may be
(iii)Capstan Barrel/ (ii) UT/RT 100% As per approved Approved Drawing NDE Report / IR P W casted separately from
Warping Head drawing same heat. Sample will
be tested at NABL Lab.
UT to be witnessed by
QA Reps. HT charts &
report review by QA
agency for all castings.
For RT, NDE report
along with radiographic
film to be submitted for
review.

Page 16 of 24
 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY

2.04 Input Raw materials for Misc components (As per Detailed Bill of Material)
Coupling, Keys, Seal Chemical & Physical 1sample/ Approved Drawing Approved Drawing & NABL TC P R CHP
Cover, Covers, Spacer, size/lot PO
Retainer Ring (in halves), Sample to be drawn
Shifter Fork, Shifter in presence of QA
Block, Pin, Chain Stopper Rep. Firm to offer
and allied parts, if any, Raw Materials for
Foundation Bolt, Deck sealing the sample for
Stool, Deck Head testing.
Lever Plate, Locking Chemical - Approved Drawing Approved Drawing & STC/ OEM P R Number of
Plate, Bearing Housing, PO TC/OEM CoC components/ items
Thrust Washer, Distance may vary from design
Piece, Retainer Plate, to design. Actual
Chain Reliever, Nut components as per
(Shifter Warping Head), approved DBOM/
Lock Plate Nut, Shifter drawings.
Wheel, Handle, Band
Drum, Hinge Pin, Nut,
Lock, Cover Housing,
Hand Wheel, Wheel Bar,
Lock Pin, Housing Cap,
Push Knob, Push Rod,
Gland Nut, Securing Tag,
Mounting Frame,
Pedestal, Roller, Roller
Pin, Lifting Hand, Bush
Bearing, etc.

2.05 Electrical Items

Motor As per latest approved SQAP for AC Motor FORM IV / P R Separate QAP or
I- Note Inclusion/Exclusion to
be submitted
Control Panel & Starter As per latest approved latest SQAP for Control Panel & Starter

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 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
2.06 COTS Items
As per Detailed Bill of VI & DI Random Approved Drawing/ Approved Drawing & STC/ OEM P R No of components/
Material (DBOM) DBOM PO TC/OEM CoC items may vary from
design to design.
[Bolts(Steel), Washers, Actual components
Oil Cap, Drain Plug, as per approved
Packing (Permanite), Oil DBOM/ drawings.
Seal, Spring Washer, Nut,
Grease Nipple, Ferodo OEM CoC can be
Lining, CSK Screw, Grub acceptable for
Screw, Air Breather cum packing
Filler , 'O' Ring, Spring,
Slipping Clutch Assembly,
Worm Gear box,
Planetary Gear Box, etc.]

Oil Level Gauge, Chain VI Random Approved Drawing/ Approved Drawing & STC/ OEM P R
DBOM PO TC/OEM CoC

Bearings Make & Model 100% Approved Drawing/ Approved Drawing STC/CoC P R
DBOM
2.07 Bought Out Item
Shock Mounts As per latest SQAP FORM IV / P R
I- Note
2.08 Lubrication & Oil

Gear Oil Brand & Grade 100% DBOM Approved DBOM & CoC P R Check for Lot No &
PO Batch No

Grease

Page 18 of 24
 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
3.00 IN PROCESS INSPECTION
3.01 Fabrication / Welding/ Forging/ Casting/ Heat Treatment
Welding
Motor Base Frame Before fabrication of 100% Approved drawing ASME IX WPS/PQR/ WPQ P R
assemblies - Welder
Gear Boxes Qualification Record
After fabrication of 100% Approved drawing Check for abnormal IR P R
assemblies – Check for distortions &
Top Cover abnormal distortion & allowances for
allowances for machining machining
Side Cover After welding/ Before 100% Approved drawing Check for cracks on NDE Report / IR P W DPT will be witnessed
machining welds of critical joint by QA Reps
Bearing Housing and by DPT
other welded Review of stress IR P R
components/ parts relieving Charts
Surface Profile after IR P R
shot blasting
3.02 Machining -
Components/ items to be machined
Gear Boxes VI, DI 100% Approved drawings Approved Drawings, IR P R
SOTR,TSP & PO
Shafts, Gears & Worm VI, DI 100% Approved drawings Approved Drawings, IR/MTC P R
Wheel SOTR,TSP & PO

Warping Head VI, DI 100% Approved drawings Approved Drawings, IR P R UT to be done either
SOTR,TSP & PO by NABL or ASNT
level II/III certified
inspector. Un-
UT 100% Approved drawings Approved Drawings, NDE Report / IR P W machined areas, as
SOTR,TSP & PO accessible, will be DP
tested. NDT will be
witnessed by QA
Reps
Lock Plate Nut VI & DI, Thread 100% Approved drawings Approved Drawings, IR P R
Conformity SOTR,TSP & PO

Page 19 of 24
 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
Brake Spindle VI & DI, Thread 100% Approved drawings Approved Drawings, IR P R
Conformity SOTR,TSP & PO
Foundation Bolt VI & DI, Thread 100% Approved drawings Approved Drawings, IR P R
Conformity SOTR,TSP & PO
As per Detailed Bill of VI & DI 100% Approved drawings Approved Drawings, IR P R
Material(DBOM): Keys, SOTR,TSP & PO
Top Covers, Seal Cover,
Oil Seals, Covers, Deck
Stool, Deck Head,
Spacers, Couplings,
Coupling Clutch, Retainer
Rings, Shifter Fork, Shifter
Block, Pins, Lever Plate,
Locking Plate (Coupling),
Bearing Housing, Thrust
Washers, Distance Piece,
Retainer Plate, Chain
Reliever, Nut (Shifter
Warping Head), Shifter
Wheel, Handle, Band
Drum, Lock Ring, Washer,
Hand Wheel, Wheel Bar,
Housing Cap, Push Knob,
Push Rod, Gland Nut,
Spring, Securing Tag,
Bush, Packing, Mounting
Frame, Pedestal, Roller,
Roller Pin, Lifting Hand,
Chain Stopper and allied
parts, etc.,.
Cable Lifter VI & DI 100% Approved drawings Approved Drawings, IR P R
SOTR,TSP & PO
Profile of Snug 100% Approved drawings Approved Drawings, IR P W Profile verification
SOTR,TSP & PO will be done during
Internal FAT

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 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
3.03 In Process Inspection – Sub Assembly Level Inspection
Gear Box Assembly Over all Dimension 100% PO/SOTR/ Approved Drawings & IR P W CHP
Approved Drg SOTR
Tooth contact by Blue
impression test OEM to certify the run
Back Lash out/ alignment
reading recorded is
Run out/ Alignment checks within limit
Oil Tightness
Drain oil completely
and check for foreign
particles.
Band Brake Overall dimension 100% PO/SOTR/ Approved Drawings & IR P R
Approved Drg SOTR
Check for operation & oil
tightness (as applicable)

Emergency Foot switch Overall dimension 100% PO/SOTR/ Approved Drawings & IR P R
Approved Drg SOTR
Functional Test 100% PO/SOTR/ Approved Drawings & IR P R
Approved Drg SOTR
Chain stopper Over all Dimension 100% PO/SOTR/ Approved Drawings & IR P R
Approved Drg SOTR
Slipping Clutch Over all Dimension 100% PO/SOTR/ Approved Drawings & IR P R
Approved Drg SOTR
Electro Magnetic Brake VI / DI 100% PO/SOTR/ Approved Drawings & IR P W
Approved Drg SOTR
Cable Lifter Over all Dimension 100% PO/SOTR/ Approved Drawings & IR P W
Approved Drg SOTR
Warping Head Over all Dimension 100% PO/SOTR/ Approved Drawings & IR P W
Approved Drg SOTR
4.00 Final Assembly
Final Assembly of Visual Inspection to check 100% Approved Drawing Conformity to IR P W
Anchor Capstan completeness of assembly approved Drawings
and overall dimension.

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 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
5.00 Functional/ Performance Tests/ Pre-requisites for FATs
5.01 Following documents to be submitted prior conduct of FAT

(a) Consolidated document of all inspection & test reports- Compiled document to be submitted.

(b) SOTR & QAP compliance matrix - Complied document to be submitted.

(c) Availability of Type test certificates:

(i) Motor

(ii) Panels

(d) Cable Lifter: Profile of snug witness can be done during Internal FAT also

5.02 Performance Check:

Approved SOTR, FAT, ATP,
No Load Run 100% FAT/Approved PO & Approved IR P W CHP
In each direction for every Drawings Drawings
speed with intermittent
cooling period
Approved SOTR, FAT, ATP,
Load Trials 100% FAT/Approved PO & Approved IR P W
Performance/ Operation of Drawings Drawings
Electromagnetic Brake,
Band Brake, Emergency
Approved SOTR, FAT, ATP,
Foot Switch, Slipping
Overload Trials 100% FAT/Approved PO & Approved IR P W
Clutch, Cable Lifter,
Warping Barrel Drawings Drawings

Noise Approved SOTR, FAT, ATP,

100% FAT/Approved PO & Approved IR P W
Drawings Drawings

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 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN
S. MATERIAL/ CHARACTERISTIC/ QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCIES REMARKS
NO COMPONENT/ TYPE OF CHECK OF DOCUMENTS CRITERIA RECORD FIRM QAE
DRG.NO/ QUALITY CHECK
ACTIVITY
6.00 TYPE TESTING
6.01 Shock Test Shock Analysis 01/ Model SOTR/NSS-II/ NSS-II as per BR NSTL Test Report/ P R Shock calculation
BR3021/ 3021 NSTL Approved report to be submitted
Applicable Std & PO/SOTR Test Report to IHQ MOD(N) post
6.02 Noise Test ABN & SBN 01/ Model SOTR/ Applicable ABN & SBN meeting ABN & SBN Report P R approval of NSTL or
Std the limits specified in any nominated
SOTR /Approved agency by IHQ
Drawing MoD(N)
6.03 Functional Test Functional Test 01/ Model SOTR/ Applicable Functional Test to be Inspection P W Functional Test
Std / ATP Satisfactory Report(IR) applicable for
Prototype Equipment
only
7.00 FINAL INSPECTION
7.01 Factory Acceptance Trial Tests as per approved 100% SOTR, FAT, ATP, Performance Test Inspection P W CHP
FAT Purchase Order & To be satisfactory Report(IR) FATs to be
Appd Drgs conducted as per
IHQ MOD(N)
approved FATs
protocol.
7.02 Submission of as-built Verification 100% Appd. Drgs./ As built drawings are As Built Drawing P R
binding drawings Concessions & approved and
Deviations complete
7.03 Liquidation of all Defect Rectification 100% Approved Drawing, All Defects liquidated Inspection P R
observations during FAT, SOTR & FAT Report(IR)
if any document
7.04 Weight Recording Weight measurement 100 % Approved Drawing, To be within specified Weight Certificate P W CHP
PO, SOTR limits as per Annexure-V be
Approved Drawing, referred for Remote
PO & SOTR Mode Inspection
7.05 Painting, Preservation, Visual Inspection 100% Approved Drawing, Conforms to Inspection P W CHP
Packing and Marking SOTR, OEM Approved Packing Report(IR) DFT to be checked by
Preservation Plan Procedure / TSP / QAE Reps.
Approved Drawing
7.06 Submission of Form IV Correctness 100% As per PO & SOTR As per PO & SOTR Form IV P Issue
(I&T Certificate) Form
IV

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 STANDARD QUALITY ASSURANCE PLAN FOR ANCHOR CAPSTAN

IMPORTANT NOTE:-

1. For Motor and Control Panel the Type Test, EMI/EMC and Environmental test are to be conducted in accordance with EED-Q-071-(R4) after QA
agencies clearance and sealing of equipment. If Type Testing, EMI/EMC and ETT have already been done in earlier projects on same item, it will not be
repeated again. The reports of earlier tested units will be submitted for review of Inspection Agency. In case of any difficulty/discrepancy in carrying out
the above, matter be referred to IHQ MoD(N)/DEE within 10 days of receipt of approved QAP under intimation to HQ DQA(WP).
2. COTS: COTS items to be accepted on the basis of Certificate of Conformance (CoC) with following conditions:-
(a) CoC must indicate governing specifications and values to which the item has been tested. The certificate must include copies of tests
reports.
(b) In case of manufacturer's certificate under relevant quality standards (like ISO, OHSAS etc), the pre published data sheet or company
quality policy bringing out the details of test carried out on specific items may be accepted.
3. Bought out items: Bought out items are those which are in the regular production range of the manufacturing firm/ sub vendor and manufactured
on placement of specific order by main firm and production is covered by main firm's quality control program.
4. All NDT procedures are to be approved by ASNT (ACCP) / ISNT Level III qualified NDT personnel based on standards and acceptance criteria
specified in SOTR / TSP / Applicable Standards.
5. RT&UT are to be carried out by ASNT (ACCP) Level-II/III or ISNT Level-II/III qualified NDT personnel. Interpretation/sentencing of RT and UT
reports are to be carried out by ASNT (ACCP) Level-III or ISNT Level-III NDT personnel only.
6. MPT & DPT are to be carried out by certified ASNT (ACCP/SNT-TC-1A) Level-II/III or ISNT Level-II/III NDT personnel. Interpretation/sentencing of
MPT and DPT reports are to be carried out by ASNT (ACCP) Level-III or ISNT Level-III NDT personnel only.
7. No of components/ items (under misc components/ Bought out/ COTS items) may vary from design to design. This list is indicative only. Actual
components/ items would be as per approved DBOM/ drawings.
8. Witness of inspections can be done in remote mode, wherever feasible. The modalities of remote inspection are to be worked out jointly by the firm
and QAO.

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