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  QUALITY AT PAGODA
 

We have a vigorous Quality Manual Plan comprising testing of incoming material, in line checks during production and final testing. The quality manual program is regularly to upgrade it. Our laboratory is equipped with all the instruments to ensure that the various tests required under different specification are conducted before cables are cleared for despatch. Each consignment of cables is despatched to the customer with exhaustive test report results of tests conducted in our laboratory. Based on the above, we are detailing below the Quality Manual Program.

TEST ON RAW MATERIALS

Raw materials are procured from approved vendors. Testing on raw material starts from vendor's end. The raw material is received along with the vendor's test report. The following tests conducted to test the raw material/verify the vendor's test report. 1.Conductor: -
Tests are conducted on conductor are as per IS: 8130:1984. Apart from these tests, if customers required other test requirements. Those tests are also conducted.

i) Conductor Resistance : 100% with the help of Kelvin Double Bridge bridge for wire up to 0.4mm. diameter. Finer wires by sampling of 10% on lot basis.

ii) Conductor Elongation : 100% on Tensile Testing machine for wires upto 0.4mm Diameter. Finer wires by sampling of 10% on lot basis.

iii) Solder Bath/Persulphate : 100% for wires up to 0.4mm. Diameter Finer wires by sampling of (For Tinned conductors only) 10% on lot basis.

iv) Wrapping Test : 100% Wrapping is done manually. (For Aluminium Conductor Only)

v) Tensile Strength : 100% with the Tensile Strength on Tensile Testing Machine. (For Aluminium Only)

2. P.V.C. COMPOUND/ POLYETHYLENE/POLYMERS.

Tests are conducted on PVC Compound/Polyethylene/Polymers are as per relevant Specification. Those tests are also conducted. Sample of every consignment is first run on Trial basis and following tests are conducted: -

i) Insulation Resistance: With Mega Ohms Meter.

ii) Elongation: With Tensile Testing Machine.

iii) Tensile Strength: With Tensile Testing Machine.

iv) Spark Testing: With on line spark testers.

v) High Voltage Test: With High Voltage Tester.

vi) Thermal Stability Test: With Oven & PH Paper.

vii) Oxygen & Temperature Index: With Oxygen Test Appartus. [For FRLS PVC/FRHF Compound]

viii) Smoke Density Test: With smoke Density Test Appartus. [For FRLS PVC/FRHF Compound]

ix) HCL Gas Generation Test: With HCL Gas EmissionTest Appartus. [For FRLS PVC/FRHF Compound]

x) Swedish Chimney Test: With Swedish Chimney Test Appartus. [For FRLS PVC/FRHF Compound]

The Following TYPE TESTS are conducted on month basis:-

i) Bleeding & Blooming: With Bleeding & Blooming tape and HST Oven.

ii) Ageing: With Ageing Oven.

iii) Hot Deformation: With Hot Deformation Apparatus.

iv) Loss of Mass: With Electronic Balance & Additional Ageing Oven with Air Flow.

3. STEEL STRIP/WIRE:-

We procure ISI marked G.I. wire & Strips. However the following Tests are conducted as per IS:3975:-

i) Dimensions: 100% with Micrometer and Vernier Callipers.

ii) Tensile Strength: 100% with Tensile Testing Machine.

iii) Dip Test: with Dip Tester.

4. POLY ALUMINIUM LAMINATE:

i) Peel Strength: From Tensile Machine.

ii) Dimensions: 100% with Micronmeter and Vernier Callipers.

ON LINE QUALITY ASSURANCE:


1. BUNCHING/STRANDING/SHAPPING OF CONDUCTOR.

i) Dia & No. of Strands.:On Sample Basis.

ii) Conductor Resistance: Sampling basis.

iii) Direction & Lay Length: Sampling Basis.

iv) Dimension over Conductor: Sampling basis.

2. INSULATION EXTRUSION.

i) On Line Spark Testers: 100% Performed by Spark Testers on each Extruder.

ii) Dimension & Centering: On line, by sampling basis.

iii) Insulation Resistance: Sampling Basis.

iv) High Voltage: Sampling Basis.

v) Tensile Strength of PVC Comp: Sampling Basis Performed as described before.

vi) Conductor Dimension: Sampling Basis. & Resistance.

vii) Shrinkage: Sampling Basis.

3. TWISTING & LAYING OF CORES:

i) Visual Examination for:100% Colour Sequence

ii) Direction & lay Length: 100% with Visual and Vernier Callipers

iii) High Voltage Test: 100% performed with High Voltage Test.

iv) Conductor Resistance: 100% on digital Resistance Meter.

v) Size of Conductor: 100% By Micrometer.

vi) Dia. Over Laid Up Cores: 100% by Vernier Callipers.

4. INNER SHEATH:

i) Thickness & Measurement: 100% with help of Vernier Callipers.

ii) Surface Conditions of Inner: Visual Examination. Sheath

5. ARMOURING.

i) Direction of Lay: Visual Examination.

ii) No. of Wires/Strip: On line, by counting.

iii) Diameter of Wire/Width: By Micrometer. & Thickness of Strip

iv) High Voltage: 100% by High Voltage Tester.

v) Dia. Over Armouring : By Vernier Callipers.

6. SHEATHING:

i) Continuity of each core before Sheathing : 100% by Continuity Tester

ii) Diameter Over Sheathing : By Vernier Callipers.

iii) Thickness of Insulation: By Vernier Callipers.

iii) Eccentricity: By Vernier Callipers.

iv) Surface Finish: Visual Examination.

v) Printing/Embossing : Visual Examination.

Same is applied for Extrusion stage.The material is tested for High Voltage before any new process commences. BRAIDED/SCREENED CABLE. All on line checks are conducted.,About 5 metres. of sample is braided and following parameters are checked before continuing production.
A)Braid construction such as Braid Wire size, No. of Wire/Spindle, Lay Length and coverage factor are checked.
B)Capacitance per meter.
C)Characteristic Impedance.

In the case of Multipair Cables, where capacitance unbalance,Near End Cross Talk and Far End Cross Talk has to be controlled and kept below specified level, the pairs are twisted with specified lay and care is taken that adjacent pairs have lays in a specified manner. When the capacitance of a twisted pair is specified, before twisting, wire of sample O/D ratio are segregated and then twisted. Only those twisted pairs are used which fall within the specified limits. On the laid up cable of 5 metres, capacitance unbalance and capacitance of individual pairs are checked on sampling basis.
FINAL TESTING:- Final Testing of Electrical Wires are carried out as per IS:694:90[ Conductor - IS:8130 (Type - II) & Insulation - IS:5831:1984 (Type - A)] Final Testing of FRLS PVC Insulated Wires are carried out as General Purpose Electrical PVC Wires in addition of FRLS Tests as per ASTM D-2843 & 2863, IEC - 754-I and BICC Hand Book Chapter - VI. Final Testing of Flame Retardent Halogen Free Compound Insulated Wires are carried out as IEC - 332-1 & 3, IEEE - 383, IEC - 754 - 1 & 2, ASTM - D 2843 & 2863. Final Testing of Cables are carried out as per IS:1554[Pt-I]:88 and any other National/International Specification required by the customers. The results are recorded on Test Report.

For PAGODA CABLES PVT. LTD.
(Quality Assurance Engineer)


 
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