Date :ANNEXURE FOR CONTROL PLAN NO.

PROCESS - Hot dip galvanizing

Sr. No. Item Code

Item Description 2.1 MW

Drawing

Rev No

1 2

51017936 51017937

Suspending Arm Front -Nose Cone S88V3 Suspending Arm Back - Nose Cone S88V3 600 KW

M411.0032-03 (Rev. 3) M411.0033-03 (Rev. 3)

3 3

1 2 51015062

Substucture of GRP Safety Cover 1.25 MW

S52.03.03.02.01 V1 S52.03.04.01

0 0

51015325

Pitch drive safety guard

S1250.03.017

Page 2 of 5

Component :

CP No : Date : 28.08.2009

Record for Process Validation

Vendor : Stage: Proto / Series Process Name Operation Description Process : Supplier : Machine Device, Tools for manufacturing Characteristics No. Product Surface Condition Bath mixing ratio Bath Density Bath pH Dipping Time Position of the components in the bath. Surface condition Rinsing Water Quality Rinsing Time Position of the components in the bath. Surface condition S.C. S.C. Process Product/ Process Spl. charac Class S.C. Methods Product/ Process Specification/ Tolerance Rust & scale free surface 33 % HCl in water 1.07 - 1.12 gm/cc Between 2 - 5 2 - 5 minutes Evaluation Measurement Technique Visual Measuring Beaker Hydrometer pH paper / pH meter Wall Clock / Wrist Watch Sample Size Two Once Once Once Freq Per Lot Per Week Per Week Per Week Control Method

Part/ Process Number

Observation

2 3 10 Derusting MS Acid Tank 4 5

100% Every Batch

Component / Components Visual fully immersed in the Bath Free from acid, & foreign particles Having value > pH 5 2 - 3 minutes Visual pH paper / pH meter Wall Clock watch / wrist

100% Every batch

1 2 20 Cold Water Rinse MS Water Tank 3

100% Every batch Once Per Week

Once Every Batch

Component / Components Visual fully immersed in the Bath Surface free from oxide formation Zinc Ammonium chloride Concentration. -50% with soln. pH>5 Density 1.18 to 1.20 S.C. Dry surface 1-2 minutes 40 - 60 C temp. Visual

100% Every batch

100% Every batch

30

Fluxing

MS Tank 2

Bath Concerntration

pH meter & hydrometer

Once

Per Week

1 40 Drying MS plate 2

Surface Condition Drying Time Drying Temp.

Visual Wall clock watch Manual / Wrist

100% Every batch One One Every batch Every batch Stage Inspection Report

Witnessed By :

Reviewed By :

Process Stage Inspection Report

Process Stage Inspection Report

Process stage Inspection Report

Approved By :

Page 3 of 5

Component :

CP No : Date : 28.08.2009

Record for Process Validation

Vendor : Stage: Proto / Series Process Name Operation Description Process : Supplier : Machine Device, Tools for manufacturing Characteristics No. Product Process Product/ Process Spl. charac Class S.C. Dip Time Methods Product/ Process Specification/ Tolerance Coating thk 120 microns min. dipping for 1 - 3 minutes Evaluation Measurement Technique Coat Meter Wall Clock / Wrist Watch Temp indicator & thermocouple Verification of Zinc material test Certificate Verification of Zinc material test Certificate Wall Clock / Wrist Watch Sample Size Freq Control Method

Part/ Process Number

Observation

100%

Every dip

50

Hot Dip Galvanizing

Furnace

Bath Temp

460C 20C temp.

On going

Every batch

Bath Composition

99 % zinc ,

100%

Bath Preparation Bath Preparatio n

Zinc Metal

99.90 % zinc ,

100%

60

Water Quench MS Water Tank

Dipping Time

1 - 3 minuts

100%

Per lot

Layer of Dicromate 70 Dichromating MS Tank 1 Dip and remove Bath Concentration Galvanized surface condition Galvanised Layer

Even uniform layer S.C. 1 - 3 minuts Sodium Dicromate concentration - 5% with soln.In water S.C.

Visual Wall Clock / Wrist Watch 3 Measuring Beaker

100% Once

Every job Per Batch Solution prepration Stage Inspection Report

Once

1 80 Finishing and inspection Manual 2

Surface free from Lumps , Ash, Black spots. Coating thk 120 microns min.

Visual

100%

Every Job

Final Inspection Report

S.C.

Coat Meter

100%

Every Job

Witnessed By :

Reviewed By :

1) Process stage Inspection Report 2) Test Certificate

Galvanised Layer

Two

Per Batch

Approved By :

Component : As per Annexture

CP No : Date : 16.05.2009 Rev : 0

Control Plan
Process : Hot Dip Galvanizing Stage: Proto / Series Process Name Operation Description Supplier : Characteristics Machine Device, Tools for manufacturing No. Product Surface Condition Bath mixing ratio Bath Density Bath pH Dipping Time Position of the components in the bath. Surface condition Rinsing Water Quality Rinsing Time Position of the components in the bath. Surface condition S.C. S.C. Process Product/ Process Spl. charac Class S.C. QAP No.: As per Annexture TS No.: As per Annexture Methods Product/ Process Specification/ Tolerance Evaluation Measurement Technique Sample Size Two Freq Per Lot Per Week Per Week Per Week Every Batch Every batch Every batch Per Week Every Batch Every batch Every batch Control Method

Part/ Process Number

Reaction plan

2 3 10 Derusting MS Acid Tank 4 5 6 1 2 20 Cold Water Rinse MS Water Tank 3 4 1 30 Fluxing

33 % HCl in water 1.07 - 1.12 gm/cc Between 2-5 2 - 15 minutes Component / Components fully immersed in the Bath

Measuring Beaker Once Hydrometer pH paper / pH meter Wall Clock Visual Once Once 100% 100% 100% Once Once 100% 100%

Process Stage Inspection Report

Rust & scale free surface Visual

Re process Adjust bath concentration Adjust Density Re adjust Re process Ensure proper dipping of components in bath Re process Replace water bath Re process Ensure proper dipping of components in bath Re process

Having value > pH 5 2 - 3 minutes Component / Components fully immersed in the Bath Surface free from oxide formation

pH paper / pH meter Wall Clock Visual Visual

MS Tank 2

Bath Concerntration

Zinc Ammonium chloride Concentration. -50% with pH meter & soln. hydrometer pH>5 Density 1.18 to 1.20

Once

Per Week

Process Stage Inspection Report

Process Stage Inspection Report

Free from acid, & foreign Visual particles

Adjust Density & pH value

Component : As per Annexture

CP No : Date : 16.05.2009 Rev : 0

Control Plan
Process : Hot Dip Galvanizing Stage: Proto / Series Process Name Operation Description Supplier : Characteristics Machine Device, Tools for manufacturing No. Product Surface Condition Drying Time 2 1 2 Galvanised Layer Dip Time Drying Temp. S.C. Process Product/ Process Spl. charac Class S.C. QAP No.: As per Annexture TS No.: As per Annexture Methods Product/ Process Specification/ Tolerance Dry surface 1-3 minutes 40 - 60 C temp. Coating thk 120 microns min. dipping for 1 - 3 minutes Evaluation Measurement Technique Visual Wall clock Manual Coat Meter Wall Clock Temp indicator & thermocouple Testing in material lab Verification of Zinc material test Certificate Wall Clock Sample Size 100% One One Two 100% On going Freq Every batch Every batch Every batch 1) Process stage Inspection Report 2) Test Certificate Per Batch Every dip Every batch Control Method

Part/ Process Number

Reaction plan

1 40 Drying MS plate

Stage Inspection Reprocess Report

Rework the complete process. Re dip & remove Maintain temp. by heating control./ time

50

Hot Dip Galvanizing

Furnace

Bath Temp

460C 20C temp.

Bath Composition

98.5 % zinc ,

once

Per Month Bath Preparatio n Per lot

Reject

Zinc Metal

99.90 % zinc ,

100%

Reject

60

Water Quench

MS Water Tank

Dipping Time

1 - 3 minuts

100%

1) Process stage Re process Inspection Report

Layer of Dicromate 70 Dichromating MS Tank 1 Dip and remove Bath Concentration Galvanized surface condition Galvanised Layer

S.C.

Even uniform layer 1 - 3 minuts Sodium Dicromate concentration 3 - 5% with soln.In water

Visual Wall Clock

100% Once

Every job Per Batch Solution prepration

Re process Stage Inspection Re process Report Top up to maintained the level

Measuring Beaker Once

80

Finishing and inspection

1 Manual 2

S.C.

Surface free from Lumps , Visual Ash, Black spots. Coating thk 120 microns min. Coat Meter

100%

Every Job

Final Inspection Report

Recleaning / Rework

S.C.

100%

Every Job

Re process