inspection and test plan for dry type lighting transformer

INSPECTION AND TEST PLAN FOR

DRY TYPE LIGHTING TRANSFORMER

SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM

OF CHECK RECORD ACCEPTANCE NORMS

SCOPE OF INSPECTION SUB

SUPPLIER SUPPLIER BARC

1.0 Procedures -- -- -- -- -- -- 2.0 Material Inspection

2.1

Incoming Raw Material like Copper Conductor, Lamination, Marshalling box, cables, fasteners and bolts, copper flexible, insulators, dials, Scanners and gauges etc.

• Dimensional and Operational checks • Physical, Chemical, Electrical

properties (as applicable) • Calibration checks (as applicable ) 100%

Material Test Certificates / Test records

Should be from reputed supplier

and grade as specified in job

specification H H -

3.0 Inprocess Inspection

3.1 Transformer Assembly Visual, Dimensions, Bill of materials. 100% Test Records Should be as per

approved drwgs/data sheet

- H -

3.2 Visual ,healthiness of impregnation(resin) 100% Test record -

- H W

4.0 Final Inspection

4.1 Transformer (Routine Tests)

• Physical and dimensional check. • Measurement of winding resistance

• Measurement of voltage ratio and check of voltage vector relationship

100%- by purchaser

Inspection test records

As per approved drwgs

IS 11171 CL 13.2 (a) / IS 2026 – 1, CL 16.2

IS 11171 CL 13.2 (b) / IS 2026 – 1, CL 16.3/Data sheet

- H W







• Measurement of impedance voltage, short-circuit impedance and load loss.

• Measurement of no-load loss and

current • Separate –source voltage withstand test

(HV test) • Measurement of Insulation Resistance

before and after HV test.

• Induced over voltage withstand test

IS 11171 CL 13.2 (c) / IS 2026 – 1, CL 16.4/Data sheet

IS 11171 CL 13.2 (d) / IS 2026 – 1, CL 16.4/Data sheet

IS 11171 CL 14 /shall withstand

IS 11171

IS 11171 CL 14 shall withstand

4.2 Transformer (Special Test)

• Temperature rise

Noise Level Test

One sample from each type/rating


IS 11171 CL 17 As per data

sheet

IS 11171 CL 19

/ AS PER NEMA chart according to

MVA/KV rating of transformer

- H H







4.3 Transformer (Type Test)

• Short circuit test • Impulse Withstand Test.

• Partial Discharge Measurement ( Applicable for HV trafo )

• Degree of Protection of Enclosure.

One sample from each type/rating


IS 11171 CL 20

IS 11171 CL 16

IS 11171 CL 18

IS 11171 CL 22 / IEC 60529

- H R

5.0 Painting

5.1 Painting and Packing • Visual, Packing list. • Proper packing to avoid any damage

during transportation. 100% Supplier’s

records

As per DS/Spec. - H -

6.0 Documentation and IC

6.1 Documentation and IC • Review of Internal Test Reports. • IC issuance 100%

Supplier’s Test Records / Inspection Certificate

(IC)

- H H







6.2 Final Document submission

Compilation of Inspection reports ,drawings, etc as per VDR / PR 100%

Final data folder

/Completeness certificate

- H H

Legends: H- Hold (Do not proceed without approval, R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work may proceed after scheduled date).

NOTES :-

1. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon).

2. Acceptance Norms for all the activities shall be as per latest version of relevant IS code/ Standards referred there in/ Job specifications /Approved documents


OIL FILED TRANSFORMERS/POWER TRANSFORMER

SL NO. STAGE/ ACTIVITY CHARACTERISTICS

QUANTUM OF

CHECK RECORD ACCEPTANCE

NORMS




2.1

Incoming material like Copper conductor, Insulation material, laminations, Transformer Oil.

Check of Physical, Chemical and Electrical properties.

100%


Should be from reputed supplier and grade as specified in job specification

H H

R

2.2

Bought out accessories like Marshalling box, Relays, Current Transformer, MOG, Bushings and Insulator, PRVs and OLTC.

Review of Manufacturer’s test certificates.

Functional check on accessories. Degree of protection, IR,HV for

Marshalling box

100% Material Test Certificates / Test records

Should be from reputed supplier and model as

specified in job specification/

data sheet

H H R


3.1 Tank and radiator fabrication (Before painting)

Dimensional Pressure test, one of each type Vacuum test, one of each type

100% Test Records

As per CBIP . Permanent deflection of flat plates after removal of pressure/vacuum shall not be more than values given in table 2 of EIL specification 6-51-0041 Rev5

H H R


4.1 Transformer (Routine Tests)

• Physical Verification, Dimensional Check and verification of BoM

• Voltage ratio and Polarity

100% by purchaser


As per approved drwgs

- H W


OIL FILED TRANSFORMERS


QUANTUM OF


NORMS



• Voltage vector relationship

• Winding resistance

• Insulation resistance before and After H.V

• Polarization Index

• No load loss and Current • Impedance voltage/Short circuit

impedance (Principal tapping) and load loss

IS 2026 – 1, CL 10.3/As per approved data sheet IS 2026 – 1, CL 10.2/As per approved data sheet IS 2026 – 1, CL 10.1.3 (i) IS 2026 – 1, CL 10.1.3 (i) (Min 1.5 ) IS 2026 – 1, CL 10.5( as per data sheet) IS 2026 – 1, CL 10.4 ( as per data sheet)




QUANTUM OF


NORMS



• Induced over voltage

• Separate Source Voltage Withstand Test

• Tests on On/off load Tap changer

/control panel (if applicable)

• HV, IR and Functional Test on Marshalling Box

• Oil Leakage(Pressure Test) • Break Down Voltage on transformer

oil • Measurement of Power taken by fans

and oil pumps. (On sample basis for one transformer)

• Noise Level.

IS 2026 – 3, CL 12 /shall withstand . IS 2026 – 3, CL 11/ shall withstand IS 2026 – 1, CL 10.8 IS 2026 and approved drwgs CBIP( No leakage) IS 335( 60 KV, average of 6 reading ) IS 2026 – 1, CL 10.1.3 (h) IS 2026 – 10/ NEMA chart according to




QUANTUM OF


NORMS



MVA/KV rating

4.2 Transformer (Type and Special Tests)

• Temperature rise. • Impulse withstand test • Short circuit level

a) Through fault b) Primary Terminals

• Degree of protection for Marshalling Box, Cable box , Transformer Adaptor Chamber etc.

100% by Purchaser


IS 2026 – 2, CL 5.0 ( as per data sheet) IS 2026 – 3, CL 13.0

IS-2026(Part 1), CL 16.11(( as per data sheet)

As defined in data sheet/drwgs

- H W*

5.0 Painting

5.1

Painting and Packing • Visual • Suitable protection to prevent entry of

foreign material. • Proper packing to prevent any damage

during transportation and storage.-

100% Packing list /

Supplier’s Records

As per DS/Spec.-

- H -


6.1 Documentation and IC • Review of Internal Test Reports. • IC issuance 100%


(IC)

-

- H H




QUANTUM OF


NORMS





Final data folder


-

- H H

* Only those Type/Special Tests as specified in the Specifications/ Data Sheet will be witnessed by BARC. Otherwise Supplier to submit Type Tested Reports for review by BARC.


NOTES :-


4. Acceptance Norms for all the activities shall be as per latest version of relevant IS code/ standards referred there in/ Job specifications /Approved documents


OUTDOOR EHV CIRCUIT BREAKER

SL NO

. STAGE/ ACTIVITY CHARACTERISTICS

QUANTUM OF

CHECK RECORD

ACCEPTANCE NORMS



1.0 Procedures -- -- -- -- -- --

2.0 Material Inspection

2.1

Incoming Material like Busbars, Insulators, Cables, Relays, Control Cubicles Motors/Compressors, Pressure Switches/ Gauges, Density monitors, Breaker Compressor, Relays etc.

• Physical, Dimensional, Functional and Operational Checks

• Test certificates of each components

100%

TC’s/ Inspection & Test records /

Lab Test Records

As per approved drgs /datasheet/ specification H H R

3.0 In process Inspection

3.1 Breaker Assembly Visual, Dimensions, Bill of Materials 100% by Supplier

Supplier’s Test Records

-

- H R


4.1 Outdoor EHV Circuit Breakers- Acceptance Tests

• Physical, Dimensional and BoM Verification

• Mechanical and electrical operation check.

• Measurement of the resistance of the main circuit.

• Compressor running time (in the

Test Records / Inspection

Witness Record

- H W



case of pneumatic operated systems) or spring charging time in the case of spring operated systems have to be checked.

• Compressed air leakage test in closed and open conditions

• Air consumption measurements for each of the switching operations

• Power frequency test for the main and auxiliary circuits (DRY Insulation Test).

• Insulation resistance before and after HV.

• Mechanical and Electrical Interlocks and other safety features.

• Functional Checks on CB Operating Mechanism.

• Pressure Switch Operation for SF6 and gas leakage Test.

• Mechanical and electrical operation check at worst conditions of Auxiliary Supply Volatge.

• Trial Switching Operation shall be performed to check the blocking Pressure.

100% Supplier & Purchaser .

IEC:62271-100, 62271-1 &

IS 13118/As per approved

drwgs/data sheet/Job

specification

4.2 Submission of Certificates/ Documents

• Type tests as specified in Latest IS/IEC shall be conducted, as a minimum and certificates shall be furnished.

• Type Test Certificates for Insulators, Bushings and CBs

Witnessed by purchaser


IEC:62271-100, 62271-1 &

IS 13118/As per job specification

/DS - H W



Legends: H- Hold (Do not proceed without approval), Random 10% , R-Review, RW-Random witness, W- Witness (Give due notice, work may proceed after scheduled date). NOTES :-


6. Acceptance Norms for all the activities shall be as per latest version of relevant IS code/ standards referred there in/ Job specifications /Approved documents

5.0 Painting and Packing


• Visual • Suitable protection to prevent

entry of foreign material. • Proper packing to prevent any

damage during transportation

100% Supplier test records

As per DS/Spec.

- H -


6.1 Documentation and IC • Review of Internal Test Reports • Issuing IC 100%


-

- - H

SL

NO. STAGE/ ACTIVITY

1.0 Procedures


Incoming Material like Insulators, Bus Bars,

Fabricated items, Bus Bar sleeves , Cable wire(FR),

2.1 instrument transformers , Relays, Indicating

Instruments, Switches, Breakers, Vacuum Bottles

etc


INSPECTION AND TEST PLAN

FOR

HV SWITCHBOARDS

QUANTUM CHARACTERISTICS

OF CHECK

-- --

Visual, Dimensional, Operational checks, Review of Manufacturer's Certificates etc. as 100%

applicable

RECORD

--

TC's/ Inspection &

Test records I Lab Test Records

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

-- -- --

H H R

SL NO.

STAGE/ ACTIVITY

3 .1 Breaker Truck Assembly •

3.2 Wiring checks


•

•

•

4.1 Switchgear Assembly

•


FOR

HV SWITCHBOARDS


OF CHECK

Mechanical Operation including spring charging mechanism, Breaker opening I

closing at normal and worst voltage 100% by conditions, Opening I closing time and Supplier and simultaneous closing of all poles, Contact random by resistance measurement, Gas leakage EIL/TPIA check (for SF6 breakers), Power Frequency Test.

Size, termination, ferruling, continuity 100%

ACCEPTANCE TESTS:

Visual check including layout, Tag plates, Paint shade, Bus marking and sleeving, Joint shrouding, Identification and location of components etc

Dimension check including operational height, Bus bar size, Clearances, Creepage distances, Compartmentalization, cable gland size, Paint thickness etc.

Verification of Bus bar support arrangement with respect to type tested panel drawings and provision for external 100%

cable termination.

Bill of material check .

RECORD

Test Records IInspection

Witness Record

Suppliers Test Records


Witness Record

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

- H w

-- H R

- H H

SL

NO.

4.2

STAGE/ ACTIVITY

Switchgear Assembly (Contd.)

Switchgear Assembly


FOR

HV SWITCHBOARDS

CHARACTERISTICS

• Rack-in and Rack-out of breakers.• Interchangeability of Truck assembly in

identical feeders.*• Pressure switches operation for SF6

breaker.• Operation check for auxiliary equipment

circuits and auxiliary contacts• Operation checks for all control

functions and interlocks as per schematicdiagrams in Test and Service positionincluding mechanical interlock check.

• Relay operation check through primary I

secondary injection.*• Measurement of resistance of main circuit.• Communication check between relays and

Data concentrator I HMI (if applicable)*• HMI operation and functional checks as

per separate agreedITP/FAT(if applicable)

• Insulation resistance of main, auxiliary andcontrol circuits before and after HighVoltage Test.

• Power Frequency voltage withstand test onmain, auxiliary and control circuits.

TYPE TESTS: • Short time current withstand test• Temperature Rise test.

QUANTUM

OF CHECK

100%

Sample Basis

RECORD


Witness Record

Test Agency Reports

SCOPE OF INSPECTION

SUB


H H

R/W** R/W**

SL NO.

ST AGE/ ACTIVITY


FOR

HV SWITCHBOARDS


OF CHECK RECORD

SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER BARC

• Internal Arc test.• Impulse and Power Frequency withstand

test• Short circuit test duties.

• Degree of protection for panels.

5.0 Painting

Painting and Packing • Visual• Suitable protection to prevent entry of Packing list I

5.1 foreign material. 100% Supplier's

• Proper packing to prevent any damage Records

during transportation and storage.


• Review of Internal Test Reports• Certification from supplier for complete

Supplier's Test Records I

6.1 Documentation and IC relay parameterization of numerical relays 100% Inspection

at worksCertificate

• IC issuance .

Compilation of Inspection reports ,drawings, Final data folder

6.2 Final Document submission 100% /Completeness etc as per VDR I PR

certificate

* Quantum of check is 100% by Supplier & random basis by EIL/TPIA** Witness if called for in job specifications. In such cases specified Type test will be considered as part of Acceptance Test.

- H -

- - H

- H H


FOR

HV SWITCHBOARDS

Legends: H- Hold (Do not proceed without approval, R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each e), W- Witness (Give due notice, work ma roceed after scheduled date).

NOTES:-

1. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unlessotherwise agreed upon).

2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents

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SL STAGE/ ACTIVITY

NO.

1.0 Procedures


Incoming material like panel fabrication, PCBs, Lamps, Push Buttons,

2.1 switches, Protective relays, Lockout relays,

Indicating Meters, Terminals, cable

wires(FR), PVC ducts, etc



FOR

RELAY & CONTROL PANEL/DESKS

QUANTUM CHARACTERISTICS RECORD

OF CHECK

--- --- ---

Visual, Physical, Finish, Dimensions, Make of components, Manufacturer's test

100% Test records certificates for model, accuracy etc. as per

relevant specifications

SCOPE OF INSPECTION

SUB


--- --- ---

H H R

SL STAGE/ ACTIVITY

NO.

3.1 Wiring Checks



•

•


FOR



OF CHECK

Size, termination, ferruling, Test

continuity 100% Records

Check for correctness of wiring

Acceptance Tests:-• Visual, Accessibility of operating

devices• Dimensional• Name Plate & Inscription details• Paint shade and surface finish• Mimic diagram and color codes• Cable entry, Cable lugs, Cable Glands

size, Lifting Hooks• Bill of material, Make of Components• Operation check of Alarm sequence/ 100% Inspection

Functional as per data sheet test record

requirement I drawings • Operation/Calibration check of all

relays, Meters and other components bycurrent injection

• Operation check for auxiliary contacts& auxiliary circuit

• Earthing• Accuracy of digital clock• High voltage test• IR test before and after High voltage

SCOPE OF INSPECTION

SUB


--- H R

H H

SL NO.

5.0

5.1

6.0

6.1

6.2

STAGE/ ACTIVITY

Painting

Painting and Packing

Documentation and IC


Final Document submission


FOR



OF CHECK

• Visual

• Suitable protection to prevent entry of Packing list foreign material. 100% I Supplier's

• Proper packing to prevent any damage Records


Supplier's • Review of Internal Test Reports, Test Test

reports for degree of protection 100% Records I• IC issuance Inspection

Certificate

Final data Compilation of Inspection reports

100% folder

,drawings, etc as per VDR I PR /Completene ss certificate



- H -

- - H

- H H

Legends: H- Hold (Do not proceed without approval, R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each ty e), W- Witness (Give due notice, work ma roceed after scheduled date).

NOTES:-


2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications I Approved documents

SL STAGE/ ACTIVITY

NO.

1.0 Procedures


Incoming material like panel

2.1 fabrication, PCBs, Lamps, Push

Buttons, Terminals, cable wires(FR), PVC ducts, etc


3.1 Wiring Checks



FOR

ANNUNICA TION PANEL

CHARACTERISTICS

--

Visual, Physical Finish , ,

Dimensions, Make of components etc. as per relevant specifications

• Size, termination ferruling' ,

continuity• Check for correctness of wiring

QUANTUM OF

CHECK

--

100%

100%

RECORD

--

Material Test Certificates ITest records

Test records

SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER BARC

-- -- --

H H R

-- H -

SL STAGE/ ACTIVITY

NO.

4.1 Annunciation Panel (Final Inspection)

5.0 Painting


FOR

ANNUNICATION PANEL

QUANTUM OF CHARACTERISTICS

CHECK RECORD

Acceptance Tests:-• isual• Dimensional• Name Plate & Alarm Inscription

details• Paint shade, Paint thickness• Cable entry, Cable lugs, Cable

Glands size, Lifting Hooks• Bill of material, Make of

Components• Interchangeability of PCBs with

identical logic design• Operation check of Alarm

100% Inspection test

sequence as per data sheet record requirement

• Operation check with ± 10%power supply variation

• Verification of Space heaterworking

• Auxiliary circuit/auxiliarycontact check

• Earthing• Accuracy of digital clock• High voltage test• IR test before and after High

voltage

SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER BARC

H H

SL

NO.

5.1

6.0

6.1

STAGE/ ACTIVITY





FOR

ANNUNICATION PANEL


CHECK

• Visual

• Suitable protection to prevententry of foreign material.

100% • Proper packing to prevent any

damage during transportation andstorage.

RECORD

Packing list ISupplier's Records

Supplier's • Review oflnternal Test Reports

100% Test Records I

IC issuance Inspection Certificate

SCOPE OF INSPECTION

SUB


- H

- -

Legends: H- Hold (Do not proceed without approval), Random - min 10% , R-Review, RW-Random witness, W- Witness (Give due notice, work may roceed after scheduled date).

NOTES:-



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SL NO.

STAGE/ ACTIVITY

1.0 Procedures


Incoming Material like Busbars, Insulators, Motors •

2.1 and reduction Gears, cables, Relays, Cables, Cable •

glands etc.


3.1 Switch Assembly


FOR

OUTDOOR EHV ISOLATERS AND EARTHING SWITCHES


CHECK RECORD

-- -- --

TC's/ Inspection Physical, dimensional and operational checks (as applicable) 100%

& Test records I

Test certificates of Suppliers Lab Test Records

Visual, Dimensions, Functional Checks 100% by Supplier's Test Supplier Records

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

-- -- --

H H R

- H R

SL NO.

ST AGE/ ACTIVITY


•

•

Outdoor EHV Isolators and •

Earthing Switches-4.1

Acceptance tests •

•

•

•

•

Outdoor EHV Isolators and •

Earthing Switches- Type •

4.2 Tests

•

•


FOR



CHECK RECORD

Physical, Dimensional and BOM Verification.

Millivolt Drop Test and Measurement of resistance of main circuit.

Mechanical and electrical operation check with Control Cubicle.

100% by Test Records ISupplier and on Inspection

Power Frequency voltage dry test on main Random basis by Witness Record

circuit . EIL/TPIA

High Voltage test on control and auxiliary circuits.

IR before and After HV .

Mechanical and Electrical Interlocks and other safety features checking.

Dielectric Tests as per relevant IS

Temperature Rise Test.

Short Circuit Making Capacity of Earthing One Type Test

Switches. Sample/Rating Records

Mechanical Endurance test.

Short Time withstand current and peak withstand current tests.

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

H H

- H R

SL NO.

4.3

5.0

5.1

6.0

6.1

ST AGE/ ACTIVITY

Submission of certificates /documents






FOR



CHECK RECORD

• Degree of protection certificate as Statutory applicable.

Sample/ Approval

• Type test Certificates . Prototype Certificates I

Type Test Certificates

• Visual• Suitable protection to prevent entry of

Supplier test foreign material. 100%

records • Proper packing to prevent any damage

during transportation

Supplier's Test • Review of Internal Test Reports and MTCs.

100% Records I

• Issuing IC Inspection Certificate

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

- H R

- H -

- H H

Legends: H- Hold (Do not proceed without approval), Random 10%, R-Review, RW-Random witness, W- Witness (Give due notice, work may roceed after scheduled date).

NOTES:-



SL STAGE/ ACTIVITY

NO.

1.0 Procedures


Incoming Material like Porcelain housing, Pressure release devices, valves, Oil,

2.1 Cable Glands, Choke, Reactor, Bushings, Insulator etc


3 .1 CT and VT assembly


FOR

OUTDOOR EHV CURRENT TRANSFORMERS AND VOLTAGE

TRANSFORMERS

CHARACTERISTICS QUANTUM

RECORD OF CHECK

-- -- --

• Physical, Dimensional, Functional andSupplier's TCs/

Inspection & Electrical Checks (as applicable) 100%


Visual, Dimensions, Bill of Materials 100% by Supplier's Test Supplier Records

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

-- -- --

H H R

- H R

SL STAGE/ ACTIVITY

NO.


•

•

Voltage Transformers- •

4.1 Acceptance Tests •

•

•

•

•

•

Current Transformer-4.2

Acceptance Tests •

•


FOR

OUTDOOR EHV CURRENT TRANSFORMERS AND VOLT AGE

TRANSFORMERS


RECORD OF CHECK

Physical, Dimensional and BoM Verification

Overvoltage Inter turn Test 100% by Test Records I

Partial Discharge Test. Supplier and on Inspection

Power Frequency High Voltage test on Random basis Witness Record

Secondary and Primary windings by EIL/TPIA

Accuracy Test .

Capacitance check for Capacitor Voltage Transformer (CVT)

Physical, Dimensional and BoM Verification.

Overvoltage Inter turn Test

Capacitance, Tan Delta and partial discharge check for CTs of rating 132 KV

Test Records Iand above.

100% by Inspection Power Frequency High Voltage test on Supplier and on Witness Record Secondary and Primary windings

Random basis Extended Primary Current (120% of by EIL/TPIA primary current)

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

H H

- H H

SL NO.

STAGE/ ACTIVITY

4.3 Type Tests



5.1


FOR


TRANSFORMERS

•

•

•

•

•

•

•

CHARACTERISTICS

Protection CTs • Knee Point Voltage and Exciting

Currents• Turns Ratio• Secondary Winding ResistanceMeasuring CTs• Accuracy Test

Temperature Rise Tests Lighting Impulse Test(applicable for use in Electrically Exposed Installation) Switching Impulse Test ( 420 KV and Above) High Voltage Power Frequency wet withstand voltage Test.(upto and including 245 KV) Measurement of Dielectric Dissipation factor for CTs.(as applicable) Short Circuit Withstand Capability test for VTs Instrument Security current test for measuring CTs.

• Visual

• Suitable protection to prevent entry offoreign material.

• Proper packing to prevent any damage

QUANTUM OF CHECK

RECORD

100% by Supplier and on Test Records IRandom basis Inspection by EIL/TPIA Witness Record

One Type Test sample/Rating Records

Packing list I100% Supplier's

Records

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

- H H

- H R

- H

SL

NO.

6.0

6.1

ST AGE/ ACTIVITY


Documentation and IC •

•


FOR


TRANSFORMERS


OF CHECK RECORD


Supplier's Test Type test Certificates. Records I

100% IC issuance . Inspection

Certificate

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

- H


NOTES:-



SL. STAGE/ACTIVITY

NO.

1.0 Procedure


2.1 Incoming material like castings, Push Button, terminals, glass, ammeter, voltmeter, knob, switch, etc


3.1 Assembly


4.1 Industrial type Control Station


FOR

INDUSTRIAL TYPE CONTROL STATIONS

CHARACTERISTICS QUANTUM RECORD

OF CHECK

- - -

Physical & Chemical Properties, Material Supplier's

Certificate, Accuracy, Make etc. Test Records/

100%/ Independent lab TC

Visual, Dimension, Bill of water 100%

Supplier's Test Records

Acceptance Tests:-

• Visual• Dimensions, Threads Inspection • Workmanship 100% witness Test • Paint Shade Records • Marking on each piece for Tag no. etc .• Terminal sizes, Lugs size(where required)• Cable Gland size

SCOPE OF INSPECTION

SUB SUPPLIER r-- ·---.

SUPPLIER BARC

- - -

H H R

- H -

- H RW

SL. STAGE/ACTIVITY

NO.

•

•

•

4.2 Submission of Certificates •




FOR

INDUSTRIAL TYPE CONTROL STATIONS

CHARACTERISTICS QUANTUM RECORD

OF CHECK

Electrical Operation test & BOM High voltage test IR test before and after High voltage

Certificate of testing agency for Certificates suitability of degree of protection ( as from testing applicable) Samples agencies

• Visual.• Suitable protection to prevent entry of

foreign material. 100% Test records • Proper packing to prevent any

damage during transportation.

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

- H R

-

H --


Supplier's

Review of Internal Test Report Test Records

6.1 Documentation and IC •

100% I Inspection - H H • IC issuance

Certificate (IC)

Final data

6.2 Final Document Compilation of Inspection reports ,drawings,

100% folder

H H submission etc as per VDR I PR /Completenes -

s certificate

Legends: H- Hold (Do not proceed without approval, R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work ma roceed after scheduled date).NOTES:-


? A rrPnt:mrP Nnrm<: fnr :i II thP :ir.tivitiP<: -:h:i II hP :i<: nPr Pn/PR I <;:t:inrforrk rPfPrrPrl thPrP in/ Tnh cnPf'ifif'<>tinnc I A nnrn"Prl rlnf'11mPntc

SL NO.

ST AGE/ ACTIVITY

1.0 Procedures


Incoming Material like Insulators, Bus Bars, Fabricated

items, Bus bar sleeves and 2.1 supports, Instrument

Transformers, Relays, Indicating Instruments, Switches, Breakers,

Contactors etc.


FOR

M.V.SWITCHBOARDS


OF CHECK

--

--

Visual, Dimensional, operational checks, Manufacturer's test 100% certificates etc. as applicable

RECORD

--

Material

Test Certificates

I Test Records

SCOPE OF INSPECTION

SUB SUPPLIER BARC

SUPPLIER

-- -- --

H H R

SL STAGE/ ACTIVITY

NO.


3.1 Wiring checks


4.1 Switchgear Assembly


FOR

M.V.SWITCHBOARDS


OF CHECK

Size, termination, ferruling, continuity 100%

• Visual check including layout,Tag plates. Paint shade, Busmarking and sleeving, jointshrouding, Identification andlocation of components etc.

• Dimension check includingoperational height, Bus size,Clearances, Creepage distances,paint thickness, gland size etc.

• Verification of Bus bar supportarrangement with respect to type 100%

tested panel drawings, provisionfor external cable termination andBus Duct flange Dimensions (ifapplicable).

• Bill of material I Make ofComponents check.

• Interchangeability of identicalmodules I feeders (if applicable).*

RECORD

Test Records

Supplier's Test

Records IInspection Witness Record

SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER BARC

-- H R

- H H

SL STAGE/ ACTIVITY

NO.

•

•

•

Switchgear Assembly (contd.) •

•

•

•


FOR

M.V.SWITCHBOARDS


OF CHECK

Operation check for control and auxiliary equipment circuits and auxiliary contacts.

Manual and electrical operation check of Breakers, Relays etc. under normal and worst voltage conditions.*

Operation checks for all control functions and interlocks as per schematic diagrams in Test and service position including mechanical interlock as applicable. 100% Relay operation check through primary/secondary injection.*

Communication check between relays and Data concentrator IHMI (if applicable).*

HMI operation and functional checks as per separate agreed ITP/F A T(if applicable).

Insulation resistance of main, auxiliary and control circuits before and after High Voltage tests.

RECORD


Witness Record

SCOPE OF INSPECTION

SUB


- H H


FOR

M.V.SWITCHBOARDS

SL QUANTUM SCOPE OF INSPECTION

STAGE/ ACTIVITY CHARACTERISTICS RECORD SUB NO. OF CHECK

SUPPLIER

• Power Frequency voltagewithstand test on main, auxiliaryand control circuits.

TYPE TESTS: • Short Circuit making and

breaking tests.Test

4.2 Switchgear Assembly Short time current withstand test.

Sample Basis Agency -

•

Reports • Temperature Rise test.• Degree of protection for panels .

5.0 Painting

Painting and Packing • Visual

• Suitable protection to prevent entryPacking list

5.1 of foreign material.

100% I Supplier's -

• Proper packing to prevent any Records damage during transportation andstorage.


• Review of Internal Test Reports Supplier's • Certification from supplier for Test

6.1 Documentation and IC Complete relay parameterization 100% Records I -

of numeral relays at works Inspection • IC issuance Certificate

* Quantum of check is 100% by Supplier & random basis by EIL/TPIA* * Witness if called for in job specifications. In such cases specified Type test will be considered as part of Acceptance Tests.

SUPPLIER BARC

R/H** R/W**

H

H H


FOR

M.V.SWITCHBOARDS

Legends: H- Hold (Do not proceed without approval), Random -10%, R-Review, RW-Random witness, W- Witness (Give due notice, work may proceed after scheduled date).

NOTES:-

I. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unlessotherwise agreed upon).


SL NO.

ST AGE/ ACTIVITY

1.0 Procedures


Incoming Material like Fabricated items, Electronic

2.1 components, PCBs, Relays, Indicating Instruments, Power Supply Unit, IGBT/SCRs, etc.


3.1 PCBs & Electronic components, Sub-assemblies


FOR

BATTERY CHARGERS


OF CHECK

-- --

Visual, Dimensional, operational checks, etc. as applicable 100%

Burn-in Test for 96 hours at 50deg C 100%

RECORD

--

TC's/ Inspection &



SCOPE OF INSPECTION

SUB SUPPLIER BARC SUPPLIER

-- -- --

H H R

H H R

SL NO.

ST AGE/ ACTIVITY


4.1 Battery Charger Assembly (Acceptance Tests)


FOR

BATTERY CHARGERS

CHARACTERISTICS

• Visual check including layout, Tag plates,Paint shade, Bus marking, Identificationand location of components, etc.

• Check calibration status of all testingequipment.

• Dimension check including operationalheight, Bus size, Clearances, paintthickness, etc.

• Bill of material/ Make of Components.

• Full Load test for 16 hours with minimum8hrs for each Charger*. Temperature risefor critical components would be recordedduring this test.

• Charger testing at constant output voltage infloat and boost charge mode, includingmeasurement of AC phase voltage,frequency, current, power, DC outputvoltage, current and output voltage rippleat nominal AC input voltage at zero, 50%and 100% of rated output current.Measurement shall be repeated at I 00%full load current at 90% and 110% ofnominal AC supply

• Charger testing under constant outputcurrent limiting condition in float andboost mode, including measurement of DC

QUANTUM OF CHECK

100% by Supplier and on Random Basis by EIL/TPIA

RECORD


Witness Record

SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER

H

B.ARC

H

SL STAGE/ ACTIVITY

NO.

Battery Charger Assembly (Acceptance Tests Contd.)

4.2 D.C Distribution Board


FOR

BATTERY CHARGERS


OF CHECK

output voltage and current with DC output voltage varying between zero and set value corresponding to constant voltage operation.

• Proper functioning of all measuringinstruments, alarms, indications, protectionand controls as per requirement.

• Parallel operation of both chargersincluding load sharing and automaticisolation of faulty charger.

• Charger Efficiency and Voltage regulation 100% BY

test. Supplier and on

• Harmonic Measurement. Random Basis

• Dynamic Response test for step load as per by EIL/TPIA

PR/spec.

• Audible noise test.• Insulation resistance before and after HV

test for power, control and auxiliarycircuits.

• High voltage withstand test for power,control and main circuits.

• Check for protection against reverse batteryconnection.

100% by Visual, Dimensions, Feeder Tag plates, Supplier and Functional checks, IR and HV test. on Random

Basis ny EIL/TPIA

RECORD


Witness Record


Inspection Witness Record

SCOPE OF INSPECTION

SUB SUPPLIER BARC.

SUPPLIER

- H H

- H H

SL NO.

STAGE/ ACTIVITY

4.3 Cell Booster

4.4 Battery

Submission of Certificates/ 4.5

Documents

5.0 Painting


5.1




FOR

BATTERY CHARGERS


OF CHECK

• Visual and Functional checks 100% by • Full load capability test at 90%, 100% and Supplier and

110% of nominal AC supply on Random • IR and HV test Basis ny

EIL/TPIA

All test as per respective ITP, as a Sample

minimum

Type test report on radio frequency•

100% interference voltages on RFI filter.

• Visual

• Suitable protection to prevent entry offoreign material. 100%

• Proper packing to prevent any damageduring transportation and storage.

• Review oflnternal Test Reports100%

• IC issuance .

RECORD



Supplier Test Record

Supplier's Test Records/

Statutory Body

Certificates


Supplier's Test Records IInspection Certificate

SCOP

SUB SUPPLIER

SUPPLIER BARC·

- H H

- H H

- H R

- H -

- H H


FOR

BATTERY CHARGERS

* Tests shall be conducted on one charger of each rating (In case of dual Chargers, both chargers will be put on load separately)


NOTES:-




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SINWAII-13011 aDmallaiall o.z

This Inspection and Test Plan covers the minimum testing & inspection requirements of three phase medium voltage squirrel cage induction motors.

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STANDARD SPECIFICATION NO. IN

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Raw Material: Body(casting or

fabrication), Rotor shaft, Core

laminations, Copper, Insulation material,

Bearings, Terminals, cable boxes, Cable glands, etc.

Material Inspection

Procedures

STAGE/ ACTIVITY

Chemical, Physical properties , finish as per relevant standard

CHARACTERISTICS

1-,

CD

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■•;

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E OF INSPECTION

, .

EIL/TPIA

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Final Inspection

Motor Assembly

Inprocess Inspection

STAGE/ ACTIVITY

•

Visual check (Nameplate, Terminal box location, terminal type, clearances, size, entries, space adequacy & gland size, Direction of rotation etc.)

•

Dimensions check (shaft height etc.)

•

Cable Glands, cable lugs size and no. of entries in Terminal Box

• Winding Resistance • No load test and measurement of Voltage, Speed, Current, Power Input

•

Measurement of Starting Torque, Starting current , full Load Torque, Pull out torque by JEC (Logarithmic proportion Current method II).

•

Reduced voltage Starting and running

•

Insulation resistance Before & after High Voltage test

•

High Voltage

•

V ibration

Vacuum impregnation and bracing of winding, core assembly, Rotor bars and end rings assembly,

Rotor balancing, Terminal box mounting and clearances in between, Bearing setting, etc as per

supplier's internal standards

n :

›..

n

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m

w

n'''

z

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c,

c,

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c>

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QUANTUM OF CHECK

5 -,

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CD

CD

o

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5-

cn

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SUB SUPPLIER

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SUPPLIER

E OF INSPECTION

cD

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EIL/TPIA

SL STAGE/ ACTIVITY

NO.

4.2 Motor (Type Tests)

5.0 Painting


5.1





FOR

MEDIUM VOLTAGE MOTORS


OF CHECK

• Full load test and measurement of Voltage,Current, Power, Slip, Power factor, BearingNoise.

• Efficiency and Pf at 100%, 75% and 50% load• Temp Rise test One sample • Momentary overload test from each • Vibration type/rating

• Noise Level

• Over speed

• Measurement of Starting Torque, StartingCurrent, Full Load Torque*

• Visual

• Suitable protection to prevent entry of foreignmaterial. 100%

• Proper packing to prevent any damage duringtransportation and storage.

• Review of Internal Test Reports• Test certificate from recognized testing

laboratory for area classification.• BIS certificate for FLP motors and accessories

as applicable.

PESO approved certificates for motors and100%

•

accessories as applicable.• Degree of protection of enclosure• IC issuance•

Compilation of Inspection reports ,drawings, etc as 100%

RECORD




Certificates from statutory

bodies IInspection

Certificate (IC)

Final data


6-81-1032 Rev. 4

Page 5 of6

SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

See Note - H

3&4

- H -

- H H

- H H

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Battery assembly

STAGE/ ACTIVITY

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Visual, Packing list.

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Proper packing to avoid any damage during transportation.

•

Acid Retention Capability Test on Separators.

•

Test on Vent Seal Operation

•

Wicking Test on Separator. • Test for Oxygen Recombination

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Test for charge retention/ Loss of capacity.

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Life cycle test on similar model.

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Dimension, Paint Shade/thickness

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SUB SUPPLIER

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•


•

IC issuance

• Visual.

•


•

Proper packing to prevent any damage during transportation.

•

Certificate from testing agency like ATEX, CIMFR BASEEFA, FM/UL , PTB etc. for suitability in specified hazardous area

•

A valid BIS license for indigenous supply

•

Statutory approval certificates from CCE/PESO for use in specified hazardous area.

•

De:_ree of .rotection certificate as a p plicable.

•

Changing Address of detectors

•

Verification of Battery type and Capacity

•

Calibration Check with standard calibrator, validity of calibrator check (if applicable)

•

Operation check on applicable accessories like Exit Signs, Beacon Lamps, Siren, Release and inhibit switches, Short circuit/fault isolator

CHARACTERISTICS

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1.0 SCOPE:


FOR

DIESEL GENRA TING SET

This Inspection Test Plan covers the minimum testing requirements of Diesel Generating Set

2.0 REFERENCE DOCUMENTS:

PO/PR/ Standards referred there in/ Job specifications /Approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS:

s. CHARACTERISTI

N STAGE/ACTIVITY cs

0

1.0 Procedures

l.lDG Set Load test I Performance test Documented

Procedure (As applicable) Procedures

1.2 WPS, PQR,WPQ Welding procedures,

Qualification


QUANTUM

OF CHECK

100%

100%

RECORD

Procedures

WPS/PQR/ WPQ Records

STANDARD SPECIFICATION No.

6-81-0059 Rev.2

Page 3 of 5

SCOPE OF INSPECTION

SUB SUPPLIER EIL/TPIA

SUPPLIER

- H R

H W-New,

-

R - Existing

s.

N STAGE/ACTIVITY 0

Incoming Material Diesel Engine, Alternator & Control

2.1 Panel (Supplier I Sub-Supplier to arrange

TPIA Certification)

Hard Ware items 2.2 Gaskets, Fasteners, Bearings & Gland

Packings etc.

Accessories

2.3 Air Receiver , Fuel Tank , Radiators OR Heat Exchanger (Coolers), Coupling etc.

3.0 In Process Inspection

3.1 Assembly of Alternator, Diesel Engine,

Control Panel, Radiators etc.


4.1 Load test I Functional test of assembled

DG Set

4.2 Final Visual I Dimension of Skid

assembly


FOR

DIESEL GENRATING SET

CHARACTERISTI QUANTUM

cs OF CHECK RECORD

Functional IPerformance test 100%

Inspection ITest report

(as applicable)

Chemical I Physical 100%

Inspection properties Report

Visual I Dimension & Leak Check &

Manufacturer's

Dynamic balancing 100% Inspection and

for coupling Test Records

Manufacturer's Visual I Dimension 100% Inspection and

Test Records

Load I Functional test 100% Test Report

Visual I Dimensional Manufacturer's

check up 100% Inspection and

Test Records


6-81-0059 Rev.2

Page 4 of 5

SCOPE OF INSPECTION

SUB

SUPPLIER SUPPLIER EIL/TPIA

H H R

H R R

H w R

- H -

- H H

- H R

s.

N STAGE/ACTIVITY

5.0 Painting

Painting of pump skid & associated 5.1

parts

6.0 Documentation

Stamping and review of inspection 6.1

documents, issue ofIC ( as applicable)

6.2 Review of final documentation of

supplier


FOR

DIESEL GENRATING SET

CHARACTERISTI QUANTUM cs OF CHECK

RECORD

Paint Scheme , Visual Inspection

& Paint thickness 100% check

Report

Review of documents for compliance as per 100% IC

PR. Compilation of

Dossier Idocuments as per

100% Completeness V DR attached with

PR. certificate


6-81-0059 Rev.2

Page 5 of 5

SCOPE OF INSPECTION

SUB SUPPLIER

SUPPLIER EIL/TPIA

- H R

- - H

- H H

Legend: H- Hold (Do not proceed without approval), P-Perform, RW - Random Witness (As specified or I 0% (min.I no. of each size and type of Bulk item)), R-Review, W-Witness (Give due notice, work may proceed after scheduled date).

NOTES (As applicable):

1. This document describes the generic test requirements. Any additional test or Inspection scope if specified in contract documents shall also beapplicable.(Unless otherwise agreed upon)

2. Acceptance Norms for all the activities shall be as per PO/PR/ST AN D AR DS referred there in /Job Specification I Approved Documents.


UNINTERRUPTED POWER SUPPLY (UPS) SYSTEM

SL NO


QUANTUM OF

CHECK RECORD

ACCEPTANCE NORMS




2.1

Incoming Material like Fabricated items, Thyristors/IGBTs, Battery, meters, Voltage Stabilizers, Filters, Invertors, PCBs, Relays, Transformers, Annunciators etc

Visual, Dimensional, operational checks, Manufacturer’s Test Certificates etc. as applicable

100%

TC’s/ Inspection & Test records /

Lab Test Records

As per approved drwgs/data sheet H H R


3.1 PCBs & Electronic components sub assemblies

Burn-in Test for 96 hours at 50 deg C 100% Supplier’s

Test Records

- - H R


4.1

UPS Assembly-Acceptance Tests

• Visual check including GA layout, Tag plates, Paint shade, Paint thickness , Bus Bar marking, Identification and location of components, Semi graphic scheme etc. Dimension check including Operational height, Bus Bar size, Termination arrangement, Clearances etc.

• Bill of material /Make of Components check.

100% acceptance

tests shall be


Witness

As per approved drwgs/data sheet

As per approved documents

-

H

W


UNINTERRUPTED POWER SUPPLY SYSTEM

SL NO


QUANTUM OF

CHECK RECORD

ACCEPTANCE NORMS



UPS Assembly- Acceptance Tests

(Contd.)

• Interconnection Cable check

• AC Input failure test

• AC Input return test • Simulation of parallel redundant

UPS fault • Auto-Manual Transfer of loads ,

bypass in synchronous & asynchronous modes with recording of transfer time and recovery time ( as applicable)

• Regulation test, Ripple Current

Measurement, Output Voltage waveform check.

• UPS Efficiency

witnessed by purchaser

100% by supplier and on random

basis by EIL/TPIA

Record


Witness Record

IEC62040-3 , Cl 6.6.1

IEC62040-3 ,

Cl 6.6.6

IEC62040-3 , Cl 6.6.7

IEC62040-3 , Cl 6.6.8

IEC62040-3 ,

Cl 6.6.9

IEC62040-3 , Cl 6.3.2.1/as per

Data sheet

IEC62040-3 , Cl 6.6.11/ as per

-

H

H



SL NO


QUANTUM OF

CHECK RECORD

ACCEPTANCE NORMS



• Light load test, Unbalanced Load

Test. • Fault Diagnostics- Functionality

Checks (if Applicable) • Operation of cooling fan and

control circuit tests/ Redundancy of Cooling fans.

• Synchronization test • Overload capability test • Short circuit current capability test • Short circuit fuse test

Data sheet

IEC62040-3 , Cl 6.6.12 & 13

As per data sheet

As per schematics

IEC62040-3 , Cl 6.6.5/ As per

data sheet

IEC62040-3 , Cl 6.6.18 /As per

data sheet

IEC62040-3 , Cl 6.6.19 /As per

data sheet

IEC62040-3 ,



SL NO


QUANTUM OF

CHECK RECORD

ACCEPTANCE NORMS



• Manual Restart • Output over voltage Protection • Dynamic Response in respect of

percentage dip/overshoot at output for loads throw in/off on individual invertors and bypass system.

• Check for Harmonics • Earth fault test • Audible noise test

Cl 6.6.20

IEC62040-3 , Cl 6.6.21

IEC62040-3 , Cl 6.6.22

IEC62040-3 , Cl 6.3.7.1/ As per data sheet

IEC62040-3 , Cl 6.6.26/ As per

data sheet

IEC62040-3 , Cl 6.6.27/ As per

data sheet

IEC62040-3 , Cl



SL NO


QUANTUM OF

CHECK RECORD

ACCEPTANCE NORMS



• Insulation resistance of main

circuits • High voltage test for power

circuits as applicable. • Hot Stand-by/Redundancy Checks

(as Applicable) • Check for

Redundancy/Changeover (as Applicable).

• Parallel Operation and load Sharing Verification (as Applicable).

• Check for protection against reverse trolley connection.

6.7.11/Maximum 75 DBA at one meter distance

- - - - - - -

4.2 UPS Assembly – Type Tests

Continuous full load Test for 32 hours at 0.8 pf with temp. rise measurement(8 hours each inverter on full load, 8 hours in parallel mode and 8 hours in bypass mode)

1 sample/type

Supplier’s Test Records

IEC62040-3/ As per data sheet

- H H

4.3 Submission of certificates /documents

• RFI Test . Sample/Prototype

Test Agency Reports

IEC62040-3 , Cl 6.6.25 - R R

4.4 Batteries, ACDB, Cell Booster

Visual, rating details, Acceptance test, Type test etc. (as per separately approved ITP)

As per ITP

Supplier’s Test Records /Inspection

witness

As per approved schematics/spec. H H H



SL NO


QUANTUM OF

CHECK RECORD

ACCEPTANCE NORMS



record 5.0 Painting

5.1

Painting and Packing • Visual • Suitable protection to prevent entry

of foreign material. • Proper packing to prevent any

damage during transportation and storage.

100% Packing list /


-As per DS/Spec.

- H -



• Review of Internal and Type Test Reports and MTCs

• IC issuance. 100%


- H H



8. Acceptance Norms for all the activities shall be as per latest version of relevant IS codes / Standards referred there in/ Job specifications /Approved documents


STATIONARY NICKEL CADMIUM BATTERY

SL NO

.

STAGE/ ACTIVITY CHARACTERISTICS QUANTUM




1.0 Procedures -- -- --

-- -- --


2.1

Incoming Material like Flame arrester, Electrodes used, Electrolyte , containers, Insulators, Battery stand and other accessories

Physical and Dimensional checks(as applicable),

Mechanical properties, Chemical properties of the electrolyte and

containers

100%

Sub-Supplier’s

TC / Supplier

Test Records/

Third party lab

As per Job spec./approved

drwgs/data sheet H H -


3.1 Battery assembly Visual, Dimensions, Bill of Material 100% Supplier’s

Test Records

- - H R




SL NO

.





4.1 Battery(Acceptance Tests)

• Visual

• Dimension, mass and layout check • Polarity and absence of short circuit • Test For Ah capacity • Test For voltage during discharge.

• Internal resistance test

• Dimension, Paint Shade and Paint Thickness of Battery Stands

100% witness by purchaser


IS 10918-1984,

Cl 10.2,

Cl 10.3.10.4/as per drwgs

Cl 10.5/as per

drwgs

Cl 10.7/as per Data sheet

Cl 10.11

Cl 10.3/as per data sheet

- H W

4.2 Battery Stand • Dimension, Paint Shade/thickness 100% Inspection

test records As per approved

drwgs - H R

4.3 Battery (Type Tests) • Air Pressure Test

One Sample/ Rating

Type Test Report

IS 10918-1984, - H R



SL NO

.





• Test for charge retention/ loss of

capacity. • Ampere hour and Watt-hour

efficiency test.

Cl 10.6/no leakage

Cl 10.8/As per data sheet

Cl 10.7/as per data sheet


5.1 Painting and Packing • Visual, Packing list. • Proper packing to avoid any damage

during transportation. 100% Supplier’s

records

As per DS/spec. - H -



• Review of Internal Test Reports. • IC issuance 100%

Supplier’s Test

Records / Inspection Certificate

(IC)

-

- H H



Final data folder

/Completeness

certificate

-

- H H




NOTES :-


10. Acceptance Norms for all the activities shall be as per LATEST VERSION OF RELEVENT IS CODE/ Standards referred there in/ Job specifications /Approved documents


HIGH VOLTAGE CAPACITOR BANKS


OF CHECK

ACCEPTANCE

NORMS RECORD



1.0 Procedures -- -- -- -- -- --


2.1

Incoming material like dielectric material polypropylene, Non PCB Impregnation material, Aluminum Plates and bus bars, Copper, Laminations, Paper Insulation, and major bought outs like Insulators, Bushings, Circuit Breaker, Relays Lightening Arrestor, Isolator, Discharge resistors, etc.

Physical Chemical, Dielectric properties, Purity, Review of Manufacturer's test

certificates, etc. as per relevant specifications

100%

Should be within specified

tolerance as per respective approved

documents/ PR spec./data sheet and drawings

TC’s/ Inspection

& Test

records / Lab Test Records

H H R

3.0 In process Inspection 3.1 Fabrication of Tanks for

series reactor and RVT, fabrication of Relay& Control Panels/Desk, Cable boxes

• Visual • Dimensional • Paint shade and surface finish • Cable entry, Cable lugs, Cable

Glands size, Lifting Hooks

100%

As per approved drawings/Spec. Suppliers

Test Records

-- H R





OF CHECK

ACCEPTANCE

NORMS RECORD



4.1

Capacitor Units (AcceptanceTests)

• Visual arrangement/rating plate

details • Sealing test • Test for capacitance measurement

• Insulation resistance

• DC Voltage test between terminals • AC Voltage test between terminals

and container for capacitor unit and banks.

• Test for efficacy of discharge device • Measurement of tangent of dielectric

loss angle (tan δ) • Checks for Control panel/desk

housing Circuit breaker, relays • Verify for make/ model of Relays,

Circuit breaker.

100% acceptance test shall be witnessed by supplier & purchaser

As per IS-13925 (Part-1): 1998 • As per appd

drawings • No Leak • As per Data

sht • As per

suppliers stds • Shall

withstand voltage.

• --do—

• As per data sht./drg

• --do— • As per data

sht./drg • --do--

Test Records / Inspection Witness Record

- H W

4.2 Series Reactor, RVT

• Visual

• Dimensional • Paint Shade/surface finish • Oil leakage

100% acceptable

test shall be witnessed by supplier &

IS5553 (Part3) 1990 for Series Reactor and IS3156 -1992 for RVT • As per data

sht./drg • --do— • --do— • No Leakage


H H W




OF CHECK

ACCEPTANCE

NORMS RECORD



• Measurement of Inductance, conductor resistance

• Inter turn Voltage withstand test

• Ratio check for RVT

• Dielectric tests for Reactor/RVT

purchaser • As per data sht./drg

• Shall withstand

• As per data sht./drg

• Shall withstand

4.3 Structural steel /Panel • Dimensional • Galvanizing check • Paint thickness ( in panel)

100% by supplier and on random

basis by EIL/TPIA

As per approved drawings/spec.


H H H

4.4 Type Tests

Capacitor Units: • Thermal stability tests • Capacitor loss tangent (tan δ) at

elevated temperature • Lightning impulse voltage test

between terminals and container • Short circuit discharge test

Reactors/RVT:

• Temperature rise • Lightening impulse test • Q factor measurement • Determination of errors as per

accuracy

1 Sample / Rating

As per IS-13925 (Part-1): 1998 for Capacitor Units.

IS5553 (Part3) 1990 for Series Reactor and IS3156 -1992 for RVT

Inspection witness

record/Test certificates from Test agencies

- H H/R**

5.0 Painting




OF CHECK

ACCEPTANCE

NORMS RECORD



5.1

Painting and Packing • Visual • Suitable protection to prevent entry of

foreign material. • Proper packing to prevent any damage


100%

As per approved drawings/Spec.

Packing list /


- H -


6.1 Documentation and IC • Review of Internal Test Reports &

MTCs • IC issuance.

100%

--

Supplier’s Test


- H H

** Witness if called for in job specifications. In such cases specified Type test will be considered as part of Acceptance Test.



12. Acceptance Norms for all the activities shall be as per latest relevant IS codes/ Standards referred there in/ Job specifications /Approved documents.

INSPECTION AND TEST PLAN FOR MEDIUM AND HIGH

VOLTAGE CABLES & ACCESSORIES


OF CHECK ACCEPTANCE NORMS RECORD SCOPE OF INSPECTION

SUB SUPPLIER SUPPLIER BARC

1.0 Procedures -- -- -- -- -- --


2.1

Incoming raw material like Copper,

Aluminum, PVC, XLPE, Galvanized

Armour.

Purity, Dimensions, Physical and Chemical Properties. 100%

Job spec./

IS-5831 for Insulation & Sheathing compound/,

IS8130 for Copper/Aluminum/wires

IS-3975 for GI wire Armour.

Material Test Certificate/Test Records/ Third

Party Lab certificate

H H R


3.1 Inspection during

insulation, sheathing

Spark test, thickness of insulation, Conductor Resistance 100%

As per approved drawings/data sheet/Job

spec./ IS1554

Test Records -- H

R


4.1 Finished Cable

Visual, Drum details, Size, Ends Capping, Marking on outer sheath

(such as Incremental Length, Voltage grade, manufacturer’s

name), Colour coding, etc.

100% for Drum details and Sample drums for balance details


spec./ IS1554 Test Records - H H/R**

4.2 Finished Cable(Routine Tests)

• Conductor Resistance. • High Voltage • Partial Discharge (for XLPE

only)



spec./ IS8130/IS1554

Supplier’s Test Records - H W**



4.3 Finished Cable (Acceptance tests)

• Check calibration status of all testing equipment.

• Dimension checks – overall dia, over/under armour, thickness of insulation, sheath, copper screen dimension, etc.

• Conductor Resistance • Insulation resistance /Volume

resistivity • High Voltage tests • Partial Discharge(for XLPE) • Hot Set (for XLPE insulation) • Tests on Conductor as

applicable • Tests on PVC/XLPE

Insulation & Sheath * • Armour Galvanization - dip

test • Volume resistivity, Insulation

resistance • Tensile and elongation

(without ageing )


As per approved drawings/data sheet/Job spec./IS 5831/IS8130/

IS3795 IS1554 /IS10810

Inspection Test Records

- H W**

4.4 Finished Cable (Special tests)

• Flammability test as per applicable specification.

• Accelerated water absorption test as per NEMA(Electrical method ) #

• Test for resistance to Ultra Violet Radiation #

• Oxygen Index test as per IS /IEC

Witness by purchaser on samples

As per approved drawings/data sheet/Job spec./IS 5831/ IS8130/

IS3795 IS1554 / IS10810 ASTM-D2863 for

Oxygen Index/Temp. Index

IEC-754 for Acid Gas

Inspection test records H W**



• Rodent & Termite repulsion check

• Drum length /surface finish check by re-winding

• Test for circuit integrity for fire survival cables as per IEC(If applicable )

4.5. Finished Cable (Type tests **)

• Dielectric Retention. • Type tests on PVC insulation

and Sheath • High Voltage test (Water

Immersion) • Dielectric power factor tests

as function of voltage, temperature. (XLPE cables)

• Heating cycle test (XLPE Cables)

• Impulse withstand test (XLPE cables

Witness by purchaser on samples

As per approved drawings/data sheet/Job spec./IS 5831/IS8130/

IS1554

Test Records H W

4.6 Cable accessories • Visual • Dimensions • Type tests** as per IS/IEC

Sample As per approved

drawings/data sheet Test Records H R

5.0 Painting -- -- -- -- -- -- --


6.1 Documentation and IC • Review of Routine,

Acceptance, Type test reports. • IC issuance

100%

-- Supplier TC & IC - - H



--

Final data folder


- H H

# In case TC (not older than one year) from independent test lab is available & type of compound used is same then the same may be accepted. * Hot deformation, Heat shock and Shrinkage tests on insulation & sheath (One sample/Lot) shall be witnessed by BARC, all other tests as per IS/IEC shall be carried out by supplier and test reports shall be reviewed by BARC.



** BARC will witness for HT cables only

Legends: H- Hold (Do not proceed without approval, R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work may proceed after scheduled date). NOTES :-


14. Acceptance Norms for all the activities shall be as per latest version of IS codes/ Standards referred there in/ Job specifications /Approved documents

INSPECTION AND TEST PLAN FOR COMMUNICTION &

FIRE ALARM CABLES


OF CHECK

ACCEPTANCE

NORMS RECORD



1.0 Procedures -- -- -- -- -- --


2.1

Incoming raw material like Copper Aluminium, PVC, PE, Jelly Compound, Armour material, etc.

Dimensional, Purity, Physical, Chemical Properties, Tests on jelly compound as per DOT spec.

Sample

DOT spec./ Job spec./

IS-5831 for Insulation &

Sheathing compound/, IS8130 for

Copper/Aluminum/wires

IS-3975 for GI wire Armour.

Sub supplier

TC/Supplier’s Test

Records/ Third party

Lab

H H -


3.1 Manufacturing Stage Dimensions at various stages, Spark test, Stage Inspection 100%

As per approved drawings/data sheet/DOT spec./Job spec.

Supplier’s Test

Records - H -


4.1 Final Inspection on completed cable

Visual, Drum details, Size, Ends Capping, Drums Condition, Marking on outer sheath (such as incremental length, voltage grade, manufacturer’s name and for

100%

As per approved drawings/data

sheet/DOT spec./Job spec.


- H RW


FIRE ALARM CABLES


OF CHECK

ACCEPTANCE

NORMS RECORD



jelly filled cables marking as per DOT spec), Colour coding of cores, etc.

4.2

Final Inspection on completed Cable(Jelly Filled Cables) Acceptance Test

• Dimension checks. • Test for insulation and

sheath. • Continuity of

conductors, absence of crossed pairs and absence of contact with poly-al tape

• Continuity in poly-al tape

• Colour coding • Conductor Resistance,

Resistance Unbalance in pair.

• Mutual capacitance (pair/average), Capacitance Unbalance (pair to ground and pair to pair)

• Cross talk • Attenuation • Drip test

Witness by purchaser

DOT spec./ approved

drawings/data sheet/Job spec./IS

5831/ IS8130/ IS3795

BS EN:50288(Pt7) / IS10810


- H W


FIRE ALARM CABLES


OF CHECK

ACCEPTANCE

NORMS RECORD



• Dielectric Strength • Insulation Resistance • Conductor Annealing • Armour Galvanization • Overall finish and Drum

length by re-winding

4.3

Final Inspection on completed Cable(Jelly Filled Cables) Type Tests

• Type tests on insulated conductors, compatibility of Insulation and filling compound as per DOT spec.

• Type tests on Composite sheath and Jacket as per DOT spec

• Oxygen index test • Water Penetration test • Cable bend test.

One Sample Witness by purchaser

DOT spec./ approved


5831/ IS8130/ IS3795

BS EN:50288(Pt7) ASTM-D2863 for

Oxygen Index/Temp.

Index

Supplier’s Test

Records - H W

4.4

Final Inspection on completed Cable( Non Jelly Filled Cables ) Acceptance Test

• Dimension checks • Continuity of conductors • Colour code • Overlap in poly-al tape

and drain wire resistance (if shielding specified)

• Conductor Resistance. • Mutual capacitance

(pair/average), Capacitance Unbalance



- H W


FIRE ALARM CABLES


OF CHECK

ACCEPTANCE

NORMS RECORD



(pair to ground and pair to pair) for communication cables

• Dielectric Strength • Insulation Resistance /

Volume Resistivity. • Tensile and Elongation

(without ageing) • Conductor Annealing • Armour Galvanization • Tests on Insulation and

sheath as per IS/IEC

DOT spec./ As per approved


5831/ IS8130/ IS3795

BS EN:50288(Pt7)

4.5

Final Inspection on completed Cable( Non Jelly Filled Cables ) Special Test

• Oxygen Index Test • Flammability test as per

applicable specification • Test for Rodent &

termite repulsion • Surface finish and drum

length check by wiring


DOT spec./ As per approved

drawings/data sheet/Job spec./

BS EN:50288(Pt7) / IS10810 Part 61

& 62 or IEC60332-3 Cat-

A for Flammability test. ASTM-D2863 for

Oxygen Index/Temp.

Index


- H W


FIRE ALARM CABLES


OF CHECK

ACCEPTANCE

NORMS RECORD



4.6

Final Inspection on completed Cable( Non Jelly Filled Cables ) Type Tests

• Type test on conductor as per spec

• Type tests on insulation and Sheath as per spec



sheet/DOT spec./Job spec./IS

5831/IS8130/ BS EN:50288(Pt7)

Supplier’s Test

Records - H W

5.0 Painting



• Review of Internal Test Reports and MTCs.

• IC issuance -

-

Supplier’s Test


(IC)

- H H

6.2 Final Document submission Compilation of Inspection

reports ,drawings, etc as per VDR / PR

100%

-

Final data folder

/Completeness

certificate

- H H

* - Thermal Stability, Hot deformation, Heat shock and Shrinkage tests on insulation and sheath shall be witnessed by BARC (One Sample/Lot), all other tests as per IS-5831 shall be carried out by supplier and test reports shall be reviewed by BARC

Legends: H- Hold (Do not proceed without approval, R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of


FIRE ALARM CABLES

each type), W- Witness (Give due notice, work may proceed after scheduled date). NOTES :-


16. Acceptance Norms for all the activities shall be as per latest version of IS code/ Standards referred there in/ Job specifications /Approved documents


LIGHTNING ARRESTORS


OF CHECK

ACCEPTANCE

NORMS RECORD



1.0 Procedures -- -- -- -- -- --


2.1

Incoming Material like Porcelain bushings, aluminium castings, gaskets, O-rings, springs, pressure release diaphragm, grading rings, bumpers, sheet metal pressed components, etc.

• Operational check • Tensile, compressive, flextural and

bonding strength of materials, wherever applicable.

• Electrical acceptance tests for electrical components.

100% by Supplier

As per drawings

/data sheet /IEC-62305-5; IS 4004-1985;

IEC-15086

Material Test Certificates H H R


3.1 Lightning Arrestor assembly • Visual, Dimensional and Bill of

material 100% by supplier

IEC-99-4 Supplier’s test records - H -


As per approved

drawings/data sheet


LIGHTNING ARRESTORS


OF CHECK

ACCEPTANCE

NORMS RECORD




• Visual and Dimensional checks. • Check calibration status of all

testing equipment. • Bill of Material • Lightning impulse residual voltage. • Reference voltage test • PD test • Sealing test • Galvanizing test • Uniformity and weight of Zinc coating • Counter operation check and meter operation check of Surge monitors, wherever applicable. • Current distribution test for multi colum arrester.

100% by supplier and

100%-witness by purchaser

IEC-62305-1 IEC-62305-3 IEC-62305-5

IEC-15086-5:2001 &

IEC-99-4

Supplier’s Test Records and


- H W

4.2 Type Test

• Type test certificates • Housed Arresters

a)Temperature cycle test b) Porosity test

● Operating Duty Test ● Long duration current Impulse withstand test. ● Partial discharge test Insulation Coordination. ● Pf Voltage Vs Time characteristics • Certificate for fireproof rating.

Prototype for each model

IEC-99-4

IS-3070 IS-2165 Type Test

Certificates - H R


LIGHTNING ARRESTORS


OF CHECK

ACCEPTANCE

NORMS RECORD



5.0 Painting

5.1 Painting and Packing • Visual. • Suitable protection to prevent

entry of foreign material. • Proper packing to prevent any

damage during transportation.

100%


sheet Test records

-

H --



• Internal test records • Issuance of IC

100%

--

Internal test reports & Inspection Certificate

- H H

6.2 Final Document submission Compilation of Inspection reports ,drawings, etc as per VDR / PR 100%

--

Final data folder


- H H

- Supplier to submit internal test reports, type test reports before offering items for Inspection to BARC.

Legends: H- Hold (Do not proceed without approval, R-Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work may proceed after scheduled date). NOTES :-


LIGHTNING ARRESTORS


18. Acceptance Norms for all the activities shall be as per LATEST VERSION of IS codes/ Standards referred there in/ Job specifications /Approved documents

inspection and test plan for dry type lighting transformer

Documents

Transcript of inspection and test plan for dry type lighting transformer