TManual Chapter 04

Transcript of TManual Chapter 04

8/19/2019 TManual Chapter 04

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POWER TRANSFORMER - STANDARDISATION MANUAL 163

Chapter - 4

STANDARD MANUFACTURING QUALITY PLAN (MQP)

Working Group Members

Mr. S. K. Negi - GETCO

Mr. M. M. Goswami - POWERGRID

Mr. Y. V. Joshi - GECO

Mr. Krishnan - Mahindra Intertrade

Mr. Gautam Bhatia - ENPAY

Mr. Baghel - ATSA Conductors

Mr. Bharat Tolia - Bharat Corrub

Mr. R S Thakkar - GETCO

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CHAPTER - 4

STANDARD MANUFACTURING QUALITY PLAN (MQP)

It is a contract document between customer and supplier to express commitment for delivery of transformer as per

agreed technical specification and match the type tested design.

Over a period of time as the transmission grid has grown leaps and bounds, with HVDC and 765 kV AC network,

this commitment document is gaining importance, because of rise in transformer failure rate and causing anxiety to

maintain uninterrupted supply for consumer and industry. Customer always wishes that transformer manufactured

and delivered must perform defect free service for its “specified design life”. It is always a challenge for supplier

(manufacturer) to keep consistency in material used and manufacturing process, which are the main cause for variation

in quality of transformer. While customer practically cannot monitor them and not expected to do so, manufacturersare on their toes to offer cost competitive and cost effective product. The cost of material plays an important role,

considering the fact that majority of parts and components like bushing, OLTC, tank body, radiators, insulation, copper,

core material etc. are outsourced. The selection of material, its grades / type and design philosophy ultimately decide

the loss capitalization figures of final product. On the manufacturing process front, seamless integration of parts

/ components through mechanical and electrical design is the prerequisite. The change in sub-venders and skilled

manpower time to time at factory also require due diligence to control and maintain the consistency of manufacturing

process. Therefore a “balanced view“ is needed to manufacture and deliver ideal Transformer meeting contract

specification and match type tested design.

It is evident from above background that there is need of mutually agreed manufacturing quality plan (MQP). Apart

from primary objective to have ideal transformer as per customer wish as explained above, the major benefit of MQP

would be timely delivery and any conflict shall be address upfront, so that manufacturing could take place uninterruptedin a faithful manner. The role of design review is important to provide all necessary inputs for structuring the MQP.

It is proposed in this power transformer standardisation manual to have MQP covering following elements:

1. Material quality and characteristics.

2. Stage inspection of material.

3. Stage inspection and manufacturing process.

4. Routine and Acceptance tests.

5. To capture “Signature values “.

6. Product dimension and physical condition before dispatch.

It is equally very important that Transformer is manufactured in a dust free clean environment with humidity control.

Any compromise on this aspect will have adverse effect in expected design life of Transformer, however good is the

quality of material used.

Standard Manufacturing Quality Plan (MQP) has been designed in a manner to share the responsibility depending upon

the source of supply, testing, location and criticality of test for the performance of Transformer. Responsibility of sub-

vendor is important for testing of raw material and components (P), but manufacturer has to play a role of verification

(V) as they have to integrate them for actual design of transformer. Similarly, responsibility of manufacturer is crucialfor routine tests (P) but customer has to actively witness (W) these tests to ensure that results are complying the

contract requirements and design review data.

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   S  r .    N  o .

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5/20


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6/20


   S  r .    N  o .



   S  a  m  p   l   i  n  g

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    (   e    )    B    i    l    l   o    f    E   n   t   r   y

   C   h  e  c   k  p  o   i  n  t  s  :

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2 .    C   u   t   t    i   n   g    B   u   r   r

    3 .    B   e   n    d    /    D   u   c   t    i    l    i   t   y   t   e   s   t

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5    A   g    i   n   g   t   e   s   t    (   t   y   p   e   t   e   s   t    )

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   g    f   a   c   t   o   r

    E   a   c    h    L   o   t

    O   n   e   s   a   m   p    l   e

   p   e   r    l   o   t

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    A   s   p   e   r   a   p   p   r   o   v   e    d    d   e   s    i   g   n

1 .    V    i   s   u   a    l    l   y    d   e    f   e   c   t    f   r   e   e ,   a   s   p   e   r    d   e   s    i   g   n

    r   e   q   u    i   r   e   m   e   n   t

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    P

    V

  -  -

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  -  -

    P

    V

    *    C   a   t   e   g




    W   -


   t

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   S  r .    N  o .



   S  a  m  p   l   i  n  g

  r  a  t  e

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    P   r   e   s   s    B   o   a   r    d

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   s    i   o   n   a    l   c    h   e   c    k ,   t    h    i   c    k   n   e   s   s ,

    w    i    d   t    h    &    l   e   n   g   t    h

    / .

    2 .    A   p   p   a   r   e   n   t    D   e   n   s    i   t   y

3 .    C   o   m   p   r   e   s   s    i    b    i    l    i   t   y    C

4 .    R   e   v   e   r   s    i    b    l   e   p   a   r   t    C   o   m   p   r   e   s   s    i    b    i    l    i   t   y

5 .    O    i    l    A    b   s   o   r   p   t    i   o   n

6 .    M   o   s    i   t   u   r   e    C   o   n   t   e   n   t

    7 .    S    h   r    i   n    k   a   g   e    M    D ,

    C    D    &    P    D

8 .   p    H   o    f   a   q   u   e   o   u   s

   e   x   t   r   a   c   t

    9 .   c   o   n    d   u   c   t    i   v    i   t   y   o    f

   a   q   u   e   o   u   s   e   x   t   r   a   c   t

1    0 .    E    l   e   c   t   r    i   c    S   t   r   e   n

   g   t    h    i   n    A    i   r

1    1 .    E    l   e   c   t   r    i   c    S   t   r   e   n   g

   t    h    i   n    O    i    l

1    2 .    A   s    h    C   o   n   t   e   n   t

1    3 .    E    l   o   n   g   a   t    i   o   n    M

    D ,    C    D

1    4 .    T   e   n   s    i    l   e   s   t   r   e   n   g

   t    h    M    D ,    C    D

    1    5 .    P    l   y    B   o   n    d    R   e   s    i   s   t   a   n   c   e

    1    6 .    F    l   e   x   u   r   a    l   s   t   r   e   n

   g   t    h    M    D ,    C    D    (    L   a   m    i   n   a   t   e    d

    B   o   a   r    d   s    )

    O   n   e   s   a   m   p    l   e

   o    f   e   a   c    h   s    i   z   e

   p   e   r    l   o   t

    I    E    C    6    0    6    4    1  -

    3  -    1    I    E    C    6    0    6    4    1  -    2 ,

    M   e   t    h   o    d   s   o    f

    T   e   s   t

    (    1    )    N   o   s   u   r    f   a   c   e    d   e    f   e   c   t   s

(    2    )    U   p   t   o    1 .    6   m   m    T    K  -    1 .    0  -    1 .    2

   >    1 .    6  -    3   m   m    T    K  -    1 .    1  -    1

.    2    5

   >    3  -    3 .    6   m   m    T    K  -    1 .    1    5  -    1 .    3    0

   >    6  -    8   m   m    T    K  -    1 .    2  -    1 .    3

    (    3    )    U   p   t   o    1 .    6  -    1    0    %   ;   >    1 .    6  -    3   m   m  -    7 .    5    %

   >    3  -    3 .    6   m   m

  -    5    %   ;   >    6  -    8   m   m    T    K  -    4    %

    (    4    )    U   p   t   o    1 .    6  -    4    5    %   ;   >    1 .    6  -    3   m   m  -    5    0    %

   >    3  -    3 .    6   m   m

  -    5    0    %   ;   >    6  -    8   m   m    T    K  -    5    0    %

    (    5    )    U   p   t   o    1 .    6   m   m    T    K  -    1    1

   m    i   n

   >    1 .    6  -    3   m   m    T    K  -    9   m

    i   n

   >    3  -    3 .    6   m   m    T    K  -    7   m    i   n

   >    6  -    8   m   m    T    K  -    7   m    i   n

    (    6    )    6    %   m   a   x

    (    7    )    M    D  -    0 .    5    %

   m   a   x ,    C    D

  -    0 .    7    %   m   a   x ,    T    h    i   c    k  -    5

    %   m   a   x

    (    8    )    6  -    9    f   o   r   s   o    l    i    d    b   o   a   r    d   s

    (    9    )    U   p   t   o    1 .    6  -    5   m   a   x    (   m

    S    /   m    )

   >    1 .    6  -    3   m   m  -    6   m   a   x ,   >    3  -    3 .    6   m   m

  -    8   m   a   x

   >    6  -    8   m   m    T    K  -    8  -    1    0

   m   a   x

    (    1    0    )    U   p   t   o    1 .    6  -    1    2    k    V    /   m   m

   >    1 .    6  -    3   m   m  -    1    1    k    V    /   m   m

   >    3  -    3 .    6   m   m

  -    1    0    k    V

    /   m   m

   >    6  -    8   m   m    T    K  -    9    k    V    /   m   m

    (    1    1    )    U   p   t   o    1 .    6  -    4    0    k    V    /   m

   m

   >    1 .    6  -    3   m   m  -    3    5    k    V    /   m   m

   >    3  -    3 .    6   m   m

  -    3    0    k    V

    /   m   m

   >    6  -    8   m   m    T    K  -    3    0    k    V    /   m   m

    (    1    2    )    1    %   m   a   x    i   m   u   m

    M    D

    C    D

    (    1    3    )    U   p   t   o    1 .    6  -    3    %

    4

    %

   >    1 .    6  -    3   m   m  -    3    %

    4

    %

   >    3  -    3 .    6   m   m

  -    3    %    4

    %

   >    6  -    8   m   m    T    K  -    3    %

    4    %

    P

    V

    V

    *    C   a   t   e   g




    W   -


   t

    *    *    *    T    C  -  -  -    T   e   s   t    C   e   r   t    i    f    i   c   a   t   e

    P    D  -  -   >    P   e   r   p   e   n    d    i   c   u    l   a

   r    D    i   r   e   c   t    i   o   n

    C    D  -  -   >    C   r   o   s   s    D    i   r   e   c   t    i   o

   n

8/20


   S  r .    N  o .



   S  a  m  p   l   i  n  g

  r  a  t  e

   R  e   f  e  r  e  n  c  e   /

   S  t  a  n   d  a  r   d


   C  a  t  e  g  o  r  y  o


   S  u   b

   V  e  n   d  o  r

   M  a  n  u   f  -

  a  c

  t  u  r  e  r

   C  u  s  t  o  m  e  r

    5

    P   e   r   m   a   w   o   o    d


   s    i   o   n   a    l   c    h   e   c    k ,   t    h    i   c    k   n   e   s   s ,

   w    i    d   t    h    &    l   e   n   g   t    h .

    2 .    D   e   n   s    i   t   y

    3 .    M   o    i   s   t   u   r   e   c   o   n   t   e   n   t

    4 .    O    i    l    A    b   s   o   r   p   t    i   o   n

   a   t    9    0    °    C

    5 .    E    l   e   c   t   r    i   c    S   t   r   e   n   g

   t    h   a   t    9    0    °    C

    6 .    T   e   n   s    i    l   e   s   t   r   e   n   g   t    h

    7 .    C   o   m   p   r   e   s   s    i   v   e   s   t   r   e   n   g   t    h   t   e   s   t

    8 .    S    h   e   a   r   s   t   r   e   n   g   t    h

   a   g   e  -   w    i   s   e

    9 .    T    h    i   c    k   n   e   s   s

    O   n   e   s   a   m   p    l   e

   o    f   e   a   c    h   s    i   z   e

   p   e   r    l   o   t

    I    S    3    5    1    3

    I    S    1    7    0    8

    I    S    1    7    3    6

    I    S    1    9    9    8

    1 .    S    h   a    l    l    b   e    f   r   e   e    f   r   o   m   s   u   r    f   a   c   e    d   e    f   e   c   t

2 .    0 .    8   t   o    1 .    3   g   m    /   c   c

    3 .    M   a   x    7    %

    4 .    M    i   n    5    %

    5 .    M    i   n    6    0    K    V

    6 .    M    i   n    f   o   r    L    D  -    7    0    0    K    V    /   c   m    2

    7 .    M    i   n    f   o   r    L    D  -    1    4    0    0    K    V

    /   c   m    2

    8 .    M    i   n    f   o   r    L    D  -    4    5    0    K    V    /   c   m    2

    9 .    T    h    i    k   n   e   s   s    (   m   m    )

    T   o    l   e   r   a   n   c   e    (   +    /  -   m   m    )

    1    0   t   o    2    5

  -

    1 .    2

    2    6   t   o    5    0

  -

    1 .    4

    5    1   t   o    1    5    0

  -

    2 .    0

    P

    V

  -  -

    6

    P   o   r   c   e    l   a    i   n    B   u   s    h    i   n   g   s

    (    H   o    l    l   o   w    )


   s    i   o   n   a    l   c    h   e   c    k .

    2 .    P   o   w   e   r    f   r   e   q   u   e   n

   c   y   v   o    l   t   a   g   e   w    i   t    h   s   t   a   n    d   t   e   s   t

    1    0    0    %

    A   s   p   e   r    I    S    /

    I    E    C

    I    S    2    0    9    9

    1 .    A   s   p   e   r   a   p   p   r   o   v   e    d    d   r   a   w    i   n   g .

    2 .    A   s   p   e   r    I    S    2    0    9    9

    P

    V

  -  -

    7

    P   o    l   y   s   t   e   r    R   e   s    i   n

    I   m   p   r   e   g   n   a   t   e    d    G    l   a   s   s

    F    i    b   r   e    T   a   p   e

    1 .    V    i   s   u   a    l    C    h   e   c    k

    2 .    V   e   r    i    f    i   c   a   t    i   o   n   o    f

   s    h   e    l    f    l    i    f   e

    3 .    T    h    i   c    k   n   e   s   s

    4 .    W    i    d   t    h

    5 .    T   e   n   s    i    l   e    S   t   r   e   n   g   t    h

    6 .    R   e   s    i   n    C   o   n   t   e   n   t

    7 .    S   o    f   t   e   n    i   n   g   p   o    i   n

   t   o    f   r   e   s    i   n

    E   a   c    h    l   o   t

    I    S    1    5    2    0    8

    1 .    F   r   e   e    f   r   o   m   v    i   s   u   a    l    d   e    f   e

   c   t

    2 .    1    2   m   o   n   t    h   s

    3 .    0 .    2    5   t   o    0 .    3    5   m   m    (       ±     0

.    0    7    )

    4 .    2    0   t   o    5    0   m   m    (       ±     2

    )

    5 .    M    i   n    2    0    0    N    /   m   m

    6 .    2    7    (       ±     3

    %    )

    7 .    M   a   x    2    0    0    °    C

    P

    V

  -  -

    8

    S   y   n   t    h   e   t    i   c    R   u    b    b   e   r

    B   o   n    d   e    d    C   o   r    k   s    h   e   e   t

    (    S    R    B    C    )

    1 .    V    i   s   u   a    l   c    h   e   c    k ,   t    h    i   c    k   n   e   s   s ,    l   e   n   g   t    h ,   w    i    d   t    h

    2 .    H   a   r    d   n   e   s   s

    3 .    C   o   m   p   r   e   s   s    i   o   n   s

   e   t

    4 .    S    i    d   e    f    l   o   w   u   n    d   e

   r   c   o   m   p   r   e   s   s    i   o   n


    6 .    F    l   e   x    i    b    i    l    i   t   y

7 .    C   o   m   p   r   e   s   s    i    b    i    l    i   t   y

    8 .    R   e   c   o   v   e   r   y

    9 .    A   g    i   n   g    i   n    O    i    l  -    F    i   n

    i   s    h ,    F    l   e   x    i    b    i    l    i   t   y    &   c    h   a   n   g   e

     i   n   v   o    l   u   m   e

    1    0 .    P    h   v   a    l   u   e

    O   n   e   s   a   m   p    l   e

   p   e   r    l   o   t

    I    S    4    2    5    3

    1 .    F   r   e   e    f   r   o   m   s   u   r    f   a   c   e    d   e

    f    f   e   c   t

    2 .    7    0       ±     1

    0    I    R    H    D

    3 .    8    5    %   m   a   x

    4 .    N    A

    5 .    1    5    5    0    k   p   a    (   m    i   n    )

    6 .    S    h   o   u    l    d    b   e   s   a   t    i    f   a   c   t   o   r   y   w    h   e   n    b   e   n   t   t    h   o   u   g    h

     1    8    0    0   r   o   u   n    d   t    h   e   m   a   t   e   r    i   a    l   o    f    d    i   a   m   e   t   e   r   t    h   r   e   e

    t    i   m   e   s   t    h   e   t    h    i   c    k   n   e   s   s   o    f   s   p   e   c    i   m   e   n .

    7 .    2    5  -    3    5    %

    8 .    8    0    %   m    i   n

    9 .    C    h   a   n   g   e    i   n   v   o    l   u   m   e    1    5

    %   m   a   x    f   o   r    7    0    h   o   u   r   s   a   t

     1    0    0    d   e   g   c    i   n   o    i    l

    1    0 .    5  -    8 .    5

    P

    V

  -  -

    *    C   a   t   e   g




    W   -


   t

9/20


   S  r .    N  o .



   S  a  m  p   l   i  n  g

  r  a  t  e

   R  e   f  e  r  e  n  c  e   /

   S  t  a  n   d  a  r   d


   C  a  t  e  g  o  r  y  o


   S  u   b

   V  e  n   d  o  r

   M  a  n  u   f  -

  a  c

  t  u  r  e  r

   C  u  s  t  o  m  e  r

    9

    C   o   n    d   e   n   s   e   r    B   u   s    h    i   n   g

    R   o   u   t    i   n   e    T   e   s   t

    (    1    )    M   e   a   s   u   r   e   m   e   n   t

   o    f    d    i    l   e   c   t   r    i   c    d    i   s   s    i   p   a   t    i   o   n

     f   a   c   t   o   r   a   n    d   c   a   p

   a   c    i   t   a   n   c   e

    (    2    )    D   r   y   p   o   w   e   r    f   r   e   q   u   e   n   c   y   v   o    l   t   a   g   e   w    i   t    h   s   t   a   n    d

    t   e   s   t

    (    3    )    M   e   a   s   u   r   e   m   e   n   t

   o    f   p   a   r   t    i   a    l    d    i   s   c    h   a   r   g   e

    (    4    )    P   r   e   s   s   u   r   e   t   e   s   t

    (    5    )    T    i   g    h   t   n   e   s   s   t   e   s   t

    (    6    )    C   r   e   e   p   a   g   e    d    i   s   t

   a   n   c   e

    (    7    )    V    i   s   u   a    l    &    d    i   m   e   n   s    i   o   n   a    l   c    h   e   c    k

    1    0    0    %

    I    S    2    0    9    9

    I    E    C    6    0    1    3    7

1 .    T   a   n    D   e    l   t   a  -    6    6    k    V  -    0 .    7    %

     A    b   o   v   e    6    6    k    V  -    0 .    4    %

    2 .    A   s   p   e   r   a   p   p   r   o   v   e    d    G    T    P

3 .    A   s   p   e   r    I    E    C  -    N   o    f    l   a   s    h  -   o   v   e   r    /   p   u   n   c   t   u   r   e

    4 .    N   o    l   e   a    k   a   g   e


    6 .    A   s   p   e   r   a   p   p   r   o   v   e    d    G    T    P

    7 .    A   s   p   e   r   a   p   p   r   o   v   e    d    d   r   a   w

    i   n   g

    P

    P    V V V V V V

    W  -  -   -  -   -  -   -  -    W W

    1    0

    B   u   c    h    h   o    l   z    R   e    l   a   y

    1 .    T   y   p   e    &   m   a    k   e

    2 .    P   o   r   o   s    i   t   y

    3 .    H    i   g    h   v   o    l   t   a   g   e

    4 .    I   n   s   u    l   a   t    i   o   n   r   e   s    i   s   t   a   n   c   e

    5 .    E    l   e   m   e   n   t   t   e   s   t

6 .    G   a   s   v   o    l   u   m   e   t   e   s   t   a   t    5    °   a   s   c   e   n    d    i   n   g   t   o   w   a   r    d   s

    c   o   n   s   e   r   v   a   t   o   r

7 .    L   o   s   s   o    f   o    i    l    &    S   u

   r   g   e   t   e   s   t

    1    0    0    %

    I    S    3    6    3    7

    1 .    A   s   p   e   r   a   p   p   r   o   v   e    d    d   r   a   w    i   n   g


    3 .    2    K    V    f   o   r    1   m    i   n .   w    i   t    h   s

   t   a   n    d

    4 .    M    i   n    1    0    M      Ω     b   y    5    0    0    V

    D    C   m   e   g   g   e   r

    5 .    N   o    l   e   a    k   a   g   e   a   t    1 .    7    5    K

   g    /   c   m    2    o

    i    l   p   r   e   s   s   u   r   e    f   o   r

     1    5   m    i   n   s

    6 .    G    O    R  -    1   :    9    0   t   o    1    6    5    C    C

     G    O    R  -    2   :    1    7    5   t   o    2    2    5    C    C

     G    O    R  -    3   :    2    0    0   t   o    3    0    0

    C    C

    7 .    G    O    R  -    1   :    7    0   t   o    1    3    0    C    C

     G    O    R  -    2   :    7    5   t   o    1    4    0    C    C

     G    O    R  -    3   :    9    0   t   o    1    6    0    C

    C

    P

    V

  -  -

    1    1

    B    i   m   e   t   a    l    l    i   c    T   e   r   m    i   n   a    l

    C   o   n   n   e   c   t   o   r

    1 .    D    i   m   e   n   s    i   o   n   a    l

    2 .    V    i   s   u   a    l   c    h   e   c    k


    4 .    R   e   s    i   s   t   a   n   c   e

    1    0    0    %

    I    S    5    5    6    1


    2 .    F   r   e   e    f   o   r   m    d   e    f   e   c   t   s

    3 .    A   s   p   e   r   t   y   p   e   t   e   s   t   r   e   p   o

   r   t

    4 .    A   s   p   e   r   t   y   p   e   t   e   s   t   r   e   p   o

   r   t

    P

    V

  -  -

    1    2

    M   a   r   s    h   a    l    l    i   n   g    B   o   x

    1 .    D    i   m   e   n   s    i   o   n    &    V

    i   s   u   a    l   c    h   e   c    k

    2 .    2    k    V   t   e   s   t    f   o   r    A   u

   x    i    l    l   a   r   y   w    i   r    i   n   g

    3 .    P   a    i   n   t   s    h   a    d   e    &    T    h    i   c    k   n   e   s   s

    4 .    W    i   r    i   n   g   r   o   u   t    i   n   g

   c    h   e   c    k

    5 .    F   u   n   c   t    i   o   n   a    l    C    h   e

   c    k

    1    0    0    %

    A   p   p   r   o   v   e    d

    d   r   a   w    i   n   g

   a   n    d   s   p   e   c    i  -

    f    i   c   a   t    i   o   n


    2 .    1   m    i   n   w    i   t    h   s   t   a   n    d


    4 .    F    i   r   m   a   n    d   a   e   s   t    h   e   t    i   c


    P

    V

  -  -

    1    3

    R   e   m   o   t   e    T   a   p

    C    h   a   n   g   e   r    C   o   n   t   r   o    l

    C   a    b    i   n   e   t

    1 .    D    i   m   e   n   s    i   o   n    &    V

    i   s   u   a    l    C    h   e   c    k

    2 .    2    k    V   t   e   s   t    f   o   r    A   u

   x    i    l    l   a   r   y   w    i   r    i   n   g

    3 .    P   a    i   n   t   s    h   a    d   e    &    T    h    i   c    k   n   e   s   s

    4 .    W    i   r    i   n   g   r   o   u   t    i   n   g

   c    h   e   c    k

    5 .    F   u   n   c   t    i   o   n   a    l    C    h   e

   c    k

    6 .    V   e   r    i    f    i   c   a   t    i   o   n   o    f

    B   o    Q

    1    0    0    %

    A   p   p   r   o   v   e    d

    d   r   a   w    i   n   g

   a   n    d   s   p   e   c    i  -

    f    i   c   a   t    i   o   n


    2 .    1   m    i   n   w    i   t    h   s   t   a   n    d


    4 .    F    i   r   m   a   n    d   a   e   s   t    h   e   t    i   c



    P

    P

  -  -

    *    C   a   t   e   g




    W   -


   t

10/20


   S  r .    N  o .



   S  a  m  p   l   i  n  g

  r  a  t  e

   R  e   f  e  r  e  n  c  e   /

   S  t  a  n   d  a  r   d


   C  a  t  e  g  o  r  y  o


   S  u   b

   V  e  n   d  o  r

   M  a  n  u   f  -

  a  c

  t  u  r  e  r

   C  u  s  t  o  m  e  r

    1    4

    A    i   r   c   e    l    l    (    F    l   e   x    i    A    i   r

    S   e   p   a   r   a   t   o   r    )

    1 .    M   a    k   e ,    V    i   s   u   a    l    &

    D    i   m   e   n   s    i   o   n   s

    2 .    P   r   e   s   s   u   r   e   t   e   s   t   a   t    0 .    1    0    5    K   g    /   c   m    2

    3 .    1    0   t    i   m   e   s    i   n    f    l   a   t    i   o   n   a   n    d    d   e    f    l   a   t    i   o   n   t   e   s   t   a   t

     0 .    1    0    5    K   g    /   c   m    2

    1    0    0    %

    I    S    3    4    0    0

    1 .    A   s   p   e   r   a   p   p   r   o   v   e    d    d   e   a

   w    i   n   g

    2 .    N   o    l   e   a    k   a   g   e    f   o   r    2    4    h   o

   u   r   s

    3 .    N   o    d   e    f   o   r   m   a   t    i   o   n

    P

    P

  -  -

    1    5

    R   o    l    l   e   r    A   s   s   e   m    b    l   y

    1 .    V    i   s   u   a    l    &    D    i   m   e   n

   s    i   o   n   s .

    2 .    M   e   c    h .    P   r   o   p   e   r   t    i   e   s    &    C    h   e   m    i   c   a    l

    c   o   m   p   o   s    i   t    i   o   n   o    f   r   a   w   m   a   t   e   r    i   a    l   u   s   e    d    f   o   r

    s    h   a    f   t    &   r   o    l    l   e   r    f   o   r   g    i   n   g

    O   n   e   s   a   m   p    l   e

   p   e   r   m   e    l   t    /

    h   e   a   t

   t   r   e   a   t   m   e   n   t

    b   a   t   c    h

    I    S    8    5    0    0

    1 .    F   r   e   e    f   r   o   m   s   u   r    f   a   c   e    d   e

    f   e   c   t

    2 .    F   o   r   s    h   a    f   t   a   s   p   e   r    M    S    E

    N    8 ,    B    S    9    7    0  -    1

     F   o   r   r   o    l    l   e   r   w    h   e   e    l   o    f   c   a

   s   t    i   r   o   n    I    S    2    1    0

     F   o   r   r   o    l    l   e   r   w    h   e   e    l   o    f    C   a

   s   t   s   t   e   e    l    I    S    1    0    3    0

    P

    V

  -  -

    1    6

    O    i    l    &   w    i   n    d    i   n   g

    T   e   m   p   e   r   a   t   u   r   e

    I   n    d    i   c   a   t   o   r

    1 .    T   y   p   e    &   m   a    k   e

    2 .    C   a    l    i    b   r   a   t    i   o   n

    3 .    2    k    V    H    V   t   e   s   t    f   o   r    1   m    i   n    b   e   t   w   e   e   n

    a    l    l   t   e   r   m    i   n   a    l   s    &

   e   a   r   t    h

    3 .    S   w    i   t   c    h   c   o   n   t   a   c   t   o   p   e   r   a   t    i   o   n   t   e   s   t

    1    0    0    %

  -  -


    2 .

       ±     1 .    5    %   o    f    F    S    D

    3 .    W    i   t    h   s   t   a   n    d    f   o   r    1   m    i   n

    4 .   o   p   e   r   a   t    i   o   n   w    i   t    h    i   n       ±     2

    °    C   o    f   s   e   t   t    i   n   g

    P

    P

  -  -

    1    7

    P   r   e   s   s   u   r   e    R   e    l    i   e    f

    D   e   v    i   c   e

    1 .    T   y   p   e    &    M   a    k   e

    2 .    O   p   e   r   a   t    i   n   g   a    i   r   p

   r   e   s   s   u   r   e

    3 .    S   w    i   t   c    h    /   c   o   n   t   a   c

   t   t   e   s   t    i   n   g

    4 .    H    V   t   e   s   t

    1    0    0    %

    I    S    2    5    0    0

    1 .    A   s   p   e   r   a   p   p   r   o   v   e    d    d   r   a   w    i   n   g    &    f   r   e   e    f   r   o   m    d   e    f   e   c   t


    3 .    S   a   t    i   s    f   a   c   t   o   r   y   o   p   e   r   a   t    i   o

   n   a   t   p   r   e   s   s   u   r   e   r   e    l   e   a   s   e

    4 .    2    k    V   w    i   t    h   s   t   a   n    d    f   o   r    1

   m    i   n

    P

    P

  -  -

    1    8

    M   a   g   n   e   t    i   c    O    i    l    L   e   v   e    l

    G   a   u   g   e    (    M    O    G    )

    1 .    T   y   p   e    &   m   a    k   e

    2 .    D    i   a    l    C   a    l    i    b   r   a   t    i   o   n    f   o   r    l   e   v   e    l

    3 .    2    k    V    H    V   t   e   s   t    f   o   r    1   m    i   n    b   e   t   w   e   e   n

    a    l    l   t   e   r   m    i   n   a    l    &   e

   a   r   t    h

    4 .    L   e   a    k   t   e   s   t

    5 .    S   w    i   t   c    h    /   c   o   n   t   a   c

   t   o   p   e   r   a   t    i   o   n   t   e   s   t

    1    0    0    %

  -  -


    2 .    C    h   e   c    k   p   o    i   n   t   e   r   p   o   s    i   t    i   o   n    f   o   r    M   a   x ,    M    i   n   a   n    d

    c   e   n   t   e   r    l   e   v   e    l

    3 .    W    i   t    h   s   t   a   n    d    f   o   r    1   m    i   n   u

   t   e

    4 .    N   o    l   e   a    k   a   g   e   a   t    4    k   g    /   c

   m    2

    5 .    O   p   e   r   a   t   e   a   t    M    i   n    l   e   v   e    l

    i   n    d    i   c   a   t    i   o   n

    P

    P

  -  -

    1    9

    V   a    l   v   e   s

    1 .    T   y   p   e ,   m   a    k   e    &    V

    i   s   u   a    l

    2 .    L   e   a    k   a   g   e   t   e   s   t    /    S   e   e   p   a   g   e   t   e   s   t

    1    0    0    %

    I    S    7    7    8



    P

    P

  -  -

    2    0

    T   r   a   n   s    f   o   r   m   e   r    O    i    l

    R   o   u   t    i   n   e    T   e   s   t   a   s   p

   e   r    I    S    3    3    5

    1    0    0    %

    I    S    3    3    5

    I    E    C    6    0    2    9    6

    A   s   p   e   r    I    E    E    M    A   s   p   e   c    i    f    i   c   a   t    i   o   n    (   s   e   e    C    h   a   p   t   e   r    6    )

    P

    V

    V

    *    C   a   t   e   g




    W   -


   t

11/20


   S  r .    N  o .



   S  a  m  p   l   i  n  g

  r  a  t  e

   R  e   f  e  r  e  n  c  e   /

   S  t  a  n   d  a  r   d


   C  a  t  e  g  o  r  y  o


   S  u   b

   V  e  n   d  o  r

   M  a  n  u   f  -

  a  c

  t  u  r  e  r

   C  u  s  t  o  m  e  r

    2    1

    T   a   n    k    &    A   c   c   e   s   s   o   r    i   e   s

    1 .    C    h   e   c    k    f   o   r   a    f    i   t   u   p    f   o   r    b   u   t   t

    w   e    l    d   s   o   n   t   a   n    k   w   a    l    l   s ,    b   a   s   e    &

    c   o   v   e   r

    2 .    D    P   t   e   s   t   o   n    B   u   t   t   w   e    l    d   s   a    f   t   e   r    f    i   t

    u   p    &    l   o   a    d    b   e   a   r    i   n   g   w   e    l    d   s

    3 .    V    i   s   u   a    l    &    D    i   m   e   n   s    i   o   n   a    l   c    h   e   c    k

    a    f   t   e   r    f    i   n   a    l   w   e    l    d

    i   n   g

    4 .    A    i   r    l   e   a    k   a   g   e   t   e   s

   t   o   n   a   s   s   e   m    b    l   e    d   t   a   n    k   w    i   t    h

   t   u   r   r   e   t   s    &   o   n   c   o   n   s

   e   r   v   a   t   o   r

    5 .    V    i   s   u   a    l   c    h   e   c    k   o    f   p   a    i   n   t   s    h   a    d   e ,

    p   a    i   n   t    f    i    l   m   t    h    i   c    k   n   e   s   s    &    f    i    l   m

    a    d    h   e   s    i   o   n

    1    0    0    %

    C    B    I    P

   m   a   n   u   a    l

    2    0    1    3

    1 .    C    h   e   c    k    f   o   r   p   r   o   p   e   r   w   e    l    d    i   n   g

2 .    C    h   e   c    k    f   o   r   p   r   o   p   e   r   w   e    l    d    i   n   g

3 .    F   r   e   e    f   r   o   m    d   e    f   e   c   t


5 .    P   a    i   n   t   t    h    i   c    k   n   e   s   s

    O   u   t   s    i    d   e   :    1    5    5   m    i   c   r   o   n

    I   n   s    i    d   e

   :    3    0   m    i   c   r   o   n

    N   o   p   e   e    l  -   o    f    f

    P

    P

  -  -

    6 .    T   a   n    k  -

     6 .    1    P   r   e   s   s   e   u   r   e   t

   e   s   t

     6 .    2    V   a   c   c   u   m   t   e   s   t

   o   n   e   p   e   r

    d   e   s    i   g   n

    C    B    I    P

   m   a   n   u   a    l

    2    0    1    3

    6 .    1    )    T   w    i   c   e   t    h   e   n   o   r   m   a    l    h

   e   a    d   +    3    0    K    N    /   m    2    f   o   r    1    h   r .

    W    i   t    h   s   t   a   n    d

    6 .    2    )    7    6    0   m   m   o    f    H   g    f   o   r    1    h   r .   w    i   t    h   s   t   a   n    d

    P

    W

    W

    2    2

    R   a    d    i   a   t   o   r   s

    1 .    D    P   t   e   s   t   o   n    l    i    f   t    i   n   g    l   u   g   s

    2 .    S   u   r    f   a   c   e   c    l   e   a   n    i   n   g   o    f    h   e   a    d   e   r

    s   u   p   p   o   r   t   a   n    d    b   r   a   c    i   n   g    d   e

TManual Chapter 04

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Transcript of TManual Chapter 04