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
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
• 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
Inspection test records
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
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
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
Inspection test records
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
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
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
INSPECTION AND TEST PLAN FOR
OIL FILED TRANSFORMERS/POWER 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 material like Copper conductor, Insulation material, laminations, Transformer Oil.
Check of Physical, Chemical and Electrical properties.
100%
Material Test Certificates / Test records
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
3.0 Inprocess Inspection
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
4.0 Final Inspection
4.1 Transformer (Routine Tests)
• Physical Verification, Dimensional Check and verification of BoM
• Voltage ratio and Polarity
100% by purchaser
Inspection test records
As per approved drwgs
- H W
INSPECTION AND TEST PLAN FOR
OIL FILED TRANSFORMERS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD ACCEPTANCE
NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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)
INSPECTION AND TEST PLAN FOR
OIL FILED TRANSFORMERS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD ACCEPTANCE
NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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
INSPECTION AND TEST PLAN FOR
OIL FILED TRANSFORMERS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD ACCEPTANCE
NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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
Inspection test records
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 -
6.0 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
INSPECTION AND TEST PLAN FOR
OIL FILED TRANSFORMERS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD ACCEPTANCE
NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
6.2 Final Document submission
Compilation of Inspection reports ,drawings, etc as per VDR / PR 100%
Final data folder
/Completeness certificate
-
- 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.
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 :-
3. 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).
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
INSPECTION AND TEST PLAN FOR
OUTDOOR EHV CIRCUIT BREAKER
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 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
4.0 Final Inspection
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
INSPECTION AND TEST PLAN FOR
OUTDOOR EHV CIRCUIT BREAKER
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
Inspection test records
IEC:62271-100, 62271-1 &
IS 13118/As per job specification
/DS - H W
INSPECTION AND TEST PLAN FOR
OUTDOOR EHV CIRCUIT BREAKER
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 :-
5. 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).
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
5.1 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 -
6.0 Documentation and IC
6.1 Documentation and IC • Review of Internal Test Reports • Issuing IC 100%
Supplier’s Test Records / Inspection Certificate
-
- - H
SL
NO. STAGE/ ACTIVITY
1.0 Procedures
2.0 Material Inspection
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
3.0 In process Inspection
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
4.0 Final Inspection
•
•
•
4.1 Switchgear Assembly
•
INSPECTION AND TEST PLAN
FOR
HV SWITCHBOARDS
QUANTUM CHARACTERISTICS
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
Test Records IInspection
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
INSPECTION AND TEST PLAN
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
Test Records IInspection
Witness Record
Test Agency Reports
SCOPE OF INSPECTION
SUB
SUPPLIER SUPPLIER BARC
H H
R/W** R/W**
SL NO.
ST AGE/ ACTIVITY
INSPECTION AND TEST PLAN
FOR
HV SWITCHBOARDS
QUANTUM CHARACTERISTICS
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.
6.0 Documentation and IC
• 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
INSPECTION AND TEST PLAN
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
2.0 Material Inspection
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
3.0 Inprocess Inspection
INSPECTION AND TEST PLAN
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
SUPPLIER SUPPLIER BARC
--- --- ---
H H R
SL STAGE/ ACTIVITY
NO.
3.1 Wiring Checks
4.0 Final Inspection
4.1 Final Inspection
•
•
INSPECTION AND TEST PLAN
FOR
RELAY & CONTROL PANEL/DESKS
QUANTUM CHARACTERISTICS RECORD
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
SUPPLIER SUPPLIER BARC
--- 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
Documentation and IC
Final Document submission
INSPECTION AND TEST PLAN
FOR
RELAY & CONTROL PANEL/DESKS
QUANTUM CHARACTERISTICS RECORD
OF CHECK
• Visual
• Suitable protection to prevent entry of Packing list foreign material. 100% I Supplier's
• Proper packing to prevent any damage Records
during transportation and storage.
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
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
- 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:-
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 I Approved documents
SL STAGE/ ACTIVITY
NO.
1.0 Procedures
2.0 Material Inspection
Incoming material like panel
2.1 fabrication, PCBs, Lamps, Push
Buttons, Terminals, cable wires(FR), PVC ducts, etc
3.0 Inprocess Inspection
3.1 Wiring Checks
4.0 Final Inspection
INSPECTION AND TEST PLAN
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
INSPECTION AND TEST PLAN
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
Painting and Packing
Documentation and IC
Documentation and IC
INSPECTION AND TEST PLAN
FOR
ANNUNICATION PANEL
QUANTUM OF CHARACTERISTICS
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
SUPPLIER SUPPLIER BARC
- 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:-
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 NO.
STAGE/ ACTIVITY
1.0 Procedures
2.0 Material Inspection
Incoming Material like Busbars, Insulators, Motors •
2.1 and reduction Gears, cables, Relays, Cables, Cable •
glands etc.
3.0 In process Inspection
3.1 Switch Assembly
INSPECTION AND TEST PLAN
FOR
OUTDOOR EHV ISOLATERS AND EARTHING SWITCHES
QUANTUM OF CHARACTERISTICS
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
4.0 Final Inspection
•
•
Outdoor EHV Isolators and •
Earthing Switches-4.1
Acceptance tests •
•
•
•
•
Outdoor EHV Isolators and •
Earthing Switches- Type •
4.2 Tests
•
•
INSPECTION AND TEST PLAN
FOR
OUTDOOR EHV ISOLATERS AND EARTHING SWITCHES
QUANTUM OF CHARACTERISTICS
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
Painting and Packing
Painting and Packing
Documentation and IC
Documentation and IC
INSPECTION AND TEST PLAN
FOR
OUTDOOR EHV ISOLATERS AND EARTHING SWITCHES
QUANTUM OF CHARACTERISTICS
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:-
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 I Approved documents
SL STAGE/ ACTIVITY
NO.
1.0 Procedures
2.0 Material Inspection
Incoming Material like Porcelain housing, Pressure release devices, valves, Oil,
2.1 Cable Glands, Choke, Reactor, Bushings, Insulator etc
3.0 In process Inspection
3 .1 CT and VT assembly
INSPECTION AND TEST PLAN
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%
Test records I Lab Test Records
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.
4.0 Final Inspection
•
•
Voltage Transformers- •
4.1 Acceptance Tests •
•
•
•
•
•
Current Transformer-4.2
Acceptance Tests •
•
INSPECTION AND TEST PLAN
FOR
OUTDOOR EHV CURRENT TRANSFORMERS AND VOLT AGE
TRANSFORMERS
CHARACTERISTICS QUANTUM
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
5.0 Painting and Packing
Painting and Packing
5.1
INSPECTION AND TEST PLAN
FOR
OUTDOOR EHV CURRENT TRANSFORMERS AND VOLT AGE
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
Documentation and IC •
•
INSPECTION AND TEST PLAN
FOR
OUTDOOR EHV CURRENT TRANSFORMERS AND VOLT AGE
TRANSFORMERS
QUANTUM CHARACTERISTICS
OF CHECK RECORD
during transportation and storage.
Supplier's Test Type test Certificates. Records I
100% IC issuance . Inspection
Certificate
SCOPE OF INSPECTION
SUB SUPPLIER BARC
SUPPLIER
- 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:-
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
SL. STAGE/ACTIVITY
NO.
1.0 Procedure
2.0 Material Inspection
2.1 Incoming material like castings, Push Button, terminals, glass, ammeter, voltmeter, knob, switch, etc
3.0 Inprocess Inspection
3.1 Assembly
4.0 Final Inspection
4.1 Industrial type Control Station
INSPECTION AND TEST PLAN
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 •
5.0 Painting and Packing
5.1 Painting and Packing
INSPECTION AND TEST PLAN
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 --
6.0 Documentation and IC
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:-
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).
? 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
2.0 Material Inspection
Incoming Material like Insulators, Bus Bars, Fabricated
items, Bus bar sleeves and 2.1 supports, Instrument
Transformers, Relays, Indicating Instruments, Switches, Breakers,
Contactors etc.
INSPECTION AND TEST PLAN
FOR
M.V.SWITCHBOARDS
QUANTUM CHARACTERISTICS
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.
3.0 Inprocess Inspection
3.1 Wiring checks
4.0 Final Inspection
4.1 Switchgear Assembly
INSPECTION AND TEST PLAN
FOR
M.V.SWITCHBOARDS
QUANTUM CHARACTERISTICS
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.) •
•
•
•
INSPECTION AND TEST PLAN
FOR
M.V.SWITCHBOARDS
QUANTUM CHARACTERISTICS
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
Test Records IInspection
Witness Record
SCOPE OF INSPECTION
SUB
SUPPLIER SUPPLIER BARC
- H H
INSPECTION AND TEST PLAN
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.
6.0 Documentation and IC
• 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
INSPECTION AND TEST PLAN
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).
2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications I Approved documents
SL NO.
ST AGE/ ACTIVITY
1.0 Procedures
2.0 Material Inspection
Incoming Material like Fabricated items, Electronic
2.1 components, PCBs, Relays, Indicating Instruments, Power Supply Unit, IGBT/SCRs, etc.
3.0 In process Inspection
3.1 PCBs & Electronic components, Sub-assemblies
INSPECTION AND TEST PLAN
FOR
BATTERY CHARGERS
QUANTUM CHARACTERISTICS
OF CHECK
-- --
Visual, Dimensional, operational checks, etc. as applicable 100%
Burn-in Test for 96 hours at 50deg C 100%
RECORD
--
TC's/ Inspection &
Test records I Lab Test Records
Supplier's Test Records
SCOPE OF INSPECTION
SUB SUPPLIER BARC SUPPLIER
-- -- --
H H R
H H R
SL NO.
ST AGE/ ACTIVITY
4.0 Final Inspection
4.1 Battery Charger Assembly (Acceptance Tests)
INSPECTION AND TEST PLAN
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
Test Records IInspection
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
INSPECTION AND TEST PLAN
FOR
BATTERY CHARGERS
CHARACTERISTICS QUANTUM
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
Test Records IInspection
Witness Record
Supplier's Test Records I
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
Painting and Packing
5.1
6.0 Documentation and IC
6.1 Documentation and IC
INSPECTION AND TEST PLAN
FOR
BATTERY CHARGERS
QUANTUM CHARACTERISTICS
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's Test Records I
Inspection Witness Record
Supplier Test Record
Supplier's Test Records/
Statutory Body
Certificates
Packing list ISupplier's Records
Supplier's Test Records IInspection Certificate
SCOP
SUB SUPPLIER
SUPPLIER BARC·
- H H
- H H
- H R
- H -
- H H
INSPECTION AND TEST PLAN
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)
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:-
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 I Approved documents
STANDARD SPECIFICATION NO.
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PO/PR & Standards referred there in /Job specifications / Approved documents.
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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laminations, Copper, Insulation material,
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Material Inspection
Procedures
STAGE/ ACTIVITY
Chemical, Physical properties , finish as per relevant standard
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Motor Assembly
Inprocess Inspection
STAGE/ ACTIVITY
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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
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SL STAGE/ ACTIVITY
NO.
4.2 Motor (Type Tests)
5.0 Painting
Painting and Packing
5.1
6.0 Documentation and IC
6.1 Documentation and IC
6.2 Final Document submission
INSPECTION AND TEST PLAN
FOR
MEDIUM VOLTAGE MOTORS
QUANTUM CHARACTERISTICS
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
Inspection test records
Packing list ISupplier's Records
Supplier's Test Records I
Certificates from statutory
bodies IInspection
Certificate (IC)
Final data
STANDARD SPECIFICATION NO.
6-81-1032 Rev. 4
Page 5 of6
SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER EIL/TPIA
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*Measurements will be made in accordance with standard JEC (Logarithmic proportion method II)
SL ST AGE/ ACTIVITY
NO.
1.0 Procedures
2.0 Material Inspection
Incoming Material like fabricated panels, IGBT/SCRs, relays,
2.1 Meters, CT/PT, transducers, transformer unit, rectifier unit, filter etc.
3.0 In process Inspection
INSPECTION AND TEST PLAN
FOR
MV VARIABLE FREQUENCY DRIVE SYSTEM
QUANTUM CHARACTERISTICS RECORD
OF CHECK
-- -- --
Material Identification Material Test Operational checks. 100% Certificates I
Test records
SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER BARC-
-- -- --
H H -
SL STAGE/ ACTIVITY
NO.
3.1 VFD Assembly
4.0 Final Inspection
4.1 VFD (Acceptance Tests)**
INSPECTION AND TEST PLAN
FOR
MV VARIABLE FREQUENCY DRIVE SYSTEM
QUANTUM CHARACTERISTICS RECORD
OF CHECK
Visual ,Dimensional, Bill of material 100% Test Records
• Visual
• Dimensional
• Bill of Material check
Simulation check of control signals
• Check of Speed/rpm at different frequency atvarious mode as applicable
• Memory function check of fault diagnostics
• Insulation Test
• Light Load and Functional test 100% By • Load characteristics Supplier and Inspection test
• Load duty test on Random records
• Check Auxiliary Devices Basis by
• Check the properties of the control equipment TPIA/EIL
• Check the Protective Devices
• Check control and functional requirements
• High voltage test
• Leakage and pressure test for cooling systemwhere provided
• Automatic restart/re-acceleration
• Noise Level Measurement
SCOPE OF INSPECTION
SUB
SUPPLIER SUPPLIER BARC
- H -
- H H
SL STAGE/ ACTIVITY
NO.
4.2 VFD (Type Tests)
INSPECTION AND TEST PLAN
FOR
MV VARIABLE FREQUENCY DRIVE SYSTEM
QUANTUM CHARACTERISTICS RECORD
OF CHECK
• Load current versus speed at different frequencyat constant torque/ Voltage/Power Mode asapplicable.
• Efficiency
• Temperature rise
• Voltage division
• Line side current distortion content
• Power factor
• Dynamic performance test
• Current limit and current loop test• Speed loop test capability to ride through One sample
Inspection test voltage dips upto 20% from each
records • Noise Level Measurement type/rating
• Capability to restart the system andresynchronize converter onto running motorafter a voltage interruption.
• Harmonic measurement at output of VFD forVoltage and Current
Integral Test is to be carried out along with job motor, as per PR/ EIL Standard Specification.
SCOPE OF INSPECTION
SUB SUPPLIER BARC
SUPPLIER
- H H
SL NO.
4.3
5.0
5.1
6.0
6.1
6.2
**
INSPECTION AND TEST PLAN
FOR
MV VARIABLE FREQUENCY DRIVE SYSTEM
QUANTUM ST AGE/ ACTIVITY CHARACTERISTICS RECORD
OF CHECK
• Degree of protection certificate as per latest
IS/IEC.• Type test certificates from recognized Statutory
Submission of certificates independent test house such as ERTL,
Sample/Proto Approval
/documents CIMFR,BASEEF A,FM/UL, PTB, A TEX etc Certificates Ifor rated current test, power loss
type Type Test
determination, temperature rise, EM Immunity Certificates and EM Emission
Painting
Painting ofVFD Panels Pre treatment, primer and final paint, shade,
100% Test records thickness
Documentation and IC
• Review oflnternal Test Reports and MTCs . Supplier's Test
Documentation and IC • IC issuance 100%
Records IInspection
Certificate (IC)
Final data
Final Document submission Compilation of Inspection reports ,drawings, etc as
100% folder
perVDR / PR /Completeness certificate
All the load tests/ Functional Checks are to be carried out either with the job motor or with Shop Motor
SCOPE OF INSPECTION
SUB SUPPLIER
SUPPLIER BARC
- H
- H R
- 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 type), W- Witness (Give due notice, work may roceed after scheduled date).
NOTES:-
INSPECTION AND TEST PLAN
FOR
MV VARIABLE FREQUENCY DRIVE SYSTEM
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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This Inspection and Test Plan covers the minimum testing & inspection requirements of Emergency Generator.
PO/PR & Standards referred there in /Job specifications / Approved documents.
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In process Inspection
Incoming Material like CTs, Auxiliary motors, Fuel Tank, other major Electrical items etc.
Material Inspection
Procedures
STAGE/ ACTIVITY
Visual, Dimensional, Bill of Material
• Manufacturer' s TC / Raw material Test Certificates.
CHARACTERISTICS
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STAGE/ ACTIVITY
The following tests shall be carried out as a minimum as per applicable IS/IEC
•
Temperature Rise Test.
•
Noise Measurement (No Load)
•
Measurement of Residual Voltage
•
Overspeed Test
•
Overload Test
•
Short Circuit withstand test and measurement of Reactance and time Constants (1000 KW and
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1.0 SCOPE:
INSPECTION AND TEST PLAN
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
2.0 Material Inspection
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.
4.0 Final Inspection
4.1 Load test I Functional test of assembled
DG Set
4.2 Final Visual I Dimension of Skid
assembly
INSPECTION AND TEST PLAN
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
STANDARD SPECIFICATION No.
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
INSPECTION AND TEST PLAN
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
STANDARD SPECIFICATION No.
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.
INSPECTION AND TEST PLAN FOR
UNINTERRUPTED POWER SUPPLY (UPS) SYSTEM
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 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
3.0 In process Inspection
3.1 PCBs & Electronic components sub assemblies
Burn-in Test for 96 hours at 50 deg C 100% Supplier’s
Test Records
- - H R
4.0 Final Inspection
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
Test Records / Inspection
Witness
As per approved drwgs/data sheet
As per approved documents
-
H
W
INSPECTION AND TEST PLAN FOR
UNINTERRUPTED POWER SUPPLY SYSTEM
SL NO
. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD
ACCEPTANCE NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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
Test Records / Inspection
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
INSPECTION AND TEST PLAN FOR
UNINTERRUPTED POWER SUPPLY SYSTEM
SL NO
. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD
ACCEPTANCE NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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 ,
INSPECTION AND TEST PLAN FOR
UNINTERRUPTED POWER SUPPLY SYSTEM
SL NO
. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD
ACCEPTANCE NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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
INSPECTION AND TEST PLAN FOR
UNINTERRUPTED POWER SUPPLY SYSTEM
SL NO
. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD
ACCEPTANCE NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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
INSPECTION AND TEST PLAN FOR
UNINTERRUPTED POWER SUPPLY SYSTEM
SL NO
. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF
CHECK RECORD
ACCEPTANCE NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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 /
Supplier’s Records
-As per DS/Spec.
- H -
6.0 Documentation and IC
6.1 Documentation and IC
• Review of Internal and Type Test Reports and MTCs
• IC issuance. 100%
Supplier’s Test Records / Inspection Certificate
- H H
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 :-
7. 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).
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
INSPECTION AND TEST PLAN FOR
STATIONARY NICKEL CADMIUM BATTERY
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 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 -
3.0 Inprocess Inspection
3.1 Battery assembly Visual, Dimensions, Bill of Material 100% Supplier’s
Test Records
- - H R
4.0 Final Inspection
INSPECTION AND TEST PLAN FOR
STATIONARY NICKEL CADMIUM BATTERY
SL NO
.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK RECORD ACCEPTANCE NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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
Inspection test records
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
INSPECTION AND TEST PLAN FOR
STATIONARY NICKEL CADMIUM BATTERY
SL NO
.
STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK RECORD ACCEPTANCE NORMS
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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
5.0 Painting and Packing
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
INSPECTION AND TEST PLAN FOR
STATIONARY NICKEL CADMIUM BATTERY
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 :-
9. 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).
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
INSPECTION AND TEST PLAN FOR
HIGH VOLTAGE CAPACITOR BANKS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
1.0 Procedures -- -- -- -- -- --
2.0 Material Inspection
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
4.0 Final Inspection
INSPECTION AND TEST PLAN FOR
HIGH VOLTAGE CAPACITOR BANKS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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
Test Records / Inspection Witness Record
H H W
INSPECTION AND TEST PLAN FOR
HIGH VOLTAGE CAPACITOR BANKS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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.
Test Records / Inspection Witness Record
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
INSPECTION AND TEST PLAN FOR
HIGH VOLTAGE CAPACITOR BANKS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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%
As per approved drawings/Spec.
Packing list /
Supplier’s Records
- H -
6.0 Documentation and IC
6.1 Documentation and IC • Review of Internal Test Reports &
MTCs • IC issuance.
100%
--
Supplier’s Test
Records / Inspection Certificate
- H H
** Witness if called for in job specifications. In such cases specified Type test will be considered as part of Acceptance Test.
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 :-
11. 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).
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
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK ACCEPTANCE NORMS RECORD SCOPE OF INSPECTION
SUB SUPPLIER SUPPLIER BARC
1.0 Procedures -- -- -- -- -- --
2.0 Material Inspection
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
3.0 Inprocess Inspection
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
4.0 Final Inspection
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
As per approved drawings/data sheet/Job
spec./ IS1554 Test Records - H H/R**
4.2 Finished Cable(Routine Tests)
• Conductor Resistance. • High Voltage • Partial Discharge (for XLPE
only)
100% witness by purchaser
As per approved drawings/data sheet/Job
spec./ IS8130/IS1554
Supplier’s Test Records - H W**
INSPECTION AND TEST PLAN FOR
HIGH VOLTAGE CAPACITOR BANKS
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 )
100% witness by purchaser
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**
INSPECTION AND TEST PLAN FOR
HIGH VOLTAGE CAPACITOR BANKS
• 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 -- -- -- -- -- -- --
6.0 Documentation and IC
6.1 Documentation and IC • Review of Routine,
Acceptance, Type test reports. • IC issuance
100%
-- Supplier TC & IC - - H
6.2 Final Document submission
Compilation of Inspection reports ,drawings, etc as per VDR / PR 100%
--
Final data folder
/Completeness certificate
- 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.
INSPECTION AND TEST PLAN FOR
HIGH VOLTAGE CAPACITOR BANKS
** 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 :-
13. 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).
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
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
1.0 Procedures -- -- -- -- -- --
2.0 Material Inspection
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 -
3.0 In process Inspection
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 -
4.0 Final Inspection
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.
Inspection Witness Record
- H RW
INSPECTION AND TEST PLAN FOR COMMUNICTION &
FIRE ALARM CABLES
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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
Inspection Witness Record
- H W
INSPECTION AND TEST PLAN FOR COMMUNICTION &
FIRE ALARM CABLES
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
• 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
drawings/data sheet/Job spec./IS
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
Witness by purchaser
Inspection Witness Record
- H W
INSPECTION AND TEST PLAN FOR COMMUNICTION &
FIRE ALARM CABLES
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
(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
drawings/data sheet/Job spec./IS
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
Witness by purchaser
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
Inspection Witness Record
- H W
INSPECTION AND TEST PLAN FOR COMMUNICTION &
FIRE ALARM CABLES
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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
Witness by purchaser
As per approved drawings/data
sheet/DOT spec./Job spec./IS
5831/IS8130/ BS EN:50288(Pt7)
Supplier’s Test
Records - H W
5.0 Painting
6.0 Documentation and IC
6.1 Documentation and IC
• Review of Internal Test Reports and MTCs.
• IC issuance -
-
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
* - 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
INSPECTION AND TEST PLAN FOR COMMUNICTION &
FIRE ALARM CABLES
each type), W- Witness (Give due notice, work may proceed after scheduled date). NOTES :-
15. 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).
16. Acceptance Norms for all the activities shall be as per latest version of IS code/ Standards referred there in/ Job specifications /Approved documents
INSPECTION AND TEST PLAN FOR
LIGHTNING ARRESTORS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
1.0 Procedures -- -- -- -- -- --
2.0 Material Inspection
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
3.0 In process Inspection
3.1 Lightning Arrestor assembly • Visual, Dimensional and Bill of
material 100% by supplier
IEC-99-4 Supplier’s test records - H -
4.0 Final Inspection
As per approved
drawings/data sheet
INSPECTION AND TEST PLAN FOR
LIGHTNING ARRESTORS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
4.1 Final Inspection
• 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
Inspection Witness Record
- 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
INSPECTION AND TEST PLAN FOR
LIGHTNING ARRESTORS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS QUANTUM
OF CHECK
ACCEPTANCE
NORMS RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER BARC
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%
As per approved drawings/data
sheet Test records
-
H --
6.0 Documentation and IC
6.1 Documentation and IC
• 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
/Completeness certificate
- 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 :-
INSPECTION AND TEST PLAN FOR
LIGHTNING ARRESTORS
17. 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).
18. Acceptance Norms for all the activities shall be as per LATEST VERSION of IS codes/ Standards referred there in/ Job specifications /Approved documents