Quality Control Procedure for HV, MV & LV Cables

1.0 PURPOSE

The purpose of this procedure is to describe the system of control for all activities and define the sequence of work for installation of HV, MV & LV Cables. This procedure also includes the interface activities, and responsibilities relating to HV, MV & LV Cables Installation & Testing activities, in compliance with project specifications and IFC drawings.

2.0 SCOPE

The scope of this procedure covers the activities during the Installation & Testing of HV, MV & LV Cables and related inspection activities

3.0 REFERENCES

3.1 CUSTOMER / COMPANY DOCUMENTS:

DEP 33.64.10.10-Gen – Electrical Engineering Guidelines
DEP 33.64.10.33-Gen – Electromagnetic Compatibility (EMC) Requirements
DEP 63.10.08.11-Gen – Field Commissioning & Maintenance of Electrical
Installation & Equipment
– Power, Control & Earthing Cables.
– Electrical Requirement for Packaged Equipment-Water
Injection Cluster.
– Electrical Bulk Materials-Water Injection Cluster.
– Hazardous Area Equipment and Electrical Bulk Materials.
DEP 82.00.10.10 Gen – Project Quality Assurance
– Material Identification & Traceability Procedure
– Material Receipt Inspection Procedure
– Preservation of Project Equipment & Material.

3.2 GALFAR DOCUMENTS:

3.2.1QA/QC Documents:

– Project Quality Plan

– Inspection and Test Plan for Electrical Installation.

– Quality Control Procedure for Material Identification and Traceability

3.2.2 HSE Document:

– Project HSE plan

4.0 ABBREVIATIONS

4.1 Company :
4.2 Contractor :
4.3 Sub Contractor
4.7 ITP : Inspection and Test Plan
4.9 QA : Quality Assurance
4.10 QC : Quality Control
4.11 RFI : Request for Inspection
4.13 NCR : Non Conformance Report
4.14 PQP : Project Quality Plan
4.10 HSE : Health Safety & Environment.

5.0 ROLES AND RESPONSIBILITIES

Following are the roles and responsibilities of personnel involved in this scope of procedure.

5.1 PROJECT MANAGER:

 Project Manager shall report to the Project Director
 Shall be responsible for the execution of the project in line with the contractual requirements.

5.2 QA/QC MANAGER:

 QAQC Manager shall report to the Project Manager.
 Shall be responsible for ensuring the Project Quality requirements and shall monitor all the Quality related issues throughout the project.

5.3 HSE MANAGER:

 HSE Manager shall report to the Project Manager
 Shall be responsible for ensuring the Project HSE requirements and shall monitor all the HSE related issues throughout the project.

5.4 PROJECT DOCUMENT CONTROLLER:

 Document controller shall report to the Project Manager.
 Shall be responsible for controlling & issuing all the Project related documents throughout the Project. He shall be key point to receive and transmit documents from the CONTRACTOR and to the CONTRACTOR. He shall maintain the status of documents like revisions, approvals etc.

5.5 CONSTRUCTION MANAGER:

 Construction manager shall report to the Project Manager
 Shall be responsible for arranging necessary equipment, man power, consumables, areas for storage, erection, preservation and ensuring that the procedure is implemented and complied with all specifications and HSE requirements.

5.6. PLANNING ENGINEER:

 Planning Engineer shall report to the Project Manager.
 Shall be responsible for monitoring the equipment receipt and erection activities in line with the schedule / targets given by the CONTRACTOR’s Project controls department. He shall be responsible for planning the field erection activities including but not limited to the materials, machinery and manpower.

5.7 CONSTRUCTION ENGINEER:

 Shall report to the Construction Manager.
 Shall coordinate and interface with Contractor’s construction engineer to ensure the work front availability at site. He shall be responsible for arranging the tools & tackles, issue of drawings for erection, monitoring the drawing revisions and modifications if any to meet the progress target set by the Project controls.
 Shall ensure the preparation of daily reports.

5.8 STORE KEEPER:

 Shall report to Material controller.
 Shall be responsible for proper storage and issue of special tools, gaskets, bolts & nuts and other accessories received with equipments, as per the manufacture’s recommendations.
5.9 QA/QC ENGINEER:
.
 Shall report to the QC Manager
 Shall be responsible to ensure that works carried out at site are complied with project quality requirements, to identify and intimate the CONTRACTOR for the hold, witness and review points as described in the inspection and test plan for Electrical Installation. He shall interface and coordinate with the CONTRACTOR’S Lead QC Manager to resolve the issues related to quality and shall monitor the Implementation of procedure at site.

5.10 QC INSPECTOR ELECTRICAL:

 Shall report to the QC Engineer.
 Shall inspect the incoming equipment and verify the materials received are confirming to the AFC Drawings.
 Shall be responsible for quality control & documentations.
 Stages of inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and Installation procedure.

5.11 ELECTRICAL SUPERVISOR / FORMAN

 Shall be report to Electrical Engineer
 Aware all procedures, work method / instructions, quality requirement for the timely completion of the job and explains to the task force for the installation of HV, MV & LV Cables.
 Execute all activities as per the contract requirements, applicable code of practice. Manufacturer’s instructions and monitor the job as per the schedule.

5.12 JOB PERFORMER

 Shall report to Electrical Supervisor
 Ensure all permit to work, safety equipments, proper tools & tackles are ready at the point of use
 Shall be responsible for to oversee & monitor the site activities on a continuous basis and ensure all control measures as stated in PTW are implemented.

6.0 CONSTRUCTION EQUIPMENTS

 Cranes, Fork Lifts, lifting belts, slings and other necessary tools and tackles for rigging & material handling operation shall be calibrated & colour coded as per HSE requirement
 Hand tools & calibrated all testing Equipments suitable for HV, MV & LV Cables installation
and testing.
 The Supervisor / Foreman shall ensure that the equipment & accessories used are suitable for the job and are in good working condition to complete the electrical work shall be as per good engineering practices.

7.0 DRAWING RECEIPT & ISSUE OF EQUIPMENT

The Engineering Department shall issue to construction department the Issued for Construction Drawings provided with Material Traceability List complete with information such as identified profile and description to corresponding material items.

After receiving the Issued for Construction Drawings, the Construction Department shall request the equipment from the Store. The Store shall issue the Material issue Slip with equipment stated.

8.0 CALIBRATION CONTROL

The measuring instruments like Insulation tester, Multimeter, Phase sequence meter,
Hi-pot Tester, surveying instruments, spirit level, measuring tape etc. deployed during installation & inspection activities shall be calibrated periodically once in six months at certified laboratory and the certificates may be submitted for review The certificates are to be made available at site during various stages of inspection.

9.0 QUALITY CONTROL

9.1 RECEIVING INSPECTION:

9.1.1 Check the availability of “IFC” drawings, vendor manuals and instructions etc.

9.1.2 All material received shall be stored according to the installation schedule,
material identification & traceability and manufacturer’s instruction.

9.1.3 All Material Receiving Inspection to be completed before installation in position and if any discrepancy found, item will be entered in the punch list and maintain a record further inform to site Engineer immediately.

9.1.4 Verify the quality, year of manufacturing (if any) and country of origin.

9.1.5 Verify the Test certificate of cable is available for reference.

9.1.6 Proper protection will be provided against wind, dust, rain corrosion etc as per
material preservation procedure

9.2 INSPECTION PRIOR TO INSTALLATION:

9.2.1 Check and verify the installation Procedure and make sure the proper method
of installation is being used as per the approved Method Statement

9.2.2 Verify the cable type, size, colour and route of the cables are as per the
approved drawing & cable schedule.

9.2.3 Continuity & Insulation resistance test on drum. Insulation resistance shall not
be less than as per DEP 63.10.08.11-Gen, A12.2 (10 x kV / km) in MΩ

9.2.4 Verify cable trench & sand bedding as per project specification.
ie, 132 kV 100 mm & all other cable 75 mm

9.2.5 Ensure trained, well experienced and skilled persons do the cable pulling.

9.3 QUALITY CONTROL CHECKS DURING INSTALLATION

9.3.1 Under Ground cables

9.3.1.1 Verify the laying sequence of the cables to avoid crossing and over lapping.

9.3.1.2 Check and verify the installation Procedure and make sure the proper method
of installation is being used as per the approved Method statement for
installation of cables

9.3.1.3 Verify actual cable length against the cable schedule.

9.3.1.4 Cable roller shall be placed at the span of every 10 meters and angle roller at all turning points where there is a change in direction.

9.3.1.4 Follow the direction shown in the cable drum for the rotation of cable drum.

9.3.1.5 Make sure the cable coming from the top of the drum and cable shall not drag
on the floor.

9.3.1.6 Follow and adhere to the manufacturer’s permissible pulling force for cable pulling.

9.3.1.7 Maintain the minimum bending radius as
Single Core Unarmoured – 20 D, Single Core Armoured – 15 D, Three Core Unarmoured – 15 D, Three Core Armoured – 12 D. (D – Diameter of Cable).

9.3.1.8 Each set of single core cables comprising a three phase circuit shall be run
close together in trefoil formation.

9.3.1.9 Cable crossing under road shall be through reinforced concrete duct bank.

9.3.2 Above Ground Cables

9.3.2.1 Cable shall be laid on trays in accordance with laying pattern indicated on
AFC layout drawings.

9.3.2.2 The cut end of the cable shall be protected from moisture entry.

9.3.2.3 Cable identification shall be for underground and above ground application, engraved stainless steel cable tags, at each end, at both ends of sleeves, all entry point to JB and along the route shall not exceed 10 M for under ground cabling. For above ground cabling the spacing between cable number shall be at every 25 meters. Cable shall also be numbered where they branch off from main route.

9.3.2.4 Witness & verify continuity & insulation resistance test are carried out as acceptable critical DEP 63.10.08.11-Gen, A 12.2 before and after installation of every length of cable.

9.3.2.5 Witness & verify the Hi-pot test for HV & MV Cables. The test voltage & timing
of Hi-pot test shall be as per DEP 63.10.08.11 Appendix A 11.1.1

9.4 QUALITY CONTROL CHECK DURING CABLE JOINTING & TERMINATION

9.4.1 All cable joints / termination shall be strictly in accordance with cable manufacturer’s recommendation

9.4.2 All cable joints / termination kits shall be compatible to the cable and shall be
Confirmed by the cable manufacturer.

9.4.3 At most care shall be taken while preparing the cable for jointing / termination

9.4.4 Qualified and well experienced person shall be engaged for cable jointing /
termination

9.4.5 Check continuity & insulation resistance with calibrated instrument before cable jointing / termination.

9.4.6 Check and ensure the cable jointing / termination kit is complete with all
materials as per the packing list.

9.4.7 All cable conductor shall be fitted with company approved make & correct size ferrule / leg. The ferrule / leg shall be crimped compression type as specified by the manufacturer.

9.4.8 Cable glands shall be double sealed compression type with earth clamping features to IP55.

9.4.9 All EE xd, EE xe cable glanding and termination shall be done by trained technician

10.0 TESTING

Following electrical test shall be conducted for HV, MV & LV cables

• Continuity & Insulation Resistance Test of the cable on Drum

• Continuity & Insulation Resistance Test of the cable before backfilling

• Hi-pot Test for MV & HV Cables

• Continuity & Insulation Resistance Test of the cable after backfilling

11.0 REQUEST FOR INSPECTION

RFI shall be raised 24 hours before the actual schedule for inspection as per
approved ITP

12.0 HEALTH AND SAFETY REQUIREMENTS
12.1 Hazards:
 Accidents during loading & unlading cable drums from storage yard to the point of installation
 Personal injury during cable pulling and using torch blower for heating during cable termination & joining.
 Electric shock during megger testing / Hi-pot testing.
 Pollution due to excess & waste materials.

12.2 control measures:
 Strictly ensure that the entire activities of cable laying, termination & joininting shall be carried out under consolidated Permit to Work system.
 Toolbox talk shall be carried out to keep the team-mates aware of job activities before starting any work, identification of all hazards including hidden one and control measures of it.
 Emergency evacuation contingency plan shall be known to work performing crew members.
 Safety equipments, warning devices and signboards shall be in position at work site.
 All work performing personal’s shall be provided with PPE and ensure proper use of it.

12.3 Safety Precautions:

 Prior to commencement of any activity, all personnel involved on the job shall attend the project HSE Induction training.
 The site management, supervisors and safety officers will closely supervise and monitor all phases of activities in connection with the compliance of safe working models.
 All equipment like Cranes, Fork lifts, Chain pulley blocks, lifting belts, slings and other necessary tools and tackles for rigging & material handling operation, electrical equipment etc. shall be inspected by competent personnel prior to use at site. Equipment will be regularly checked and inspected by the safety officer.
 Any accident / Injury / near miss shall be reported immediately to appropriate authorities. Work shall stop and area secured until approved
 The Construction Engineer / Supervisor shall immediately correct any hazards observed or reported to him. In the case of major hazards, work shall be stopped and appropriate and satisfactory permanent action to remove the hazards shall be taken.
 Good housekeeping shall be maintained at all times
 All activities reflected to HSE shall be carried out according to the approved documents
a) Project HSE Plan –
b) Contractor HSE Plan –

13.0 DOCUMENTATION & RECORDS

Mateerial Receipt Inspection Checklist –
Material Receipt & Inspection Repor (MRIR) –
Excess, Shortage and Damage Report (ESDR) –
List of Critical Items for Material Receipt Checking –
Receipt & Shotage Checklist –
– Insulation Resistance & Continuity test record-Electrical cable on drum
(before installation)
– Cable trench & duct bank inspection before cable pulling.
– Insulation Resistance & Continuity test record-Electrical cable on trench,
Before backfilling.
– Inspection of cables in trench before final backfilling..
– Cable jointing certificate for LV/MV/HV cables.
– Inspection of electrical cables after installation, glanding and termination.
– Insulation resistance & continuity test record-Low voltage cables after
Glanding and termination
– Hi-Pot test of MV / HV cables.

NOTE: Sample copies of above are as attachments of this procedure.

Quality Control procedure for Power Transformer

1.0 PURPOSE

The purpose of this procedure is to describe the system of control for all activities and define the sequence of work for installation of Power Transformer. This procedure also includes the interface, and responsibilities relating to Power Transformer Installation & Testing activities, in compliance with project specifications and IFC drawings.

2.0 SCOPE

The scope of this procedure covers the activities of Power Transformer and related inspection activities to meet project specification & shell standards.

3.0 REFERENCES

3.1 CUSTOMER / COMPANY DOCUMENTS:

DEP 33.65.40.31- Gen – Power Transformers
DEP 33.64.10.10- Gen – Electrical Engineering Guidelines
– Power Transformers
DEP 82.00.10.10 Gen – Project Quality Assurance
– Material Identification & Traceability Procedure
– Material Receipt Inspection Procedure
– Preservation of Project Equipment & Material.
– Engineering Specification for Concrete works.
– Power & Auxiliary Transformers, Water Injection Cluster.
– Specification for Neutral Earthing Resistor.
– Hazardous Area Equipment & Electrical Bulk Materials.
– Electrical Engineering Design.

3.2 DOCUMENTS:

3.2.1QA/QC Documents:

– Project Quality Plan

– Inspection and Test Plan for Electrical Installation.

– Quality Control Procedure for Material Identification and Traceability

3.2.2 HSE Document:

– Project HSE plan

4.0 ABBREVIATIONS

4.1 Company :
4.2 Contractor :
4.3 Sub Contractor :
4.7 ITP : Inspection and Test Plan
4.9 QA : Quality Assurance
4.10 QC : Quality Control
4.11 RFI : Request for Inspection
4.13 NCR : Non Conformance Report
4.14 PQP : Project Quality Plan
4.10 HSE : Health Safety & Environment.

5.0 ROLES AND RESPONSIBILITIES

Following are the roles and responsibilities of personnel involved in this scope of procedure.

5.1 PROJECT MANAGER:

 Project Manager shall report to the Project Director
 Shall be responsible for the execution of the project in line with the contractual requirements.

5.2 QA/QC MANAGER:

 QAQC Manager shall report to the Project Manager.
 Shall be responsible for ensuring the Project Quality requirements and shall monitor all the Quality related issues throughout the project.

5.3 HSE MANAGER:

 HSE Manager shall report to the Project Manager
 Shall be responsible for ensuring the Project HSE requirements and shall monitor all the HSE related issues throughout the project.

5.4 PROJECT DOCUMENT CONTROLLER:

 Document controller shall report to the Project Manager.
 Shall be responsible for controlling & issuing all the Project related documents throughout the Project. He shall be key point to receive and transmit documents from the CONTRACTOR and to the CONTRACTOR. He shall maintain the status of documents like revisions, approvals etc.

5.5 CONSTRUCTION MANAGER:

 Construction manager shall report to the Project Manager
 Shall be responsible for arranging necessary equipment, man power, consumables, areas for storage, erection, preservation and ensuring that the procedure is implemented and complied with all specifications and HSE requirements.

5.6. PLANNING ENGINEER:

 Planning Engineer shall report to the Project Manager.
 Shall be responsible for monitoring the equipment receipt and erection activities in line with the schedule / targets given by the CONTRACTOR’s Project controls department. He shall be responsible for planning the field erection activities including but not limited to the materials, machinery and manpower.

5.7 CONSTRUCTION ENGINEER:

 Shall report to the Construction Manager.
 Shall coordinate and interface with Contractor’s construction engineer to ensure the work front availability at site. He shall be responsible for arranging the tools & tackles, issue of drawings for erection, monitoring the drawing revisions and modifications if any to meet the progress target set by the Project controls.
 Shall ensure the preparation of daily reports.

5.8 STORE KEEPER:

 Shall report to Material controller.
 Shall be responsible for proper storage and issue of special tools, gaskets, bolts & nuts and other accessories received with equipments, as per the manufacture’s recommendations.

5.9 QA/QC ENGINEER:
.
 Shall report to the QC Manager
 Shall be responsible to ensure that works carried out at site are complied with project quality requirements, to identify and intimate the CONTRACTOR for the hold, witness and review points as described in the inspection and test plan for Electrical Installation. He shall interface and coordinate with the CONTRACTOR’S Lead QC Manager to resolve the issues related to quality and shall monitor the Implementation of procedure at site.

5.10 QC INSPECTOR E & I:

 Shall report to the QC Engineer.
 Shall inspect the incoming equipment and verify the materials received are confirming to the AFC Drawings.

6.0 CONSTRUCTION EQUIPMENTS

 Cranes, Fork Lifts, lifting belts, slings and other necessary tools and tackles for rigging & material handling operation shall be calibrated & colour coded as per HSE requirement.

 Hand tools & calibrated Testing Equipments suitable for Transformer installation & testing
 The Supervisor / Foreman shall ensure that the equipment & accessories used are suitable for the job and are in good working condition. Electrical Connections made to complete the electrical work shall be as per good engineering practices.

7.0 DRAWING RECEIPT & ISSUE OF EQUIPMENT

The Engineering Department will issue to construction department the Issued for Construction Drawings provided with Material Traceability List complete with information such as identified profile and description to corresponding material items.

After receiving the Issued for Construction Drawings, the Construction Department will request the equipment from the Store. The Store will issue the Material issue Slip with equipment stated.

8.0 CALIBRATION CONTROL

The measuring instruments like Insulation Tester, Low resistance meter(Ductor), Multimeter, Clamp meter, Primary & Secondary Current injection Testing Kit. and surveying instruments, spirit level, measuring tape etc. deployed in erection activities shall be calibrated periodically once in six months at certified laboratory and the certificates may be submitted for review. The certificates are to be made available at site during various stages of inspection.

9.0 QUALITY CONTROL

9.1 Receiving Inspection:

9.1.1 Check the availability of “IFC” drawings, vendor manuals and instructions etc.

9.1.2 Equipment received will be stored according to the installation schedule
and manufacturer’s instruction.

9.1.3 All Material Receiving Inspection to be completed before installation in position and if any discrepancy found, item will be entered in the punch list and maintain a record.

9.1.4 Proper protection will be provided against wind, dust, rain corrosion etc.

9.2 Inspection Prior to Installation:

9.2.1 Foundation release note shall be received from civil department prior to installation work.

9.2.2 Prior to installation of the equipment foundation shall be inspected in order to
Confirm AFC drawing requirements for dimension, center line coordinate,
elevation and layout.

9.2.3 Check that the orientation marks are provided prior to installation.

9.2.4 Test certificates for the lifting cranes, tools & tackles shall be made available &
accepted by HSE person.

9.2.5 All the tools and tackles used for installation works shall be of good quality.

9.2.6 Lifting space availability shall be verified.

9.2.7 Temporary platform or scaffolding required shall be fixed prior to lifting the
equipment.

9.2.8 Safety personnel shall be informed about all the heavy lifts well in advance.

9.3 The erection area shall be cordoned off and proper signboards shall be provided.

Preservation & protection shall be followed by the vendor instruction manual /
Preservation of project equipment

9.4 Assembly:

9.4.1 Contractor shall ensure site assistance of the equipments Vendor support
specialized person present & supervise during assembly of the transformer.

9.4.2 RFI shall be raised 24 hours before the actual schedule for Inspection as per
the approved ITP.

9.4.3 Extreme care shall be taken against any entry of foreign contaminants into the Transformer tank during assembly or internal inspection.

9.4.4 No blank plate or access disk shall be opened or removed from the
transformer assembly if there is slightest possibility of disturbed environmental
changes (sand storm, dust cloud, rain or heavy humidity)

9.4.5 Any open earthworks or grading operation within the local vicinity of the
transformer erection / installation shall be suspended until the transformer
installation & oil circulation actions are completed.

9.4.6 The number of tools used inside the Transformer shall be counted before and
after work, in order to ensure that non left inside.

9.4.7 Tightening of the gaskets shall be as per Vendor manual instruction.

9.4.8 Examine the bushing for dirt deposit and clean them as per Vendor Manual

9.4.9 Check the oil level in the oil cup and ensure that air passages are free in the
breather.

9.4.10 Check the OTI and WTI pockets and replenish oil if required.

9.4.11 Do not leave secondary terminals of CT open.

9.4.12 Do not mix OLTC oil with main tank oil during circulation.

9.4.13 Fire fighting equipment shall be available near the oil treatment equipment as
well as the work site adjacent to the transformer.

9.4.14 All installation shall be carried out as per Vendor Manual.

9.5 INSTALLATION PROCEDURE

9.5.1 Transformer Position & Levelling.

9.5.1.1 Transformer shall be installed at a level floor strong enough to support the
weight and prevent accumulation of water.

9.5.1.2 The Transformer foundation shall be provided with adequate oil soak pit and
drains.

9.5.1.3 The Transformer foundation shall be prepared at a location such that the
Transformer shall get enough air circulation to cool the Transformer.

9.5.1.4 The Transformer shall be moved into position on the substation pad and base
shall be leveled. Install shims under the base for levelling if necessary.

9.5.1.5 The Transformer Installation shall be such that there is easy accessibility for
inspection.

9.5.1.6 The Transformer position shall be such that the breather, oil level indicator,
name plate, dial thermometer etc can be examined with the Transformer
energized.

9.5.1.7 The sampling valve, drain valve etc shall be at convenient locations.

9.5.2 Turret Installation

Remove the blank plate on the turret and on the transformer tank. Drain if any
oil present in the turret. Clean properly and placed them on the tank in correct
orientation as per the drawing, tighten all nuts over the stud.

9.5.3 Bushing Installation

9.5.3.1 Before starting the bushing installation check for any damage or oil leakage and clean the Bushing as per vendor Manual Instruction

9.5.3.2 Lift the bushing to inclined position with respect to vertical, the angle of
inclination shall match with the angle of position to which the bushing to be
erected.

9.5.3.3 Care shall be taken to avoid dragging the bushing on the floor while lifting from
its horizontal position to vertical inclination.

9.5.3.4 Open the blank plate of the turrets and take out the winding leads.

9.5.3.5 Slowly insert the bushing through the turret, which is bolted with the winding
leads. Finally the lead reaches the top of the bushing and the bushing sits
over the turret.

9.5.4 Radiator Installation

9.5.4.1 Radiator panels and flange mating surface shall be inspected for any damage
during transportation.

9.5.4.2 Check all valves on tank flanges are closed and remove all blank plates

9.5.4.3 Remove blank plates on radiator flanges and inspect for moisture or any type
of contamination inside radiator headers. If radiators are contaminated,
flushing is required.

9.5.4.4 Lift the radiator by means of single lifting eye at the top and install radiators.
Bolts shall be drawn up evenly, alternating across the corners, top and
bottom, until spring washers are fully compressed.

9.5.4.5 Follow the vendor manual Procedure for Transformer oil filling

9.5.5 Installation of Cable Box & Termination

Bushing insulation of cable box shall be checked for damage.

9.5.6 Temperature Indicator

Oil & winding temperature indicators shall be calibrated & fixed on the top of
the main tank

9.5.7 On Load Tap Changer Assembly

Check the tap couple with the driving mechanism

9.5.8 Neutral Earthing Resistor

9.5.8.1 Open and check for any physical damage.

9.5.8.2 Align the NER panel as per the manufacturer’s drawing.

9.5.8.3 Earthing connection of the Transformer shall be done as per AFC drawing.

9.5.9 Buchloz Relay

The Buchloz relay shall be installed between the transformer tank and oil conservator.

9.5.10 All Cable support, Cable Connection shall be completed as per AFC drawing &
Specification.

10.0 TESTING

Following electrical test shall be completed before energizing the transformer

• Transformer oil dielectric Test (BDV Test)

• Winding Insulation Resistance Test

• Primary Winding Resistance Test.

• Secondary Winding Resistance Test

• Vector Group Test

• All CT Test (Polarity Ratio & Magnetization Test if required)

• Protection Device Functional Test

• Tap Changer Setting / Ratio Test in all Taps

• If any other Test recommended by Vendor shall be done.

11.0 HEALTTH AND SAFETY REQUIREMENTS

 Prior to commencement of any activity, all personnel involved on the job shall attend the project HSE Induction training.
 The site management, supervisors and safety officers will closely supervise and monitor all phases of activities in connection with the compliance of safe working models.
 Personnel shall use protective gears and clothing in accordance with the project general safety guidelines. All personnel working in this project shall wear proper personal protective equipment (PPE) such as safety helmets, safety glasses, safety shoes, hand gloves etc. as required.
 All equipment like Cranes, Fork lifts, Chain pulley blocks, lifting belts, slings and other necessary tools and tackles for rigging & material handling operation, electrical equipment etc. shall be inspected by competent personnel prior to use at site. Equipment will be regularly checked and inspected by the safety officer.
 Any accident / Injury / near miss shall be reported immediately to appropriate authorities. Work shall stop and area secured
 The Construction Engineer / Supervisor shall be responsible for presenting all employees with a Pre-work briefing / Tool box talk using the risk assessment before work starts.
 The Construction Engineer / Supervisor shall immediately correct any hazards observed or reported to him. In the case of major hazards, work shall be stopped and appropriate and satisfactory permanent action to remove the hazards shall be taken.
 Good housekeeping shall be maintained at all times

12.0 DOCUMENTATION & RECORDS

– Material Receiving Inspection Check sheet
– Storage Handling & preservation Check sheet
– Inspection of Power Transformer Installation
– Power Transformer Insulation Resistance / Dielectric Absorption / Polarization Index Test Record.
– Power Transformer Oil Dielectric Strength Test
– Grounding Transformer / Neutral Earthing Resistor
– Installation of Neutral Earth Resistor
– Test Record for Neutral Earthing

NOTE: Sample copies of above are as attachments of this procedure.

Quality Control Procedure for SWGR & MCC

QUALITY CONTROL PROCEDURE FOR INSTALLATION & TESTING OF HV, MV, LV SWGR & MCC

1.0 PURPOSE

The purpose of this procedure is to describe the system of control for all activities and define the sequence of work for installation of HV, MV & LV Switchgears & MCC. This procedure also includes the interface activities, and responsibilities relating to HV, MV & LV Switchgears & MCC Installation & Testing activities, in compliance with project specifications and IFC drawings.

2.0 SCOPE

The scope of this procedure covers the activities during the installation & testing of HV, MV & LV Switchgears & MCC and related inspection activities

3.0 REFERENCES
3.1 DOCUMENTS:

DEP 33.67.51.31- Gen – HV Switchgears & Controlgear Assemblies
DEP.33.67.01.31- Gen – LV Switchgears & Controlgear Assemblies
DEP 33.64.10.10- Gen – Electrical Engineering Guidelines
– HV Switchgear – Water Injection Cluster
– LV Switchgear – Water Injection Cluster
– 11 KV Ring Main Unit
DEP 82.00.10.10 Gen – Project Quality Assurance
– Material Identification & Traceability Procedure
– Material Receipt Inspection Procedure
– Preservation of Project Equipment & Material.
– Hazardous Area Equipment & Electrical Bulk Materials.
– Electrical Engineering Design

3.2.QA/QC Documents:

– Project Quality Plan

– Inspection and Test Plan for Electrical Installation.
– Quality Control Procedure for Material Identification and Traceability

3.2.2 HSE Document:

– Project HSE plan

4.0 ABBREVIATIONS

4.1 Company :
4.2 Contractor :
4.3 Sub Contractor :
4.7 ITP : Inspection and Test Plan
4.9 QA : Quality Assurance
4.10 QC : Quality Control
4.11 RFI : Request for Inspection
4.12 NCR : Non Conformance Report
4.13 PQP : Project Quality Plan
4.14 HSE : Health Safety & Environment.

5.0 ROLES AND RESPONSIBILITIES

Following are the roles and responsibilities of personnel involved in this scope of procedure.

5.1 PROJECT MANAGER:

 Project Manager shall report to the Project Director
 Shall be responsible for the execution of the project in line with the contractual requirements.

5.2 QA/QC MANAGER:

 QAQC Manager shall report to the Project Manager.
 Shall be responsible for ensuring the Project Quality requirements and shall monitor all the Quality related issues throughout the project.

5.3 HSE MANAGER:

 HSE Manager shall report to the Project Manager
 Shall be responsible for ensuring the Project HSE requirements and shall monitor all the HSE related issues throughout the project.

5.4 PROJECT DOCUMENT CONTROLLER:

 Document controller shall report to the Project Manager.
 Shall be responsible for controlling & issuing all the Project related documents throughout the Project. He shall be key point to receive and transmit documents from the CONTRACTOR and to the CONTRACTOR. He shall maintain the status of documents like revisions, approvals etc.

5.5 CONSTRUCTION MANAGER:

 Construction manager shall report to the Project Manager
 Shall be responsible for arranging necessary equipment, man power, consumables, areas for storage, erection, preservation and ensuring that the procedure is implemented and complied with all specifications and HSE requirements.

5.6. PLANNING ENGINEER:

 Planning Engineer shall report to the Project Manager.
 Shall be responsible for monitoring the equipment receipt and erection activities in line with the schedule / targets given by the CONTRACTOR’s Project controls department. He shall be responsible for planning the field erection activities including but not limited to the materials, machinery and manpower.

5.7 CONSTRUCTION ENGINEER:

 Shall report to the Construction Manager.
 Shall coordinate and interface with Contractor’s construction engineer to ensure the work front availability at site. He shall be responsible for arranging the tools & tackles, issue of drawings for erection, monitoring the drawing revisions and modifications if any to meet the progress target set by the Project controls.
 Shall ensure the preparation of daily reports.

5.8 STORE KEEPER:

 Shall report to Material controller.
 Shall be responsible for proper storage and issue of special tools, gaskets, bolts & nuts and other accessories received with equipments, as per the manufacture’s recommendations.

5.9 QA/QC ENGINEER:
.
 Shall report to the QC Manager
 Shall be responsible to ensure that works carried out at site are complied with project quality requirements, to identify and intimate the CONTRACTOR for the hold, witness and review points as described in the inspection and test plan for Electrical Installation. He shall interface and coordinate with the CONTRACTOR’S Lead QC Manager to resolve the issues related to quality and shall monitor the Implementation of procedure at site.

5.10 QC INSPECTOR ELECTRICAL:

 Shall report to the QC Engineer.
 Shall inspect the incoming equipment and verify the materials received are confirming to the AFC Drawings.
 Shall be responsible for quality control & documentations.
 Stages of inspections and surveillance in accordance with ITP & assurance of quality of work as per specification and installation procedure.

6.0 CONSTRUCTION EQUIPMENTS

 Cranes, Fork Lifts, lifting belts, slings and other necessary tools and tackles for rigging & material handling operation shall be calibrated & Colour coded as per HSE requirement

 Hand tools & Calibrate all Testing Equipments suitable for HV, MV, LV Switchgears & MCC
Installation & testing

 The Supervisor / Foreman shall ensure that the equipment & accessories used are suitable for the job and are in good working condition. Electrical Connections made to complete the electrical work shall be as per good engineering practices.

7.0 DRAWING RECEIPT & ISSUE OF EQUIPMENT

The Engineering Department shall issue to construction department the Issued for Construction Drawings provided by client together with Material Traceability List complete with information such as identified profile and description to corresponding material items.

After receiving the Issued for Construction Drawings, the Construction Department shall request the equipment from the Store. The Store shall issue the Material issue Slip with equipment stated.

8.0 CALIBRATION CONTROL

The measuring instruments like Insulation Tester, Low Resistance meter(Ductor), Multimeter, Clamp meter, Primary & Secondary current Injection Testing Kit, surveying instruments, spirit level, measuring tape etc. deployed in during installation & testing of HV, MV & LV cable, activities shall be calibrated periodically once in six months at certified laboratory and the certificates may be submitted for review of The certificates are to be made available at site during various stages of inspection.

9.0 QUALITY CONTROL

9.1 Receiving Inspection:

9.1.1 Check the availability of “IFC” drawings, vendor manuals and instructions etc.

9.1.2 Equipment received will be stored according to the installation schedule
and manufacturer’s instruction.

9.1.3 All material Receiving Inspection to be completed before installation in position and
if any discrepancy found, item shall be entered in the punch list and maintain a
record, further inform to site Engineer immediately.

9.1.4 Proper protection will be provided against wind, dust, rain corrosion etc.

9.2 Inspection Prior to Installation:

9.2.1 Foundation release note shall be received from civil department prior to installation work.

9.2.2 Prior to installation of the equipment foundation shall be inspected in order to
Confirm AFC drawing requirements for dimension, center line coordinate, elevation
and layout.

9.2.3 Check that the orientation marks are provided prior to installation.

9.2.4 Test certificates for the lifting cranes, tools & tackles shall be made available &
accepted by, HSE person.

9.2.5 All the tools and tackles used for installation works shall be of good quality.

9.2.6 Lifting space availability shall be verified.

9.2.7 Temporary platform or scaffolding required shall be fixed prior to lifting the equipment.

9.2.8 Safety personnel shall be informed about all the heavy lifts well in advance.

9.3 QUALITY CONTROL CHECKS DURING INSTALLATION

9.3.1 General Requirements

9.3.1.1 All materials received at site shall be inspected upon receipt in accordance with
the PQP-

9.3.1.2 All tests shall be recorded as defined herein and witnessed by Client in
accordance with the requirement of ITP-

9.3.1.3 All test instrument shall have valid calibration certificate with a minimum of
one Year validity.

9.3.1.4 Vendor’s instructions shall be followed.

9.3.2 Installation Checks

9.3.2.1 Base plate, floor fixings etc. shall be checked for level and location and fixing
points check against their position on the respective panels, cable sleeves
and ducts shall be inspected to ensure correct line and location.

9.3.2.2 Before installing in position, panel sections shall be opened up and inspected for
cleanliness and to ensure no foreign bodies are present. Dust shall be removed
using vacuum cleaner.

9.3.2.3 Panel section shall inspect for any mechanical damage and megger check to
ensure no direct contact to earth.

9.3.2.4 Installation shall be witnessed to ensure the equipment is vertical and fixing bolts
tightened. Where equipment consists of a number of panel sections,
the assembly shall commence from the centre section. Sections on either side of the centre shall be alternated, leveled and shimmed as necessary.

9.3.2.5 The complete assembly shall be checked to ensure alignment and level after
tightening of the bolts.

10.0 TESTING

10.1 Test Before Energization

10.1.1 Doors and panels shall be checked to ensure proper opening and closing.
10.1.2 Withdrawable units shall be checked to ensure freedom of movement.

10.3.3 Fuse ratings, protection devices, indicators and ammeters shall be checked
against the panel schedule. Current transformer ratios shall be checked.

10.3.4 Busbar connections shall be inspected for correct phasing and tightness.

10.3.5 The mechanical operation of spring wound circuit breakers shall be checked.

10.3.6 Earthing shall be checked to ensure that it is as per the IFC drawing.

10.3.7 Insulation Resistance Test of internal Busbar

10.3.8 Torque Test of Busbar Joints.

10.3.9 Contact Resistance Test of Busbar joints.

10.3.10 Relay Test for Control, Protective and metering devices.

10.3.11 Over Current Relays shall be checked at their minimum, maximum and
normal setting values.

10.3.12 Under Voltage Relays shall be checked by voltage simulation noting the
drop-out and pick-up values.

10.3.11 Switchgear & MCC Insulation Resistance Test.

10.3.12 All test shall be witnessed and recoded as per the ITP-

10.3.13 If any other test recommended by vendor shall be done.

10.3.14 Upon completion of the tests and settings of the relays, a final physical and
megger check shall be carried out prior to the equipment being deemed
ready for energization.

10.2 Energization Tests

10.2.1 The Equipment shall be energized and witnessed according to the contract
procedures and with specified authorizations.

10.2.2 The Equipment shall be functionally checked prior to the connection of outgoing
power and control cables. The checks shall commence with the incoming
breakers, bus tie, auxiliary suppliers and progress through the main outgoing
feeders

10.2.3 Breakers shall be closed and tripped manually. Particular attention shall be
paid to the alignment of contacts on main breakers and auxiliary relays.

10.2.4 Inter-tripping of incoming supplies shall be checked first by simulating control
Inputs followed by actual energization of associated supplies.

10.2.5 Remote operation of breakers shall be checked by simulating inputs at the
Control wiring terminal block.

10.2.6 Mechanical interlocks such as door interlocks etc. shall be checked by actual
opening and closing.

11.0 REQUEST FOR INSPECTION

RFI shall be raised 24 hours before the actual schedule for Inspection as per the approved ITP.

12.0 HEALTH AND SAFETY REQUIREMENTS

 Prior to commencement of any activity, all personnel involved on the job shall attend the project HSE Induction training.
 The site management, supervisors and safety officers will closely supervise and monitor all phases of activities in connection with the compliance of safe working models.
 Personnel shall use protective gears and clothing in accordance with the project general safety guidelines. All personnel working in this project shall wear proper personal protective equipment (PPE) such as safety helmets, safety glasses, safety shoes, hand gloves etc. as required.
 All equipment like Cranes, Fork lifts, Chain pulley blocks, lifting belts, slings and other necessary tools and tackles for rigging & material handling operation, electrical equipment etc. shall be inspected by competent personnel prior to use at site. Equipment will be regularly checked and inspected by the safety officer.
 Any accident / Injury / near miss shall be reported immediately and appropriate authorities. Work shall stop and area secured until approved by client
 The Construction Engineer / Supervisor shall be responsible for presenting all employees with a Pre-work briefing / Tool box talk using the risk assessment before work starts.
 The Construction Engineer / Supervisor shall immediately correct any hazards observed or reported to him. In the case of major hazards, work shall be stopped and appropriate and satisfactory permanent action to remove the hazards shall be taken.
 Good housekeeping shall be maintained at all times.

13.0 DOCUMENTATION & RECORDS

– Material Receiving Inspection Check sheet
– Storage Handling & preservation Check sheet
– Inspection of Switchgear / Motor Control Centers
– Ductor Test of Busbar joints.
– Inspection Record for Current Transformer
– Inspection Record for Voltage transformer
– Inspection Record for Protection Relays and Metering Devices
– Low Voltage Switchgear and Motor Control Center-LV Circuit Breaker
Checks
– Low Voltage Switchgear and Motor Control Center-Motor Starter Checks.
– Low Voltage Switchgear and Motor Control Center-Fused Switch/Isolator
Checks.
– MV Circuit Breaker Circuit Breaker Checks

NOTE: Sample copies of above are as attachments of this procedure.