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

3 Sub Contractor : 4.5 CONSTRUCTION MANAGER: ϖ Construction manager shall report to the Project Manager ϖ Shall be responsible for arranging necessary equipment. erection. areas for storage. approvals etc.7 ITP : Inspection and Test Plan 4.14 HSE : Health Safety & Environment.3 HSE MANAGER: ϖ HSE Manager shall report to the Project Manager ϖ Shall be responsible for ensuring the Project HSE requirements and shall monitor all the HSE related issues throughout the project. 5.0 ROLES AND RESPONSIBILITIES Following are the roles and responsibilities of personnel involved in this scope of procedure.4. 5. preservation and ensuring that the procedure is implemented and complied with all specifications and HSE requirements.2 QA/QC MANAGER: ϖ QAQC Manager shall report to the Project Manager. He shall maintain the status of documents like revisions.2 Contractor : 4.1 Company : 4.1 PROJECT MANAGER: ϖProject Manager shall report to the Project Director ϖ Shall be responsible for the execution of the project in line with the contractual requirements. 5. ϖ Shall be responsible for controlling & issuing all the Project related documents throughout the Project. 5. 5. 5.13 PQP : Project Quality Plan 4.11 RFI : Request for Inspection 4.10 QC : Quality Control 4. He shall be key point to receive and transmit documents from the CONTRACTOR and to the CONTRACTOR. .12 NCR : Non Conformance Report 4. man power. consumables. ϖ Shall be responsible for ensuring the Project Quality requirements and shall monitor all the Quality related issues throughout the project.9 QA : Quality Assurance 4.4 PROJECT DOCUMENT CONTROLLER: ϖ Document controller shall report to the Project Manager.

slings and other necessary tools and tackles for rigging & material handling operation shall be calibrated & Colour coded as per HSE requirement . ϖ Shall be responsible for quality control & documentations. 5. to identify and intimate the CONTRACTOR for the hold. 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. lifting belts. 5. ϖ 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. as per the manufacture’s recommendations.9 QA/QC ENGINEER: . Fork Lifts. bolts & nuts and other accessories received with equipments.8 STORE KEEPER: ϖ Shall report to Material controller. witness and review points as described in the inspection and test plan for Electrical Installation. 6. monitoring the drawing revisions and modifications if any to meet the progress target set by the Project controls. ϖ Shall coordinate and interface with Contractor’s construction engineer to ensure the work front availability at site. gaskets.7 CONSTRUCTION ENGINEER: ϖ Shall report to the Construction Manager. ϖ Shall be responsible for proper storage and issue of special tools. issue of drawings for erection. He shall be responsible for arranging the tools & tackles. ϖ Shall inspect the incoming equipment and verify the materials received are confirming to the AFC Drawings. He shall be responsible for planning the field erection activities including but not limited to the materials. ϖ Shall ensure the preparation of daily reports. ϖ Shall report to the QC Manager ϖ Shall be responsible to ensure that works carried out at site are complied with project quality requirements. ϖ Stages of inspections and surveillance in accordance with ITP & assurance of quality of work as per specification and installation procedure.0 CONSTRUCTION EQUIPMENTS ϖ Cranes.5.10 QC INSPECTOR ELECTRICAL: ϖ Shall report to the QC Engineer. machinery and manpower. 5.6. PLANNING ENGINEER: ϖ Planning Engineer shall report to the Project Manager. 5.

the Construction Department shall request the equipment from the Store. The Store shall issue the Material issue Slip with equipment stated. Multimeter.4 Proper protection will be provided against wind. 9.3 All material Receiving Inspection to be completed before installation in position and if any discrepancy found. MV & LV cable. 7. measuring tape etc. deployed in during installation & testing of HV.1 Receiving Inspection: 9. Clamp meter.1.1. Primary & Secondary current Injection Testing Kit. MV.ϖ Hand tools & Calibrate all Testing Equipments suitable for HV. 9.1. vendor manuals and instructions etc. Low Resistance meter(Ductor).0 QUALITY CONTROL 9.1. Electrical Connections made to complete the electrical work shall be as per good engineering practices. . 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.0 CALIBRATION CONTROL The measuring instruments like Insulation Tester.2 Inspection Prior to Installation: 9. item shall be entered in the punch list and maintain a record.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. 8.2 Equipment received will be stored according to the installation schedule and manufacturer’s instruction. After receiving the Issued for Construction Drawings.2. dust. 9. 9. surveying instruments. 9. spirit level.1 Check the availability of “IFC” drawings. further inform to site Engineer immediately. rain corrosion etc.1 Foundation release note shall be received from civil department prior to installation work. LV Switchgears & MCC Installation & testing ϖ The Supervisor / Foreman shall ensure that the equipment & accessories used are suitable for the job and are in good working condition.

3 Check that the orientation marks are provided prior to installation.1.2 Before installing in position.2.1. . 9.6 Lifting space availability shall be verified.2 Prior to installation of the equipment foundation shall be inspected in order to Confirm AFC drawing requirements for dimension. elevation and layout. panel sections shall be opened up and inspected for cleanliness and to ensure no foreign bodies are present. 9. 9.2.2 All tests shall be recorded as defined herein and witnessed by Client in accordance with the requirement of ITP9. HSE person.8 Safety personnel shall be informed about all the heavy lifts well in advance.9.3.1. center line coordinate. 9. 9.3.2.3. 9. floor fixings etc.2.1 All materials received at site shall be inspected upon receipt in accordance with the PQP9.1 General Requirements 9.2.2 Installation Checks 9. cable sleeves and ducts shall be inspected to ensure correct line and location.2.5 All the tools and tackles used for installation works shall be of good quality.1 Base plate. 9.1.2.3.4 Test certificates for the lifting cranes.2. tools & tackles shall be made available & accepted by. 9. Dust shall be removed using vacuum cleaner.2.3 All test instrument shall have valid calibration certificate with a minimum of one Year validity.2.3. 9.3.7 Temporary platform or scaffolding required shall be fixed prior to lifting the equipment.3 Panel section shall inspect for any mechanical damage and megger check to ensure no direct contact to earth.4 Vendor’s instructions shall be followed.3. 9. shall be checked for level and location and fixing points check against their position on the respective panels.3.3.3 QUALITY CONTROL CHECKS DURING INSTALLATION 9. 9.

5 The complete assembly shall be checked to ensure alignment and level after tightening of the bolts. 9.3.5 The mechanical operation of spring wound circuit breakers shall be checked. Where equipment consists of a number of panel sections.3.9. the assembly shall commence from the centre section. indicators and ammeters shall be checked against the panel schedule.2. Protective and metering devices. leveled and shimmed as necessary. 10. .11 Switchgear & MCC Insulation Resistance Test.11 Over Current Relays shall be checked at their minimum.3.3.1 Test Before Energization 10.3.1 Doors and panels shall be checked to ensure proper opening and closing. 10. 10.13 If any other test recommended by vendor shall be done.8 Torque Test of Busbar Joints.3.3.1. 10.2 Withdrawable units shall be checked to ensure freedom of movement.3.0 TESTING 10. 10. 10. maximum and normal setting values.4 Installation shall be witnessed to ensure the equipment is vertical and fixing bolts tightened.4 Busbar connections shall be inspected for correct phasing and tightness.3 Fuse ratings.7 Insulation Resistance Test of internal Busbar 10.3.2. 10.12 All test shall be witnessed and recoded as per the ITP10. 10.3. Current transformer ratios shall be checked.12 Under Voltage Relays shall be checked by voltage simulation noting the drop-out and pick-up values. 10. Sections on either side of the centre shall be alternated.3. 10.3. 10. 10.6 Earthing shall be checked to ensure that it is as per the IFC drawing. protection devices.9 Contact Resistance Test of Busbar joints.3.3.10 Relay Test for Control.3.1. 10.

ϖ The site management. Work shall stop and area secured until approved by client ϖ The Construction Engineer / Supervisor shall be responsible for presenting all employees with a . Equipment will be regularly checked and inspected by the safety officer. slings and other necessary tools and tackles for rigging & material handling operation.2. 10.3.1 The Equipment shall be energized and witnessed according to the contract procedures and with specified authorizations. All personnel working in this project shall wear proper personal protective equipment (PPE) such as safety helmets.5 Remote operation of breakers shall be checked by simulating inputs at the Control wiring terminal block. 10. bus tie. 10. lifting belts. 10. 10.0 HEALTH AND SAFETY REQUIREMENTS ϖ Prior to commencement of any activity. electrical equipment etc.2. ϖ Personnel shall use protective gears and clothing in accordance with the project general safety guidelines. The checks shall commence with the incoming breakers. Particular attention shall be paid to the alignment of contacts on main breakers and auxiliary relays. hand gloves etc. Chain pulley blocks. ϖ Any accident / Injury / near miss shall be reported immediately and appropriate authorities. safety shoes.2. a final physical and megger check shall be carried out prior to the equipment being deemed ready for energization. all personnel involved on the job shall attend the project HSE Induction training.3 Breakers shall be closed and tripped manually.2 Energization Tests 10.2. shall be checked by actual opening and closing. safety glasses. 11.2.0 REQUEST FOR INSPECTION RFI shall be raised 24 hours before the actual schedule for Inspection as per the approved ITP. shall be inspected by competent personnel prior to use at site. auxiliary suppliers and progress through the main outgoing feeders 10.14 Upon completion of the tests and settings of the relays.2 The Equipment shall be functionally checked prior to the connection of outgoing power and control cables. ϖ All equipment like Cranes. 12.10. Fork lifts. supervisors and safety officers will closely supervise and monitor all phases of activities in connection with the compliance of safe working models.2.6 Mechanical interlocks such as door interlocks etc. as required.4 Inter-tripping of incoming supplies shall be checked first by simulating control Inputs followed by actual energization of associated supplies.

13. – MV Circuit Breaker Circuit Breaker Checks NOTE: Sample copies of above are as attachments of this procedure. ϖ The Construction Engineer / Supervisor shall immediately correct any hazards observed or reported to him. ϖ Good housekeeping shall be maintained at all times. work shall be stopped and appropriate and satisfactory permanent action to remove the hazards shall be taken. .Pre-work briefing / Tool box talk using the risk assessment before work starts. – 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. In the case of major hazards.0 DOCUMENTATION & RECORDS – Material Receiving Inspection Check sheet – Storage Handling & preservation Check sheet – Inspection of Switchgear / Motor Control Centers – Ductor Test of Busbar joints. – Low Voltage Switchgear and Motor Control Center-Fused Switch/Isolator Checks.