Quality Control Procedure for SWGR & MCC

February 4, 2018 | Author: Mohan Babu Vengalathuri | Category: Relay, Personal Protective Equipment, Quality Assurance, Construction Management, Calibration
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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 Gen – HV Switchgears & Controlgear Assemblies DEP. Gen – LV Switchgears & Controlgear Assemblies DEP Gen – Electrical Engineering Guidelines – HV Switchgear – Water Injection Cluster – LV Switchgear – Water Injection Cluster – 11 KV Ring Main Unit DEP 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: ϖProject Manager shall report to the Project Director ϖ Shall be responsible for the execution of the project in line with the contractual requirements. 5.2 QA/QC MANAGER: ϖ QAQC Manager shall report to the Project Manager. ϖ Shall be responsible for ensuring the Project Quality requirements and shall monitor all the Quality related issues throughout the project. 5.3 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. 5.4 PROJECT DOCUMENT CONTROLLER: ϖ Document controller shall report to the Project Manager. ϖ 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: ϖ Construction manager shall report to the Project Manager ϖ 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: ϖ Planning Engineer shall report to the Project Manager. 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. He shall be responsible for planning the field erection activities including but not limited to the materials, machinery and manpower. 5.7 CONSTRUCTION ENGINEER: ϖ Shall report to the Construction Manager. ϖ 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. ϖ Shall ensure the preparation of daily reports. 5.8 STORE KEEPER: ϖ Shall report to Material controller. ϖ 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: . 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, 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: ϖ Shall report to the QC Engineer. ϖ Shall inspect the incoming equipment and verify the materials received are confirming to the AFC Drawings. ϖ Shall be responsible for quality control & documentations. ϖ Stages of inspections and surveillance in accordance with ITP & assurance of quality of work as per specification and installation procedure. 6.0 CONSTRUCTION EQUIPMENTS ϖ 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

ϖ Hand tools & Calibrate all Testing Equipments suitable for HV, MV, 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. 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 All materials received at site shall be inspected upon receipt in accordance with the PQP9.3.1.2 All tests shall be recorded as defined herein and witnessed by Client in accordance with the requirement of ITP9.3.1.3 All test instrument shall have valid calibration certificate with a minimum of one Year validity. Vendor’s instructions shall be followed. 9.3.2 Installation Checks 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. 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. Panel section shall inspect for any mechanical damage and megger check to ensure no direct contact to earth. 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. 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 ITP10.3.13 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 ϖ Prior to commencement of any activity, all personnel involved on the job shall attend the project HSE Induction training. ϖ 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. ϖ 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. ϖ 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. ϖ Any accident / Injury / near miss shall be reported immediately and appropriate authorities. Work shall stop and area secured until approved by client ϖ 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. ϖ 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. ϖ 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.

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