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INSPECTION AND TEST PLAN FOR HV SYNCHRONOUS GENERATOR

STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2
Page 1 of 6

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A-9r f4fiaTur zfrINSPECTION AND TEST PLAN FOR HV SYNCHRONOUS GENERATOR

2 1 0 Rev. No.

29.06.12 24.12.07 31.03.03 Date

Revised and Re-issued Revised and Re-issued Issued for implementation Purpose

P SA RG Prepared by

RJD CRM AKC Checked by

AKC MVKK AKB Standards Committee Convenor

DM VC GRR Standards Bureau Chairman

Approved by

Format No. 8-00-0001-F7 Rev. 0

Copyright EIL All rights reserved

SiIIWIZIEtek ENGINEERS A LMTED z iaalitg 'S INDIA

INSPECTION AND TEST PLAN FOR HV SYNCHRONOUS GENERATOR

STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2
Page 2 of 6

Abbreviations AS BASEEFA BIS CCE or CCOE CELL CIMFR CE DFT DT DPT ERTL FCRI FM FLP HIC ITP IP IC IGC IEC JEC LPT Alloy Steel British Approval Service for Electrical Equipment in Flammable Atmospheres Bureau of Indian Standards Chief Controller of Explosives Certification Engineers International Limited Central Institute of Mining & Fuel Research Carbon Equivalent Dry Film Thickness Destructive Testing Dye Penetrate Testing Electronics Regional Test Laboratory Fluid Control Research Institute Factory Mutual Flame Proof Hydrogen Induced Cracking Inspection and Test Plan Ingress Protection Inspection Certification Inter Granular Corrosion International Electro technical Commission Japanese Electro technical Committee Liquid Penetrate Testing MPT/MT MRT MTC MOC NPSH NDT NEMA PO PESO PQR PR PMI PVC QC RT TC TPI or TPIA UT UL VDR WPS WPQ XLPE : : : Magnetic Particle Testing Mechanical Run Test Material Test Certificate Material of Construction Net Positive Suction Head Non Destructive Testing National Electrical Manufacturers Association Purchase Order Petroleum Explosive Safety Organization Procedure Qualification Record Purchase Requisition Positive Material Identification Poly Vinyl Chloride Quality Control Radiography Testing Test Certificate Third Party Inspection Agency Ultrasonic Testing Under writer Laboratories Vendor Data Requirement Welding Procedure Specification Welders Performance Qualification Cross Linked Poly Ethylene

: : : :

: : :

: : : :

Inspection Standards Committee Convenor : Members: Mr. S.C. Gupta Mr. G. Suresh
Format No. 8-00-0001-F7 Rev. 0

Mr. A.K. Chaudhary Mr. RK Singh Mr. Rajeev Kumar Mr. MP Jain (Projects) Mr. G. Poornachandra Rao
Copyright EIL All rights reserved

g,

at ENGINEERS wagsINDIA LIMITED

INSPECTION AND TEST PLAN FOR HV SYNCHRONOUS GENERATOR

STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2
Page 3 of 6

1.0 SCOPE This Inspection and Test Plan covers the minimum testing & inspection requirements of HV Synchronous Generators. 2.0 REFERENCE DOCUMENTS PO/PR & Standards referred there in /Job specifications / Approved documents. 3.0 INSPECTION AND TEST REQUIREMENTS SL NO. 1.0 2.0 STAGE/ ACTIVITY Procedures Material Inspection Raw Material: Body(casting or fabrication), Rotor shaft, Core laminations, Copper, Insulation material, Bearings, Space heater, CT?PT, Lighting Arrestor, Power supply, RTD, BTD, Instrument, cable boxes, Cable glands, etc. AVR, Forced Lubrication System for sleeve bearings (if applicable), Forced Ventilation system, Heat Exchanger. CHARACTERISTICS -QUANTUM OF CHECK -RECORD -SCOPE OF INSPECTION SUB EIL/TPIA SUPPLIER SUPPLIER ----

2.1

Visual, Mechanical & Chemical properties, Surface finish, Dimensions as per Supplier's standard. Shaft MPT & UT

As per Supplier's standard

Material Test Certificates / Test records

H/R

R (For major items only)

2.2

Visual/Dimension/Pressure test/Material test certificate. Functional Tests, Lubrication system check and performance check for guaranteed performance of motors and fans

100%

Manufacturer's test Certificates/ test records

H/R

Format No. 8-00-0001-F7 Rev. 0

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ENONEERS ill tataieuw INDIA LIMITED "'"w""'


SL NO. 3.0

INSPECTION AND TEST PLAN FOR HV SYNCHRONOUS GENERATOR


QUANTUM OF CHECK

STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2
Page 4 of 6

STAGE/ ACTIVITY Inprocess Inspection

CHARACTERISTICS

RECORD

SCOPE OF INSPECTION SUB SUPPLIER EUL/TPIA SUPPLIER

3.1

In Process Checks for main stator, main rotor, exciter stator and exciter rotor. Final Inspection

Resistance, HV Test, IR Test., Inter turn insulation, Dynamic Balancing of Rotor Assembly, i Radial air gap measurement

100%

Test Records

4.0

4.1

Generator (Routine Tests)

General visual check, dimensional check, nameplate details including punching of statutory references and markings Check calibration status of all testing equipment. Mounting, Shaft centre height. Paint shade Terminal box location and internal clearances Winding Resistance measurement 1R before & after HV Test for main stator, main rotor, exciter stator, exciter rotor & space Polarization Index Test IR on RTDs & Snace heaters HV Test on main stator, main rotor, exciter stator exciter rotor and space heater. No load Characteristics (OCC) Short Circuit characteristics Regulation test Phase sequence test

100%

Inspection test records ecords

II/W

Format No. 8-00-0001-F7 Rev. 0

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la1151zehelA ENGINEERS 7 tii5tenlif INDIA LIMITED us


IA Gov( oe Ind* -Mono)

INSPECTION AND TEST PLAN FOR HV SYNCHRONOUS GENERATOR


QUANT UM OF CHECK

STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2
Page 5 of 6

SL NO.

STAGE/ ACTIVITY

CHARACTERISTICS Pressure Test on coolers of closed circuit cooling system [wherever applicable] Measurement of bearing current/shaft voltage (above 1000 KW) Vibration Measurement [under no-load-halflcey] Measurement of Shaft Vibrations Functional Tests on AVR Checks on line & Neutral cubicles Checks on Excitation Panels Temperature Rise test Over speed Test Determination of Efficiency Waveform & Harmonic analysis, transient voltage dip, rise and recovery time. Three phase short circuit withstand test and measurement of reactance and time constants (above 1000KW) Measurement of Leakage Reactance and Potier Reactance. Test certificate from recognized testing laboratory for area classification. BIS certificate for FLP motors and accessories as applicable. CCOE/PESO approved certificates for motors and accessories as applicable Tests for degree of protection of enclosure Terminal Box fault level test certificate Pre treatment, primer and final paint, shade, thickness

RECORD

SCOPE OF INSPECTION SUB SUPPLIER EIL/TPIA SUPPLIER

100%

Inspection test records

H/W

4.2

Generator (Type Tests)

One sample from each type/rating

Inspection test records

H/W

4.3

Submission of Documents/ Certificates

1 Machine/ Type/rating

Supplier's Test Records / Certificates ... trom statutory berliec

5.0 5.1

Painting Painting of Motor frames 100% Test records H --

Format No. 8-00-0001-F7 Rev. 0

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lamzetibENONEERS flowegver INDIA LIMITED


=am) IA GoN ot Ind. UndaMirgl

INSPECTION AND TEST PLAN FOR HV SYNCHRONOUS GENERATOR


QUTUM AN OF CHECK

STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2
Page 6 of 6

SL

NO. 6.0 6.1

STAGE/ ACTIVITY

CHARACTERISTICS

RECORD

SCOPE OF INSPECTION SUB SUPPLIER EIL/TPIA SUPPLIER

Documentation and IC Documentation and IC Review of Internal Test Records IC issuance 100% Supplier's Test Records / Inspection Certificate (IC)

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 (As applicable): Wherever W/R or fl/W is indicated, Inspection Engineer shall decide the option to be exercised for the particular stage and supplier In case of conflict between purchase specification, contract documents and ITP, more stringent conditions shall be applicable. This document describes generally the requirements pertaining to all types of the item. Requirements specific to PO and the item are only applicable. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents

Format No. 8-00-0001-FT Rev. 0

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