6-81-1035 Rev 2

7/28/2019 6-81-1035 Rev 2

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IN SPEC T ION A N D T EST PL A NFO R

H V S Y N C H R O N O U S G E N E R A T O R

STANDARD SPE CIFICATION NO.

6-81-1035 Rev. 2

o f 6

t R i . 0 )4fiaT u r zfr- - 9 r

INSPECTION AND TEST PLAN

FOR

HV SYNCHRONOUS GENERATOR

2 29.06 .12 Revised and Re- issued P R J D AK C DM

1 24.12.07 Revised and Re- issued SA C R M MVKK VC

0 31.03.03 I ssued for implementation R G AK C AK B G R R

Rev.N o.

Date PurposePrepared

byChecked

by

Standards CommitteeConvenor

Standards BureauChairman

Approved by

Format No. 8-00-0001-F7 Rev. 0 Copyright EIL — All r ights reserved

7/28/2019 6-81-1035 Rev 2


MPT/MT : Magnetic Particle Testing

MRT Mechanical Run Test

MTCMOC

NPSH

NDT

NEMA

PO

PESO

PQR

PR

PM IPV C

QCRT

T CTPI or TPIA

UT

UL

VDR

WP S

WP Q

XLPE

: 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

SiIIWIZIEtek ENGINEERSz iaalitg'SINDIA LMTE D

IN SPEC T ION A N D T EST PL A NF O R


S T A N D A RD S P E C I F I C A T IO N N O .

6-81-1035 Rev. 2

of 6

Abbreviations

AS

BASEEFA

BIS

CCE or CCOE

CELL

CIMFR

CEDFT

DTDPT

ERTL

FCRIFM

FLP

HICIT PIP

IC

IG CIE C

JE C

LP T

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 InstituteFactory 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

Inspection Standards Committee

Convenor : Mr. A.K. Chaudhary

Members:

Mr. S.C. Gupta Mr. RK Singh Mr. MP Jain (Projects)

Mr. G. Suresh Mr. Rajeev Kumar Mr. G. Poornachandra Rao

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

Copyright EIL — Al l rights reserved

7/28/2019 6-81-1035 Rev 2


at E N G IN E E RSg wagsINDIA LI MI TE D

INSPECTION AND TEST PLANFO R


STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2

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

S L

NO.STAGE/ ACTIVITY CHARACTERISTICS

QUANTUM

OF CHECKRECORD

SCOPE OF INSPECTION

SU B

SUPPLIERSUPPLIER EIL/TPIA

1.0 Procedures -- -- -- -- -- --

2.0 Material Inspection

2. 1

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.

Visual, Mechanical & Chemical properties,

Surface finish, Dimensions as per Supplier's

standard.

Shaf t — MPT & UT

As per

Supplier's

standard

Material Test

Certificates /

Test records

H H/R

R

(For major

items only)

2 .2

AVR, Forced Lubrication

System for sleeve bearings

(if applicable), Forced

Ventilation system, Heat

Exchanger.

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 H/R R

Copyright EIL — Al l rights reservedormat No. 8 -00-0001-F7 Rev . 0

7/28/2019 6-81-1035 Rev 2


E N O N E E R Sillataieuw I N D I A L I M I T E D" '"w"" '

I N S P E C T IO N A N D T E S T P L A N

F O R


S T A N D A R D S P E C I F IC A T I O N N O .

6 - 8 1 -1 0 3 5 R e v . 2

of 6

S LNO.

STAGE/ ACTIVITY CHARACTERISTICSQUANTUM

OF CHECKRECORD

SCOPE OF INSPECTION

S U BSUPPLIER EUL/TPIA

SUPPLIER

3.0 Inprocess Inspection

3. 1

In Process Checks for main

stator, main rotor, exciter

stator and exciter rotor.

i Resistance, HV Test, IR Test., Inter turn

insulation, Dynamic Balancing of Rotor Assembly,

Radial air gap measurement100% Test Records - H -

4.0 Final Inspection

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

ecords

100% Inspection test

records

- H II/W

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

Copyright EIL — Al l rights reservedormat No. 8 -00-0001-F7 Rev . 0

7/28/2019 6-81-1035 Rev 2


l a 11 5 1 z eh e l A E N G I N E E R S7 t i i5 tenli f INDIA L IMITED

IA Gov( oe Ind* us-Mono)

IN SPEC T ION A N D T EST PL A NFO R


STANDARD SPECIFICATION NO.

6-81-1035 Rev. 2

of 6

SL


QUANT

OF CHECK

UMRECORD

SCOPE OF INSPECTION

S U B


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

100% Inspection test

records

- H H/W

4.2 Generator (Type Tests)

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.

One sample

from each

type/rating

Inspection test

recordsH H/W

4 .3Submission of Documents/

Certificates

Test certificate from recognized testing

laboratory for area classification.

BIS certificate for FLP motors and accessories

as applicable.

CCOE/PESO approved certificates for motorsand accessories as applicable

1 Machine/

Type/rating

Supplier's Test

Records /

.. .

Certificates

trom statutory

berliec

- H R

Tests for degree of protection of enclosure

Terminal Box fault level test certificate

5. 0 Painting

5.1 Painting of Motor framesPre treatment, primer and final paint,

shade, thickness100% Test records - H --

Copyright EIL — All rights reservedormat No. 8-00-0001-F7 Rev. 0

7/28/2019 6-81-1035 Rev 2


l a mz e t i b ENONEERSflowegver INDIA LIMITED

=am) IA GoN ot Ind. UndaMirgl

IN SPEC T ION A N D T EST PL A NF O R


S T A N D A RD S P E C I F I C A T IO N N O .

6-81-1035 Rev. 2

of 6

SL


NUTUM

OF

A

CHECKRECORD

SCOPE OF INSPECTION

S U B


6.0 Documentation and IC

6. 1 Documentation and ICReview of Internal Test Records

IC issuance100%

Supplier's Test

Records /

Inspection

Certificate (IC)

- 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

aeschedueddae

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

Copyright EIL — Al l rights reserved

6-81-1035 Rev 2

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