Third Party Inspection for Control Panel

The Third Party Inspection for Control Panel article provides you with information about the control panel test and control panel inspection in the manufacturing shop. You may need to review this article along with the following article:
This content guides you through all the necessary stages in the production of the control panels, including the raw material, final inspection, preservation and packing, and dispatch to site. You need to take this point into account: this article is written for a typical control panel and might not be detailed for special cases. This content may be useful for second party inspectors, control panel manufacturer quality control personnel, engineering companies, and purchasers, as well. All control panel inspection and testing is done against the approved drawings, purchase order specifications, purchasers or company standards, and within the practices and rules of the country, state or province and any government decrees, laws, ordinance or regulation as may apply The applicable codes and specifications for a control panel that is under the construction process is:

Design code Purchase order specification Purchaser's standards Approved drawings

The applicable codes and standards may be based any international standards. This content is general and can be useful for all recognized standards. Required Documents for Third Party Inspector Review: The list of documents normally is agreed upon in the Pre-Inspection meeting, which is held several weeks before the actual commencement of the inspection work. The parties that participate in this meeting are the manufacturer, purchaser and third party inspection agency representatives. This is already explained in the Inspection and Test Plan for Control Panel article. These are the list of documents that are normally agreed upon to be presented to the inspector:

Control Panel Purchase Order or Contract Control Panel Manufacture Quality Control Plan Control Panel Inspection and Test Plan Control Panel Data Sheet

Arun Pandey (Er.-Planning )

Control Panel Approved Drawings, (arrangements, schematics, wiring, single line) Control Panel Material Test Reports Control Panel Welding Specification Procedures (WPS) and Procedure Qualification Records(PQR) Control Panel Welders Qualifications Reports Control Panel Calibration Certificates for Test Equipment Control Panel Special Procedures Control Panel Special Qualifications Control Panel Preparation and Painting Procedure Control Panel Preservation, Packing and Shipping Procedure Control Panel Packing List

Third Party Inspection for Control Panel-Material Inspection The first actual inspection work in the control panel is the raw materials inspection. The original or authenticated copies of mill certificates of material normally are available at the manufacturer's premises. The third party inspector examines these certificates for compliance with specifications, and where appropriate, drawings. The review includes checks on:

Certificate No. Heat or cast No. Chemical composition. Mechanical properties. Heat treated condition. NDE applied and results. Surface finish

Then the inspector witnesses the materials identification on the certificates against the materials marking. It is also necessary to check these with the control panel drawing datasheet, material list and other specifications as appropriate. Visual inspection for surface finish and probable defects is done and dimensional compliance with specification need to be controlled, as well. When the third party inspector carries out the material inspection, then provides the inspection visit report (IVR), the report contains the following items:

Confirmation of satisfactory document review Record of the endorsement of certification reviewed/witnessed Record of all non-conformities Record of any tests witnessed and the result

Third Party Inspection for Control Panel Construction

Arun Pandey (Er.-Planning )

When the control panel raw material inspection is carried out, and the results were satisfactory or non-conformities were closed by remedial action, then the control panel manufacturer will start fabrication. The third party inspector checks the following points on the control panel, based on the inspection and test plan (ITP), which has already been agreed upon between the purchaser and the control panel manufacturer. The inspection scope is determined in the ITP. Some purchasers prefer to have stringent controls and assign the TPI for more hold or witness points for inspection and test activities, and some others prefer less hold or witness points and assign the TPI much more work in the review document. This depends in the inspection budget, which purchasers assign for inspection. Much more inspection will have a much larger cost and less risk, and conversely, less inspection will have less cost but more risks. For more details, review the Inspection and Test Plan for Control Panel article. There is a draft of the ITP in this article, which we believe is the best practice for control panel inspection. The third party inspector checks the following items in the control panel casing inspection process:

Paint using specified colour swatch, thickness measurement, if specified Name plate control Outline dimensions, interface dimensions, bus bar dimensions and Clearances and other specified dimensions Tightness/torque of terminals Degree of protection

It is necessary the results to meet drawings and applicable standards. Third Party Inspection for Control Panel - General Arrangement Check The third party inspector checks that all instruments, compartments, control switches etc. are correctly rated and are correctly located, with specified labelling in accordance of approved drawings. If the third party inspector is not in the hold or witness point in the ITP for this inspection stage, then he/she will review the control panel manufacturer quality control report in his/her coming visit or on the final inspection day. Third Party Inspection for Control Panel - Insulation Resistance Test Insulation resistance is measured between control circuits and earth (with sensitive devises excluded) with a 500V Megger. Similarly, insulation resistance is measured in all applicable permutations for any power circuits, if these are included within the control system, with a Megger selected to the voltage calculated appropriate to the applicable specification.

Arun Pandey (Er.-Planning )

The test result depends to the circuit but would not be acceptable if it is less than 2 Megohms. Similarly, If the third party inspector is not in the hold or witness point in the ITP for this inspection stage, then he/she will review the control panel manufacturer quality control report in his/her coming visit or on the final inspection day. Third Party Inspection for Control Panel - Withstand Voltage Test (Dialectric Test) Power frequency voltage of 1.5 kV is applied between control circuits and earth for 1 minute. Similarly power frequency voltage, calculated appropriate to the applicable specification, is applied to all applicable permutations for power circuits for 1 minute. The test would be acceptable if the no flashover and puncture occurs during the test. Similarly, If the third party inspector is not in the hold or witness point in the ITP for this inspection stage, then he/she will review the control panel manufacturer quality control report in his/her coming visit or on the final inspection day. Third Party Inspection for Control Panel Sequence Test Control circuitry is functionally tested and circuits proven by appropriate tests. The test result would be acceptable if meet approved schematic diagrams (including appropriate, recorded, as built alterations) and project philosophy Similarly if the third party inspector is not in hold or witness point in the project ITP for this stage, then will review control panel manufacture quality control report in his/her coming visit or in the final inspection day. Third Party Inspection for Control Panel Mechanical Operation Test The following mechanisms are checked for operation:

Locking Interlocking systems Drawing mechanisms Opening and shutting mechanisms Interchangeability.

The test would be acceptable if all the mechanisms work correctly. Similarly, If the third party inspector is not in the hold or witness point in the ITP for this inspection stage, then he/she will review the control panel manufacturer quality control report in his/her coming visit or on the final inspection day. Third Party Inspection for Control Panel - Painting and Coating Inspection

Arun Pandey (Er.-Planning )

Surface preparation for painting is checked for the following points, according to specification by third party inspector:

Cleaning method (Blast or scraping and wire brushing) Preparation grades Freedom from weld spatter, blow-holes and other defects Dry film thickness is checked according to specification

It is necessary surface condition to be free from pin-holes, runs damage and other discontinuity.

Third Party Inspection for Control Panel - Reporting The third party inspector provides an Inspection Visit Report (IVR) after each visit, as well as a final report summarizing the activities carried out during the control panel production in accordance with the contract requirements and circulated within the time limits specified in the contract. The report is in the format required by the client and clearly indicates final acceptance or rejection of the control panel. Third Party Inspection for Control Panel - Release Note When required by the contract or purchase order, a release note is issued by the third party inspection agency and given to the manufacturer when the control panels have been accepted. Third Party Inspection for Control Panel Packing, Marking and Shipping: The following points are checked by the third party inspector:

Verify that the packing materials conform to specifications and accepted practice for the mode of transport. Verify protection against humidity, abrasion, distortion and other damage. Verify shipping marks to marking instructions and record. Verify handling marks.

Arun Pandey (Er.-Planning )

Third Party Inspection for Bus Duct

This content guides you about all necessary stages in the production of the Bus Ducts from the examination of the raw material, final inspection, preservation and packing to dispatch to site. This content is written for typical Bus Duct and might not be detail for special cases. This content would be useful for second and third party inspectors, Bus Duct manufacture quality control personnel, engineering companies, purchasers and any interested individuals Bus Duct inspection and test is done against the approved drawings, purchase order specifications, purchasers or company standards, and within the practices and rules of the country, state or province and any government decrees, laws, ordinance or regulation as may apply. The applicable codes and specifications for Bus Duct which is under construction or supply process are: The applicable codes and standards may be based any international standards. This content is general and can be useful for all recognized standards.

Design code Purchase order specification Purchaser's standards Approved drawings

The applicable codes and standard may be based any international standards. This content is general and can be useful for all recognized standards. Required Documents for Third Party Inspector Review: The list of documents normally is agreed in the Pre Inspection meeting which is hold several weeks before actual commencement of inspection work. The parties which are participated in this meeting are manufacture, purchaser and third party inspection agency representatives. This already explained in the Inspection and Test Plan for Bus Duct article. These are the list of documents which are normally agreed to be presented to the inspector:

Bus Duct Purchase Order or Contract Bus Duct Manufacture Quality Control Plan Bus Duct Inspection and test plan Bus Duct Data Sheet Bus Duct Approved Drawings Bus Duct Material Test Reports Bus Duct Welding Specification Procedures Qualification Records(PQR)

(WPS)

and

Procedure

Arun Pandey (Er.-Planning )

Bus Duct Welders Qualifications Reports Bus Duct NDE procedures Bus Duct NDE Personnel qualifications Reports Bus Duct Calibration Certificates for Test Equipment Bus Duct Special procedures Bus Duct Special qualifications Bus Duct Preparation and Painting Procedure Bus Duct Preservation, Packing and Shipping Procedure Bus Duct Packing List

Third Party Inspection for Bus Duct - Material Inspection The first actual inspection work is raw materials inspection. The original or authenticated copy of mill certificates normally is available at manufacturer's premises. The third party inspector examines these certificates for compliance with specifications and where appropriate with drawings. The review includes checks on:

Certificate No. Heat or cast No. Chemical composition. Mechanical properties. Heat treated condition. NDE applied and results. Surface finish

Inspector witnesses the materials identification on the certificates against materials marking. It is also necessary to check with Bus Duct drawing datasheet, material list and other specification as appropriate. Visual inspection for surface finish and probable defects are done and dimensional compliance with specification need also to be controlled. When third party inspector carried out the material inspection, then provides inspection visit report (IVR), the report contains following items:

Confirmation of satisfactory document review Record of the endorsement of certification reviewed/witnessed Record of all non-conformities Record of any tests witnessed and the result

Third Party Inspection for Bus Duct Construction When Bus Duct raw material inspection carried out and results was satisfactory or non-conformities closed by remedial action, then Bus Duct manufacture will start fabrication.

Arun Pandey (Er.-Planning )

The third party Inspector checks following points on Bus Duct based on the inspection and test plan (ITP) which is already agreed between purchaser and Bus Duct manufacture. The inspection scope is determined in the ITP, some purchasers prefer to have stringent control and assign the TPI inspector in more hold or witness points for inspection and test activities and some others prefer lesser hold or witness points and assign TPI much more in thereview document. This depend to the inspection budget which purchasers assign for inspection, much more inspection will have much more costs and less risks and conversely less more inspection will have less costs but more risks. For more detail review Inspection and Test Plan for Bus Duct article. There is draft ITP in this article which I believe it is the best practice for Bus Duct inspection. The third party inspector (TPI) checks following in accordance of approved drawings and applicable standards:

Paint using specified colour swatch, measure thickness, if specified Panel condition Outline dimensions, interface dimensions, bus bar dimensions and clearances and other specified dimensions Check tightness/torque of terminals Principal dimensions

If TPI is not in the hold or witness point in the ITP for this inspection stage, will review the Bus Duct manufacture quality control report in coming visit or in the final inspection day. Third Party Inspection for Bus Duct General Arrangement Check The third party inspector checks that all compartments, bars etc., are correctly rated and are correctly located, with specified labelling in accordance of approved drawings. Similarly If TPI is not in the hold or witness point in the ITP for this inspection stage, will review the Bus Duct manufacture quality control report in the coming visit or in the final inspection day. Third Party Inspection for Bus Duct Insulation Resistance Test Insulation resistance is measured at each circuit with a 500V or (for circuits over 500V) a 1000V Megger. The test would be acceptable if the measured value is not less than 1 Megohm. Similarly If TPI is not in the hold or witness point in the ITP for this inspection stage, will review the Bus Duct manufacture quality control report in the coming visit or in the final inspection day. Third Party Inspection for Bus Duct Withstand Voltage Test (Dialectric Test)
Arun Pandey (Er.-Planning )

Power frequency voltage (at specified voltage) is applied between each circuit and earth and between bars, for 1 minute. The test would be acceptable if no flashover and puncture occurs during the test. Similarly If TPI is not in the hold or witness point in the ITP for this inspection stage, will review the Bus Duct manufacture quality control report in the coming visit or in the final inspection day. Bus Duct Painting and Coating Inspection Surface preparation and painting is checked according to the specification. The checking include to the following items:

Cleaning method (Blast or scraping and wire brushing) Preparation grade Freedom from weld spatter, blow-holes and other defects Dry film thickness is measured according to specification

It is necessary surface to be free from pin-holes, runs damage and other discontinuity. Third Party Inspection for Bus Duct - Reporting: Third party inspector provides Inspection Visit Report (IVR) after each visit as well as a final report summarising the activities carried out during the Bus Duct production in accordance with the contract requirements and circulated within the time limits specified in the contract. The report normally is in the format required by the client and clearly indicates final acceptance or rejection of the Bus Duct. Third Party Inspection for Bus Duct - Release Note: When required by the contract or purchase order a release note is issued by third party agency and given to the manufacturer when the Bus Ducts have been finally accepted.

Third Party Inspection for Bus Duct -Bus Duct Packing, Marking and
Shipping:

The following points are checked by third party inspector:

Verify that the packing materials conform to specifications and accepted practice for the mode of transport. Verify protection against humidity, abrasion, distortion and other damage. Verify shipping marks to marking instructions and record. Verify handling marks.

Arun Pandey (Er.-Planning )