Third Party Inspection for Switchgear - Procedure

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The Third Party Inspection for switchgear article provides a sample

procedure/instruction for switchgear testing and inspection in manufacturing
shop. You might need to review this article with theswitchgear inspection and
test plan.

This content guides you through all the necessary stages in the production of the
switchgears, 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 switchgear
and might not be detailed for special cases.

All switchgear 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 switchgear that is under the construction
process is:

 Design code and Standard

 Purchase order specification
 Purchaser's standards
 Approved drawings

The applicable codes and standards may be based on any international standards.
This content is general and can be useful for all recognized standards.
Third Party Inspection for Switchgear - 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.

These are the list of documents that are normally agreed upon to be presented to the
inspector:

 Switchgear Purchase Order or Contract

 Switchgear Manufacture Proforma Invoice
 Switchgear Manufacture Quality Control Plan
 Switchgear Inspection and Test plan
 Switchgear Data Sheet
 Switchgear Approved Drawings, (arrangements, schematics, wiring, single line)
 Switchgear Raw Material Test Reports
 Switchgear Calibration Certificates for Test Equipment
 Switchgear Functional Testing Procedure
 Switchgear Special Procedures
 Switchgear Special Qualifications
 Switchgear Preservation, Packing and Shipping Procedure
 Switchgear Packing List

Third Party Inspection for Switchgear - Material Inspection

The first actual inspection work in the switchgear 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:

 Maker’s name and location

 Certificate number, grade
 Batch number
 Chemical composition
 Mechanical Properties
 Cast or Heat number (for metal parts)
 Heat treatment condition
 Surface finish
 Structural observations, notable defects
Ancillary items may be supported by test certification, or by certificates of conformity.
It is necessary the content of certification to be appropriate to the required scope of
the items.

Then the inspector witnesses the materials identification on the certificates against the
materials marking. It is also necessary to check these with the switchgear 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 Switchgear - Construction

When the switchgear raw material inspection is carried out, and the results were
satisfactory or non-conformities were closed by remedial action, then the switchgear
manufacturer will start fabrication.

The third party inspector checks the following points on the switchgear, based on the
inspection and test plan (ITP), which has already been agreed upon between the
purchaser and the switchgear 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.

The third party inspector checks the following items in the switchgear casing inspection
process:

 Surface profile, DFT thickness, paint color and paint type

 Name plate
 Outline dimensions, interface dimensions, bus bar dimensions and clearances
and other specified dimensions
 Tightness / torque of terminals
 Degree of protection
Third Party Inspection for Switchgear - 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.

The inspection is carried out in accordance of approved drawings.

Third Party Inspection for Switchgear Resistance Test

Switchgear Insulation resistance is measured between control circuits and earth (with
sensitive devises excluded) with a 500V Megger.

In the second step Insulation resistance is measured in all applicable permutations for
power circuits with a Megger selected to the voltage calculated appropriate to the
applicable specification.

The acceptable limit depends to the circuit but normally more than 2 Megohms would
not be acceptable.

Third Party Inspection for Switchgear - Withstand Voltage Test (Dialectric Test)

Power frequency voltage of 1.5 kV is applied between control circuits and earth for 1
minute. Then 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 no flashover and puncture occurs during the test.

Third Party Inspection for Switchgear - Sequence Test

Circuitry is functionally tested and circuits proven by appropriate tests. The acceptance
criteria for sequence test is approved schematic diagrams (including appropriate,
recorded, “as built” alterations) and project philosophy

Third Party Inspection for Switchgear - Characteristics Test of Protection Relays

Relay functions and operating curves is observed through primary and /or secondary
injection methods etc. The performance normally is in accordance of manufacturer’s
data.

Third Party Inspection for Switchgear - Mechanical Operation Test

Third party inspector checks the following mechanisms for operation:

 Locking
 Interlocking systems
  Drawing mechanisms
 Opening and shutting mechanisms
 Handling mechanisms
 Charging mechanisms (trip and closing etc.)
 Interchangeability.

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 switchgear
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 switchgear.

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 switchgears have
been accepted.

Packing and marking

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.
 Inspection and Test Plan for Switchgear
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switchgear test and switchgear inspection in manufacturing shop. The draft Inspection
and test plan provided as well.

Click here if you like immediately review the Inspection & Test Plan for
Switchgear draft sheet.

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Switchgear article.

Click following link if you need to review general definition for Inspection and Test Plan.

Inspection and Test Plan

The IEC, NEC, NEMA, FDF, ISO ANSI, CI, IPCEA standard requirements normally
are applied for inspection and test plan in manufacturing shop.

The witness of some inspection and test by third party inspector is mandatory and
cannot be waived. These points in the inspection and test plan for switchgear are hold
points and can not be waived.

Some others must only monitored and fully witnessing are not necessary, for these
thing, the inspection man-days etc. depends to the purchaser decision, some prefer
stringent monitoring and even assign resident inspector in manufacturing shop and
some others relay to quality control system of the manufacture and assign only few
days for monitoring points.

These are some of inspection points which need to be witnessed, monitored and
reviewed by third party inspector in Switchgear manufacture shop.

Inspection and Test Plan for Switchgear - Important Points

 Witnessing the High voltage tests

 Witnessing the Electric tests on secondary wiring.

 Witnessing the Insulation resistance tests

 Witnessing the Sequence testing of relays.

 Witnessing the Operation for circuit breakers and check for

interchangeability

 Checking all busbars and busbar connections for tightness, clearance in

air/oil compound (before filling), rating, and color marking of phases.

 Where busbar chambers are oil or compound filled, check welding of tank
joints leakage.

 Checking current transforms and voltage transformers for records of

Vendor`s individual tests, correct phasing and polarity, correct ration and
VA on CT labels and voltage transformers correctly connected, fuses of
links are fitted, and phases are correct.

 Checking protective relays, instruments, contractors, switches, fuses etc.

 Checking wiring, generally for correct grade and size of wire, terminations
for tightness, earthing arrangements for continuity in circuit and general
standard, checking on concealed runs for possible damage to installation.

 Checking incoming and outgoing cable boxes and glands.

 Checking all shutters and interlock operation.

 Checking all circuit breakers for fit up and fitting ease of operation.

 Checking complete boards for finish, lines out of units where applicable,
range and setting of meters and relays, correct fitting of doors, circuit
labels and dimensions to GA Drawing