4. cathodic protectionlyonsengineers.com/vol_ii of ii_tech laying-part-2.pdf(qjlqhhulqj 6wdqgdug...

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4. CATHODIC PROTECTION

Remarks

M C TPIA

Approved Drawing & Data Sheet Inspection Report P W W

Approved Drawing Inspection Report P W W

fitness test, terminal to body resistance.

Randamly Approved Drawing & Data Sheet Inspection Report P W W

Approved Drawing Inspection Report P W W

Approved Drawing & Data Sheet Inspection Report P W W

Approved Drawing & Data Sheet IP 55 Test Certificate S R R

Approved Drawing & Data SheetIRN H P R

OWNER

PROJECT

QUALITY ASSURANCE PLAN FOR TEST STATIONS

PROJECT NO

TPIA

CONSULTANT Lyons Engineering Engineering Pvt. Ltd.

DATE:-

CONTRACTOR

CP CONTRACTOR

REFERENCE SPECIFICATION ENG-STD-CP-DOC-TS-001

QAP NO 01 REV. 0

REFERENCE DESIGN DOCUMENT

REFERENCE DATA SHEET

REFERENCE DRAWING

VENDOR

DESCRIPTION / TYPE OF INSPECTION REFERENCE DOCUMENTFORMAT OF

RECORDINSPECTION BY

Compliance with approved Drawing & Data sheet (Manufacturer, type &Model)

Visual Inspection: 100%

Dimensional Check: 25%

Manufacturer Test Certificate (IP 55)

Document / Marking

LEGEND: P-PERFORM, W-WITNESS ALL, S-SUBMITTED BY, R-REVIEWED BY, H-HOLD M-Manufacturer C-Contractor TPIA-Third Party Inspection Agency H-Hold

Thickness Check :25%

Terminals to TS Body

RemarksM C TPIA

Approved Drawing & Data Sheet Inspection Report P W/R W/R

Approved Drawing & Data Sheet Test Report P R W

PROJECT

QUALITY ASSURANCE PLAN FOR SECRIFICIAL ZINC ANODE

OWNER

QAP NO

DATE:-

02 REV. 0

CONSULTANT Lyons Engineering Engineering Pvt. Ltd.CONTRACTORCP CONTRACTOR

PROJECT NOTPIA

REFERENCE SPECIFICATION ENG-STD-CP-DOC-TS-001REFERENCE DESIGN DOCUMENTREFERENCE DATA SHEETREFERENCE DRAWINGVENDOR

RECORDINSPECTION BY

Destructive Testing

a. Surface 100 %, Length ± 2.5 %, Width/ Thickness ± 5%b. Visual : Longitudinal cracks of more than 40 mm long and 3 mm deep not acceptable

c. Weight tolerance: + %5 (Total weight of all anodes shall not have negative tolerance)Radiographic Test

Approved Drawing & Data Sheet Test Report P W/R

Inspection

Approved Drawing & Data Sheet Inspection Report

W/R

One anode per heat shall be subjected to radiography to evaluate cracks, voids, slack inclusion etc.

W/R

One anode per heat shall be subjected to destructive testing for slag inclusions, bond between anode and

insert.

W/RP

RemarksM C TPIA

PROJECT

QUALITY ASSURANCE PLAN FOR SECRIFICIAL ZINC ANODE

OWNER

QAP NO

DATE:-

02 REV. 0

PROJECT NOTPIA

RECORDINSPECTION BY

Approved Drawing & Data Sheet Test Report P R R

Mass per liner meter ALL Approved Drawing & Data Sheet Test Report P R W

Anode to core resistance Randamly Approved Drawing & Data Sheet Test Report P R W

Approved Drawing & Data Sheet Test ReportSubmission

R W

Approved Drawing & Data Sheet IRN H P R

be subjected to destructive testing for slag inclusions, bond between anode and insert.

Document / Marking

LEGEND: P-PERFORM, W-WITNESS ALL, S-SUBMITTED BY, R-REVIEWED BY, H-HOLD M-Manufacturer C-Contractor TPIA-Third Party Inspection Agency

R Wa.)Open circuit potential shall lie within (+) 10 mV and (-) 50 mV of the guaranteed value.b.)Consumption rate by weight loss method (consumption rate shall not be more than the specified value).

All the above Manufacturer Test Reports

ChemicaL Analysis; One anode sample per heat by Spectrography Sample in the beginning for first heat, end of second heat, at the beginning of third heat and so on.

Electrochemical Test

Approved Drawing & Data Sheet Test Report R

RemarksM C TPIA

Approved Drawing & Data Sheet Inspection Report P W R

CONTRACTORCP CONTRACTOR

DATE:-

03 REV. 0

REFERENCE DESIGN DOCUMENTREFERENCE DATA SHEETREFERENCE DRAWINGVENDOR

RECORD

PROJECTOWNERPROJECT NOTPIACONSULTANT Lyons Engineering Engineering Pvt. Ltd.

QAP NOREFERENCE SPECIFICATION ENG-STD-CP-DOC-TS-001

INSPECTION BY

Compliance with approved Drawing & Data sheet (Manufacturer, type &Model)Inspection

Approved Drawing & Data Sheet Inspection Report P W/R

a. Surface 100 %, Length ± 2.5 %, Width/ Thickness ± 5%b. Visual : Longitudinal cracks of more than 40 mm long and 3 mm deep not acceptablec. Weight tolerance: + %5 (Total weight of all anodes shall not have negative tolerance)

W

One anode per heat shall be subjected to radiography to evaluate cracks, voids, slack inclusion etc.

Destructive Testing

Radiographic Test

Approved Drawing & Data Sheet Test Report P W

One anode per heat shall be subjected to destructive testing for slag inclusions, bond between anode and insert.

QUALITY ASSURANCE PLAN FOR SACRIFICIAL MAGNESIUM ANODE

W

RemarksM C TPIA

CONTRACTORCP CONTRACTOR

DATE:-

03 REV. 0

RECORD

PROJECTOWNERPROJECT NOTPIACONSULTANT Lyons Engineering Engineering Pvt. Ltd.

QAP NOREFERENCE SPECIFICATION ENG-STD-CP-DOC-TS-001

INSPECTION BY

QUALITY ASSURANCE PLAN FOR SACRIFICIAL MAGNESIUM ANODE

Mass per liner meter ALL Approved Drawing & Data Sheet Test Report P R W

Anode to core resistance Randamly Approved Drawing & Data Sheet Test Report P R W

Approved Drawing & Data Sheet Test Report Submission

R R

Approved Drawing & Data Sheet IRNH P RDocument / Marking

R R

One anode per heat shall be tested fora.)Open circuit potential shall lie within (+) 10 mV and (-) 50 mV of the

b.)Consumption rate by weight loss method (consumption rate shall not be more than the specified value).

R

ChemicaL Analysis; One anode sample per heat by Spectrography Sample in the beginning for first heat, end of second heat, at the beginning of third heat and so on.

Electrochemical Test

Approved Drawing & Data Sheet

Test Report

All the above Manufacturer Test Reports

RemarksM C TPIA

ALL Approved Data Sheet Inspection Report P W W

Diamentional Check ALL Approved Drawing & Data Sheet Inspection Report P W W

Electrical Test , coating consumtion rate ALL Approved Drawing & Data Sheet Inspection Report P W W

Leak proof test (Helium Test), cable length, coating resistivity & Coating thickness

Randamly Approved Drawing & Data Sheet Inspection Report P W W

Inspection as per below attached vendor’s ITP

ALL Vendor’s ITP is attached below Inspection Report P R R

Document / Marking ALL Approved Drawing & Data Sheet IRN H P R

PROJECT NOTPIA

DATE:-

PROJECT

QUALITY ASSURANCE PLAN FOR MMO ANODE

OWNER

REFERENCE SPECIFICATION ENG-STD-CP-DOC-TS-001REFERENCE DESIGN DOCUMENT

QAP NO 04 REV. 0

REFERENCE DATA SHEETREFERENCE DRAWINGVENDOR

RECORDINSPECTION BY

RemarksM C TPIA

Approved Data Sheet & Design Specification

Inspection Report Inspection Report P W/R W/R

Manufacturer Test Report

Approved Data Sheet & Design Specification

Test Certificate Test Certificate P R R

Inspection Release Note IRN H P R

OWNER

PROJECT

QUALITY ASSURANCE PLAN FOR POLARISATION CELL

PROJECT NO

TPIA

DATE:-

CONTRACTOR

CP CONTRACTOR

QAP NO 05 REV. 0

REFERENCE DRAWING

VENDOR

DESCRIPTION / TYPE OF INSPECTION REFERENCE DOCUMENT FORMAT OF RECORDINSPECTION BY

RemarksM C TPIA

Approved Data Sheet & Drawing Inspection ReportP W / R W/R

Approved Data Sheet & Drawing/ Technical specification P W / R W/R

Approved Data Sheet & Drawing Test Certificate Submission

R R

IRNH P R

PROJECT NO

TPIA

DATE:-

PROJECT

QUALITY ASSURANCE PLAN FOR PERMANENT REFERENCE CELL (Ag/Agcl)

OWNER

CONTRACTOR

CP CONTRACTOR

QAP NO 06 REV. 0

REFERENCE DRAWING

VENDOR

RECORDINSPECTION BY

Manufacturer Certificates

Inspection Release Note

Visual Inspection 100%

RemarksM C TPIA

Approved Data Sheet & Drawing Inspection Report P W / R W/R

Approved Data Sheet & Drawing Test CertificateSubmission

R R

IRN H H P

PROJECT

QUALITY ASSURANCE PLAN FOR PERMANENT REFERENCE CELL (Cu/CuSo4)

OWNER

QAP NO

DATE:-

07 REV. 0

PROJECT NOTPIA

RECORDINSPECTION BY

Inspection Release Notee

REMARKS

M TPIA CLIENT1 BOUGHT OUT ITEMS

1. Physical Check Measuring Tape 100%Approved Drawing

Manufacturer specification

Incoming Test Certificate

P R R

2 Physical damge if any. Physical Test 1 in Lot P3 Verification with Manufacturer specification.

Verification of Test Certificate

Approved Drawing P R R

1.2Receving Inspection of Meters,PCB'S,Semiconductor & Electrical Iterms

1. Dimensions, SizeFunctional test 2.Mechnical/Ele ctrical Measurement

sampling 10%Approved Drawing

Manufacturer specification

Test Report

1.Manufacturer Test Report

2.IncomingTest Report

P R R

2. Electrical Parameters 1 in Lot P W W

1.3Sub assembly- Transformer,Choke,

1. Insulation Test 2. No Load Test

100% Approved drawing Test Certificate Test Certificate P R R

1.4Sub assembly- Timer-Inspection & Test

1. Visual inspection 2. Functional Test 3. Internal settings

Functional test 2.Mechnical/Ele ctrical

100% Approved drawing Test Certificate Test Certificate P R R

1.5 Assembly Process1. Electrical wiring and tighteness of all connections 2. Labeling and Marking

Measurement Visual 100% Approved drawing Test Report Test Report P R R

1.6 Auxilary device check Verification as per BOM Visual 100% Approved Drawing Test Report Test Report P R R

1.7 Insulation Test

Insulation and High Voltage Test between primary to Earth,Secondary to Earth and/or Primary to secondary

Electrical Measurement

100% Approved Drawing Test Report Test Report P R R

1.8Sub/assembly-control card Inspection & Test

1. Visual inspection 2. Functional Test

Functional Test 100% Approved Drawing Test Report Test Report P R R

1.9 Heat Run Test

Heat run at at rated Load for at least 12/16 Hrs with Temperature measurement on all power devices and Magnetics at the end of test

Electrical Test & Inspection

100%

1.Approved Drawing 2.Approved Specification

Test Report Test Report P R R

Lyons Engineering Engineering Pvt. Ltd.0

PROJECTCLIENT REV. NO.-

QAP FOR TRANSFORMER UNIT

PMC

QAP NO.

MANUFACTURERP.O NO.

CONTRACTOR

P.O DATE

REF. DOC.08

RATING AND QUANTITYDATE:-

AgencyItem/ Component Characterstics Type of Check

Reference Document

Acceptance Norms

Format of RecordExtent of WorkSr.No.

Receving Inspection for Fabricated

1

REMARKS

M TPIA CLIENT

Lyons Engineering Engineering Pvt. Ltd.0

PROJECTCLIENT REV. NO.-

QAP FOR TRANSFORMER UNIT

PMC

QAP NO.

MANUFACTURERP.O NO.

CONTRACTOR

P.O DATE

REF. DOC.08

RATING AND QUANTITYDATE:-

AgencyItem/ Component Characterstics Type of Check

Reference Document

Acceptance Norms

Format of RecordExtent of WorkSr.No.

6. Continuity (ON-OFF) Electrical 100% P R R

2 Functional Test of Unit

1. Visual Inspection 2. Insulation Test 3. Operation in Manual Mode 4. Operation in AVCC & Voltage/current. 5. Regulation 6. Operation in Auto and PSP regulation 7. Ripple content in DC Output 8. Indication and alarm 9. Remote signal and Potenrtial free contacts Conveter and Timer(if any)10.HV 11. Annuciation

Inspection 100%

1.Approved Drawing. 2. Approved Specification.

Test Report Test Report P W W

2.1 Heat Run Test

10.Efficiency/power factor Heat run at at rated Load for at least 8 Hrs with Temperature measurement on all power devices and Magnetics at the end of test

Electrical Test & Inspection

40%

1.Approved Drawing 2.Approved Specification

Test Report Test Report P W/R W/R

5 Inspection Release NoteTechnical

SpecificationTechnical

SpecificationH P R

10.1WarrantyCertificate P R R

10.2 Operation ManualP R R

LEGEND: P-PERFORM, W-WITNESSE, S-SUBMITTED, R-REVIEW OF RECORDS, H-HOLD, M-MANIFACTURER, C-CONTRACTOR, TPIA-THIRD PARTY INSPECTION AGENCY

FINAL TEST

6Documents to be Sumitted at time of Dispatch and Packing

RemarksM C TPIA

Approved Data Sheet & Drawing Test Certificate P R R

IRN H P R

PROJECT NOTPIA

DATE:-

PROJECT

QUALITY ASSURANCE PLAN FOR PLAN SURGE DIVERTER

OWNER

REFERENCE SPECIFICATION ENG-STD-CP-DOC-TS-001REFERENCE DESIGN DOCUMENT

QAP NO 09 REV. 0

REFERENCE DATA SHEETREFERENCE DRAWINGVENDOR

RECORDINSPECTION BY

Manufacturer TEST Report

RemarksM C TPIA

Approved Data Sheet & Drawing Test CertificateSubmission

R R

IRN H H P

PROJECT

QUALITY ASSURANCE PLAN FOR ER PROBE & ER PROBE READER

OWNER

QAP NO

DATE:-

10 REV. 0

PROJECT NOTPIA

RECORDINSPECTION BY

RemarksM C TPIA

Approved Drawing & Data Sheet Inspection Report P W w

Visual Inspection ALL Approved Drawing & Data Sheet Inspection Report P W W

Dimensional Check, Physical verification, locking , painting

ALL Approved Drawing & Data Sheet Inspection Report P W W

Fitness Test Randamly Approved Drawing & Data Sheet Inspection Report P W WThickness check, Terminal to body check

Manufacturer Test Certificate (IP 55) ALL Approved Drawing & Data SheetTest Report Submi

ssionR R

Approved Drawing & Data SheetIRN

H H P

PROJECT

QUALITY ASSURANCE PLAN FOR CATHODE JUNCTION BOX

OWNER

QAP NO

DATE:-

11 REV. 0

PROJECT NOTPIA

RECORDINSPECTION BY

Document/Marking

RemarksM C TPIA

Visual Inspection ALL Approved Drawing & Data Sheet Inspection Report P W WDimensional Check, Physical verification, locking , painting

Fitness Test Randamly Approved Drawing & Data Sheet Inspection Report P W WThickness check, Terminal to body check

Manufacturer Test Certificate (IP 55) ALL Approved Drawing & Data Sheet Test Certificate P R RApproved Drawing & Data Sheet IRN H P R

PROJECT

QUALITY ASSURANCE PLAN FOR ANODE JUNCTION BOX

OWNER

QAP NO

DATE:-

12 REV. 0

PROJECT NOTPIA

REFERENCE SPECIFICATION ENG-STD-CP-DOC-TS-001REFERENCE DESIGN DOCUMENTREFERENCE DATA SHEET

Document / MarkingLEGEND: P-PERFORM, W-WITNESS ALL, S-SUBMITTED BY, R-REVIEWED BY, H-HOLD M-Manufacturer C-Contractor TPIA-Third Party Inspection Agency

REFERENCE DRAWINGVENDOR

RECORDINSPECTION BY