prototype inspection checklist
TRANSCRIPT
Common_Check Points Page 1 of 20
Sr. No. Item Description Check Point Punch Point Remarks
1 Cabinet Make & dimensions 1) Rittal 800(D) x 2100(H) x 800(W)
2 Cabinet Colour 1) RAL 7035
3 Cable Entry 1) Bottom Entry
4 Gland Plate
1) Removable plate
2) Separate for Front & Rear Side
3) Plate Fittings
5 Fan Assembly
1) Make as per HAIL Standard
2) Proper Mounting
6 Tube Light
1) RITTAL - SZ 4155.100
2) With motion Sensor
3) 240VAC cable termination
4) Tube light position & mounting
7 Cabinet Nameplate
1) Trafolyte Material Hail to confirm material used is Trafolyte
2) Proper Nameplate Position Position of Nameplate is not proper
Name plate size is not proper
Complied (C)
Not Complied
(NC)
Not Applicable (NA)
Position of Tube Light in network cabinet is not proper
3) Cabinet Front & Rear side identified in the Name
4) Name Plate Size, Font Size & style appropriate
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
Common_Check Points Page 2 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
Not Complied
(NC)
Not Applicable (NA)
8 Frame Earth & Signal Earth
9 Utility Socket
10 Acrylic Covers
11 Cabinet Alarms
1) Temperature alarm
2) Fan Failure alarm
3) Power Supply alarm as applicable
12 Ferruling
1) Barrel or Tube Type
2) Cross Ferrule
3) Ferrule Orientation
4) Ferrule Print Quality
5) Is all text printed on Ferrule visible?
1) Short Link between cabinet frame and door frame is provided
2) Signal Earth bus bar is provided with required thickness
3) Frame Ground bus bar provided with required thickness
1) Utility socket (UPS / Non-UPS Powered)
1) Provided for 110VAC and 240VAC distribution to avoid direct exposure to individuals.
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
Common_Check Points Page 3 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
Not Complied
(NC)
Not Applicable (NA)
13 Lugging 1) Are all wires terminated using lugs
14 MCB
1) MCB labels
2) Siemens make
3) Proper MCB mounting
15 Cable duct and Cable Dressing
16 Terminal Types
1) Terminal used suitable for cable size
2) Phoenix make
3) Front Entry Screw less Type
4) Gray colour terminals for for Non-IS
5) Blue terminals for IS
1) Are all cables routed through Cable ducts
2) Cable duct colour coding (Gray for Non-IS and Blue for IS)
3) Sufficient distance between duct and terminals
6) At least one terminal Fused wherever switching of supply voltage is involved.Terminal shall be indicating type.
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
Common_Check Points Page 4 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
Not Complied
(NC)
Not Applicable (NA)
17 Filters
1) Air filters are provided
2) Proper Position of Air Filters
18 Cabinet Side Mountings 1) TBs not to be mounted at side Panel
19 Space for Future expansion
20 Installed Spares
1) 20% installed spare TBs
2) 20 % installed spare MCBs
3) 20% installed spare Barriers
4) 20% installed spare relays
21 Bus bars
22 Terminal Markers
23 Thermostat position 1) Proper thermostat position
24 Swing of the Doors 1) Sufficient Front and Rear Door swing
1) 20% of each IO Card type installed in the Cabinet
5) 20% annunciator windows, Push button, selector switches, Lamps
1) Bus Bars are provided for Power distribution (24 VDC, 110VAC and 240VDC)
1) Terminal markers are provided for all terminals
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
PDB Cabinet Page 5 of 20
Sr. No. Item Description Check Point Punch Point Remarks
1 Reviewed Cabinet Drawings
2
1) Voltmeter & Ammeter make HAIL STD
2) Voltmeter and Ammeter Properly labeled
3) Properly positioned
4) Lamps properly positioned
3 MCCB
1) L&T make
2) Proper & correct wire terminations
3) Proper labels
4) Proper MCCB position
4 CT
1) CTs properly positioned
2) CTs properly labeled
3) Proper Cable Terminations
5 Cable colour coding 2) Signal Cable colour coding and sizes
3) Power cable colour coding and sizes
Complied (C)
Not Complied
(NC)
Not Applicable (NA)
1) Hardware cabinet and design is as per reviewed PDBCabinet Drawings
Items Installed on Front & Rear Doors
1) Attach the colour coding sheet in functional design specification (FDS)
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
PDB Cabinet Page 6 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
Not Complied
(NC)
Not Applicable (NA)
6 Lugging
1) Are all wires terminated using lugs
7 Bus bars
2) Proper Cable termination on bus bars
8 Cable duct and Cable Dressing 2) Are all cables routed through Cable ducts
9 Terminal Types
1) Terminal used suitable for cable size
2) Phoenix make
3) Terminal colour Gray
10 Labels
1) All items properly labeled
13 Location of TBs
2) Proper lugs and termination provided for larger sq. mm cables
1) Bus Bars are provided for power distribution.
1) Cable bundles in ducts are flexible and sufficient space for future expansion is available.
3) Sufficient distance between duct and terminals is maintained for ease of termination and removal of cable.
2) Labels to the MCCB, MCBs, CTs etc are not permanent and can be reused when item/component labeld is replaced.
1) TBs not located at extreme bottom side of cabinet to permit ease of maintenance.
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
PDB Cabinet Page 7 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
Not Complied
(NC)
Not Applicable (NA)
14 Ferruling
1) Barrel or Tube Type
2) Cross Ferrule
3) Ferrule Orientation
4) Ferrule Print Quality
5) Is all text printed on Ferrule visible?
15 TB End Clamps 1) End clamps provided for all TBs
16 Earth bus bar 1) Earth Bus bar provided
17 Feeders
1) Primary Feeder on front side & Secondary Feeder on rear side
2) Individual Feeder provided for each consumer
2) Individual Feeder provided for each consumer
3) Maximum two feeders at one side of cabinet (2 Nos. Front & 2 No. Rear)
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
Network Cabinet Page 8 of 20
Sr. No. Item Description Check Point Punch Point Remarks
1 Reviewed Cabinet Drawings
2 Switches
1) Properly positioned
2) All Ethernet switches are 24 port
3) Power Cable properly routed
4) Cisco make for Ethernet
5) Moxa Make for safenet (ESD safenet)
3
1) 24 port , Rack mount type
2) Patch cord connectors SC type
3) Patch cord duplex type
Complied(C)
NotComplied
(NC)
Not Applicable (NA)
1) Hardware cabinet and design is as per reviewed Network Cabinet Drawings
Light Interface Unit (LIU)for fiber optic termination
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
Network Cabinet Page 9 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
NotComplied
(NC)
Not Applicable (NA)
4 Cable duct and Cable Dressing 2) Are all cables routed through Cable ducts
5 Location of LIU and Switches
6 Fiber Optic Converters
1) Proper position
2) Make - Santeliequip
7 Labels
1) All items properly labeled
8 Cable colour coding 2) Signal Cable colour coding and sizes
3) Power cable colour coding and sizes
1) Cable bundles in ducts are flexibleand sufficient space for futureexpansion is available.
3) Sufficient distance between duct and terminals is maintained for ease of termination and removal of cable.
1) LIUs and Switches not located at extreme bottom side of cabinet to permit ease of maintenance
2) Labels to MCBs, Converters, Switches, LIUs etc are not permanent and can be reused when item/component is replaced
1) Attach the colour coding sheet in functional design specification (FDS)
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
DCS_FF Marshalling Cabinet Page 10 of 20
Sr. No. Item Description Check Point Punch Point Remarks
1 Reviewed Cabinet Drawings
2
1)Analog IS and Analog NIS
2) Digital IS and Non IS
3) Digital NIS (MCC + SOV)
4) Digital DI Relay Cabinet
5) Digital DO Relay Cabinet
3 Cable ducts for Cabinet
1) Blue colour duct for IS field cable
2) Gray colour duct for Non IS field cable
3) Sufficient distance between duct and terminals
4 Terminal Types
1) Terminal used suitable for cable size
2) Phoenix make
3) Front Entry Screw less Type
4) Gray colour terminals for Non-IS
5) Blue terminals for IS
Complied(C)
NotComplied
(NC)
NotApplicable
(NA)
1) Hardware cabinet and design is as per reviewed DCS Marshalling Cabinet Drawings
Cabinet SegregationNotes:1) IS and Non IS cab be clubbed with front rear segregation wherever I/O count does not justifies separate cabinet2) Digial DI relay and DO relay Cabinet can be clubbed with front and rear segregation wherever I/O count does not justifies separate cabinet
6) At least one terminal Fused wherever switching of supply voltage is involved.Terminal shall be indicating type
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
DCS_FF Marshalling Cabinet Page 11 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
NotComplied
(NC)
NotApplicable
(NA)
5 TB Grouping
1) TB grouping as per Cable No.
2) Labeling provided for each TB group
3) Barriers are grouped as per JB Grouping / Cable Groping
6 Barrier
1) For AI MTL5541
2) For AO MTL5546/Y
3) For DI MTL5511
7 FF Power Supply
1) FISCO IIC MTL 9121-IS
2) FISCO IIA/IIB MTL 9122-IS
3) FNICO IIC MTL 9111-NI
4) FNICO IIA/IIB MTL 9112-NI
8 Surge Protectors 1) MTL FP32
9 Bulk Power Supply
1) Proper position of bulk power supply
2) Proper Cable terminations
10 Diode Oring Module 1) Proper Cable terminations
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
DCS_FF Marshalling Cabinet Page 12 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
NotComplied
(NC)
NotApplicable
(NA)
11 Labels
1) All items properly labeled
12 FTA/RTP cabling 1) Prefab cable provided between FTA/RTP to I/O Card
13 Cable colour coding 2) Signal Cable colour coding and sizes
3) Power cable colour coding and sizes
14 Relay Models
1) For DI and DO Omron make LY2N
2) Relays are provided with casing and suppression diode
15 Cable Colour Coding for FF
1) FNICO Orange Black
2) FISCO Orange Blue
2) Labels to MCBs, Controller Module, I/O Module, Chassis, Power supplies, Relays, Barriers, TBs etc are not permanent and can be reused when item/component is replaced
1) Attach the colour coding sheet in functional design specification (FDS)
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
ESD Marshalling Page 13 of 20
Sr. No. Item Description Check Point Punch Point Remarks
1 Reviewed Cabinet Drawings
2
1)Analog IS and Analog NIS
2) Digital IS and Non IS
3) Digital NIS (MCC + SOV)
4) Digital DI Relay Cabinet
5) Digital DO Relay Cabinet
3 Cable ducts for Cabinet
1) Blue colour duct for IS field cable
2) Gray colour duct for Non IS field cable
3) Sufficient distance between duct and terminals
5 Terminal Types
1) Terminal used suitable for cable size
2) Phoenix make
3) Front Entry Screw less Type
4) Gray colour terminals for Non-IS
5) Blue terminals for IS
Complied(C)
NotComplied
(NC)
NotApplicable
(NA)
1) Hardware cabinet and design is as per reviewed ESD Marshalling Cabinet Drawings
Cabinet SegregationNote:1) IS and Non IS cab be clubbed with front rear segregation wherever I/O count does not justifies separate cabinet2) Digital DI relay and DO relay Cabinet can be clubbed with front and rear segregation wherever I/O count does not justifies separate cabinet
6) At least one terminal Fused wherever switching of supply voltage is involved.Terminal shall be indicating type
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
ESD Marshalling Page 14 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
NotComplied
(NC)
NotApplicable
(NA)
6 TB Grouping
1) TB grouping as per JB/Cable grouping
2) Labeling provided for each TB group
3) Barriers are grouped as per JB/Cable grouping
7 Barrier
1) For AI MTL5541
2) For AO MTL5546/Y
3) For DI MTL5511
10 Bulk Power Supply
1) Proper position of bulk power supply
2) Proper Cable terminations
11 Diode Oring Module 1) Proper Cable terminations
12 Labels
1) All items properly labeled
13 FTA/RTP cabling 1) Prefab cable provided between FTA/RTP to I/O Card
2) Labels to MCBs, FTAs,TBs, Power supplies , Relays, Barriers etc are not permanent and can be reused when item/component is replaced
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
ESD Marshalling Page 15 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
NotComplied
(NC)
NotApplicable
(NA)
14 HART Patch Card
1) Patch Cards MTL make
2) Properly installed
16 HART master slave
1) MTL make
2) Proper position of Patch Card
17 Cable colour coding 2) Signal Cable colour coding and sizes
3) Power cable colour coding and sizes
18 Relay Models 1) For DI and DO SIL 3 certified PILZ PNOZ X1
1) Attach the colour coding sheet in functional design specification (FDS)
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
IRP Cabinet Page 16 of 20
Sr. No. Item Description Check Point Punch Point Remarks
1 Reviewed Cabinet Drawings
5 Terminal Types
1) Terminal used suitable for cable size
2) Phoenix make
3) Front Entry Screw less Type
6 TB Grouping
1) TB grouping as per JB/Cable grouping
2) Labeling provided for each TB group
10 Bulk Power Supply
1) Proper position of bulk power supply
2) Proper Cable terminations
11 Diode Oring Module 1) Proper Cable terminations
12 Labels
1) All items properly labeled
13 Cable colour coding 2) Signal Cable colour coding and sizes
3) Power cable colour coding and sizes
Complied(C)
NotComplied
(NC)
NotApplicable
(NA)
1) Hardware cabinet and design is as per reviewed IRP Cabinet Drawings
4) At least one terminal Fused wherever switching of supply voltage is involved.Terminal shall be indicating type.
2) Labels to MCBs,TBs, Power supplies , Relays etc are not permanent and can be reused when item/component is replaced
1) Attach the colour coding sheet in functional design specification (FDS)
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
IRP Cabinet Page 17 of 20
Sr. No. Item Description Check Point Punch Point RemarksComplied
(C)
NotComplied
(NC)
NotApplicable
(NA)
14 Relay Model for DCS IRP
1) For DI Omron LY2N
2) For Omron DO with MCC Control Voltage 240VAC LY2N
3) DO with MCC Control Voltage 110VDC MM2XPN
4) Relays are provided with casing & suppression diode
15 Relay Model for ESD and FGS IRP
1) For DI SIL 3 certified PNOZ X1
3) DO with MCC control voltage 110VDC Omron MM2XPN
2) For DO with MCC Control Voltage 240VAC SIL 3 certified PILZ PNOZ X1
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
NC
NA
Cable Colour Coding Sheet - DCS Page 18 of 20
Legend Sheet - DCS Page 19 of 20
Legend Sheet - DCS Page 20 of 20