6-81-1019 rev 2

7/28/2019 6-81-1019 Rev 2

http://slidepdf.com/reader/full/6-81-1019-rev-2 1/7

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2 29.06.12

Revised and Reissued

1 28.09.07 Revised and Re- issued

0 30.04.02 Issued for implemen ta t ion

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INSPECTIO N AND TEST PLANF OR

B ATTER Y CH AR GER S

ST A N D A R D SPE CI F I CA T ION N O .

6-81-1019 Rev. 2

of 7

een

Wteir -crtur r r zWrINSPECTION AND TEST PLAN

FOR

BATTERY CHARGERS

R e v .

No .Date Purpose

Standards Committee St anda r ds B u r eauPrepared Checked Convenor Chairman

by byApproved by

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

7/28/2019 6-81-1019 Rev 2


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IA Gov of 'Ma unbilakingj

INSPECTIO N AND TEST PLANFOR


S T ANDAR D S P E CI F I CAT ION NO .

6-81-1019 Rev. 2

of 7

AbbreviationsAS

BASEEFA

BI S

CCE or CCOE

CELL

CIMFR

C EDFT

DT

DPT

ERTL

FCRI

FMFLP

HT

HI CIT P

IPICIG CIE CJE C

LPT

Alloy Steel

British Approval Service for Electrical Equipment in Flammable

Atmospheres

Bureau of Indian Standard

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 Institute

Factory Mutual

Flame Proof

Heat Treatment

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

MPT/MT

MRT

MTC

MOC

NPSH

NDT

NEMA

PO

PESO

PQR

PR

PMI

PV C

QCRT

TCTPI or TPIA

UT

UL

VDR

WPSW PQ

XLPE

Magnetic Particle Testing

Mechanical Run Test

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

Inspection Standards C ommittee

Convenor : Mr. A.K. Chaudhary

Members:Mr. S.C. Gupta

Mr. G. Suresh

Mr. RK Singh Mr. MP Jain (Projects)

Mr. Rajeev Kumar Mr. G. Poomachandra Rao

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

7/28/2019 6-81-1019 Rev 2


leZedek NGINEERS

$1g709talrINDIA LIMITED

INSPECTIO N AND TEST PLANFO R


S T ANDAR D S P E CI F I CAT I ON NO.

6-81-1019 Rev. 2

of 7

1.0 SCOPE

This Inspection and Test Plan covers the minimum testing requirements of Battery Chargers (DC System consisting of Battery Charger, Cell Booster, DCDB and

Battery).

2.0REFERENCE DOCUMENTS

PO/PR/ Standards referred there in/Job specifications/Approved documents.

3.0 INSPECTION AND TEST REQUIREMENTS

SL

NO .STAGE/ ACTIVITY CHARACTERISTICS

AN UMUT

OF CHECKRECORD

SCOPE OF INSPECTION

SU B

SUPPLIERSUPPLIER EIL/TPIA

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

2.0 Material Inspection

2.1

Incoming Material like

Fabricated items, Electronic

components, PCBs, Relays,

Indicating Instruments,

Power Supply Unit,

IGBT/SCRs, etc.

Visual, Dimensional, operational checks, etc.

as applicable 100%

TC's/ Inspection

&

Test records / Lab

Test Records

H II/R R

3 .0 In process Inspection

3 .1PCBs & Electronic

components, Sub-assembliesBurn-in Test for 96 hours at 50deg C 100%

Supplier's Test

RecordsH H R

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7/28/2019 6-81-1019 Rev 2


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STANDARD SPECIFICATION NO.

6-81-1019 Rev. 2

of 7

SL


QUANTUM

OF CHECKRECORD

SCOPE OF INSPECTION

SU BSUPPLIER EIL/TPIA

SUPPLIER

4.0 Final Inspection

4.1 Battery Charger Assembly

(Acceptance Tests)

Visual check including layout, Tag plates,

Paint shade, Bus marking, Identification

and location of components, etc.

Check calibration status of all testing

equipment.

Dimension check including operational

height, Bu s size, Clearances, paint

thickness, etc.

Bill of material/ Make of Components.

Full Load test for 16 hours with minimum

Stirs for each Charger*. Temperature rise

for critical components would be recorded

during this test.

Charger testing at constant output voltage in

float and boost charge mode, including

measurement of AC phase voltage,

frequency, current, power, D C output

voltage, current and output voltage ripple

at nominal AC input voltage at zero, 50%

and 100% of rated output current.Measurement shall be repeated at 100%

full load current at 90% and 110% of

nominal AC supply

Charger testing under constant output

current limiting condition in float and

boost mode, including measurement of DC

100% by

Supplier and on

Random Basis

by EIL/TPIA

Test Records /

Inspection

Witness Record

- H H/ W

Format No. 8-00-0001-F7 Rev. 0C o p y r i g h t E I L — A l l r ig h t s r e s e r v e d

7/28/2019 6-81-1019 Rev 2


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6-81-1019 Rev. 2

of 7

SL


QUANTUM

OF CHECKRECORD

SCOPE OF INSPECTION

SU BSUPPLIER EIL/TPIA

SUPPLIER

Battery Charger Assembly

(Acceptance Tests Contd.)

output voltage and current with DC output

voltage varying between zero and set value

corresponding to constant voltage

operation.

Proper functioning of all measuring

instruments, alarms, indications, protection

and controls as per requirement.

Parallel operation of both chargers

including load sharing and automatic

isolation of faulty charger.

Charger Efficiency and Voltage regulation

test.

Harmonic Measurement.

Dynamic Response test for step load as per

PR/spec.

Audible noise test.

Insulation resistance before and after HV

test for power, control and auxiliary

circuits.

High voltage withstand test for power,

control and main circuits.

Check for protection against reverse battery

connection.

Random Basis

100% BY

Supplier and on

by EIL/TPIA

Test Records /

Inspection

Witness Record

- H H/W

4. 2 D.0 Distribution Board

Visual, Dimensions, Feeder Tag plates,

Functional checks, IR and HV test.

100% bySupplier and

on Random

Basis ny

EIL/TPIA

Supplier's

Test Records /

Inspection

Witness

Record

H H/R

Format No. 8-00-0001-F7 Rev. 0Copyr ight E I L — A l l rights reserved

7/28/2019 6-81-1019 Rev 2


Bin5kre? gal ENCJNEERS

E l l 5 t e g NIV INDIA LIMITEDIaRT (A GON 01 Inds Und.thk.g1

INSPECTION AND TEST PLANFO R

BATTERY CHARGERS


6-81-1019 Rev. 2

of 7

SL


QUANTUM

OF CHECKRECORD

SCOPE OF INSPECTION

SU BEIL/TPIASUPPLIER

SUPPLIER

4.3 Cell Booster

Visual and Functional checks

Full load capability test at 90% , 100% and

110% of nominal AC supply

IR and HV test

100% by

Supplier and

on Random

Basis ny

EIL/TPIA

Supplier's

Test Records /

Inspection

Witness

Record

- H H/R

4. 4 BatteryAll test as per respective

minimum ITP, as aSample

Supplier Test

Record_ H H/R

4. 5Submission of Certificates/

Documents

Type test report on radio frequency

interference voltages on RFI filter as per

VDE-0875 grade-N

100%

Supplier's

Test Records/

Statutory

Body

Certificates

- H R

5.0 Painting

5.1Painting of panels

(prior to assembly)

Pre treatment, primer and final paint,

shade, thickness100%

Supplier test

recordsH 11/W

6.0 Documentation and IC

6.1 Documentation and IC • Review of Internal Test Reports

IC issuance.

100%

Supplier's Test

Records /

InspectionCertificate

- H H

Format No. 8-00-0001-F7 Rev. 0Copyright EIL — A l l rights reserved

7/28/2019 6-81-1019 Rev 2


ISORZIeT azt4 ENGINEERS

4 1g a t a r d u , v . INDIA LIMITEDG ov t d I n d ia Un d Ot t e i n g )

INSPECTIO N AND TEST PLANFOR



6-81-1019 Rev. 2

of 7

* Tests shall be conducted on one charger of each rating (In case of dual Chargers, both chargers will be put on load separately)

Legends: H- Hold (Do not proceed without approval), Random 10% , R-Review, RW-Random witness, W- Witness (Give due notice, work maypoceedaeschedueddae

NOTES (As applicable):Wherever W/R or H/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-F7 Rev. 0Copyright EIL — Al l rights reserved