FIELD QUALITY PLAN FOR EHV SUBSTATION

Code of Authorisation for different categories of checks :-

Classification Check to be Counter check Accepting Disposing

of Check Witnessed by Surveillance by Authority Authority

A Field Central Central Head Central

Critical Quality Quality Quality Quality Assurance
Assurance Assurance Assurance in consultation (if
necessary) with Head,
Engineering

B Concerned Field Concerned Head Field Quality

Major erection/ Quality erection/ Assurance
commissioning Assurance commissioning in consultation
engineer engineer with Project Manager

C Contractor's Concerned Concerned Head, Concerned

Minor representative erection/ erection/ erection/
commissioning commissioning commissioning
engineer engineer department

Items covered in this FQP and abbreviations used for them are as under :
Items Referred Item Description Referred as
Description as

Circuit Breaker CBr Conductor & Shield wire Con

Instrument Transformer IT Power & Control Calbe Cab
Insulator Ins Marshalling Kiosks MK
RC
PC

Structure Str
Earthing Material Eth
Insulator Hardware IHW
Clamps & Connector CC
Alumimum Tube Alu

Items covered in this FQP and abbreviations used for them are as under :
Nomenc. Document Point of Time of
Description Generation Generation

PL Packing List Manufacturing Place Before dispatch

IR Inspection Report Manufacturing Place Before dispatch
MRR Material Receipt Report Site On the day of receipt
SIR Site Inspection Report Site at the earliest after receipt.
BOM Bill of Material Manufacturing Place Design, engineering
IM Instruction Manual Manufacturing Place Standard documents
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Desc. Of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

A PRE - COMMISSIONING

1 GENERAL
1.1 Check that the survey is conducted to ensure the Physical A 100% Lay out drawings Inspection reports
completeness of switchyard erection, dimensional
conformity, and cleanliness of the total installation.

1.2 Check for the proper earthing of the switchyard Physical A 100% Earthing layout and Inspection reports
installation and all its associated cubicles and megger equipment earthing
equipments with main earthing grid. drawing
Check IR values.

1.3 Check sectional/electrical clearance of the Physical A 100% Layout drawings / IS Inspection reports
Switchyard

1.4 Check name plates of all equipments to ensure Physical A 100% Layout drawings Inspection reports
that equipments are same as per Single line diagram
system requirement.

2 STRUCTURE
2.1 Check for the general alignment, verticality and Visual A 100% Structure drawings Inspection report
physical appearance of all the structure.

2.2 Check that step bolts have been fixed Visual B 100% Structure drawings Inspection reports

2.3 Check that all joints have been properly made with Visual B 100% Structure drawings Inspection reports
proper bolts and nuts, cover plates and filler washer.

2.4 Check that all bolts and nuts have been Physical Torque B 10% Inspection reports
properly tightened. wrench

2.5 Check for any bending / sagging of beams/columns Physical B 100% Inspection reports

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR COMMISSIONING
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 1 of 7
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Desc. Of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

2.6 Check that all the structures have been Physical B 100% Structure earthing Inspection reports
properly earthed. drawing

3 CT & VTs

3.1 Check that the instrument transformers have been Physical A 100% Single line diagram Inspection reports
installed in proper sequence. (P1, P2 positions
and ratio)

3.2 Check that the secondary wiring of instrument Physical A 100% CT/CVT wiring Inspection reports
transformer conforms to wiring diagram diagram

3.3 Check that the secondary leads have been Physical A 100% CT/CVT wiring Inspection reports
properly clamped and fastened and that no diagram
loose wire is hanging.

3.4 Check for the tightness of all bolts and nuts Physical A 100% CT/CVT wiring Inspection reports
including those on covers and fixing arrangement. diagram

3.5 Check oil level and leakage, if any Visual B 100% Inspection reports

3.6 Tightness and correctness of all primary/secondary Physical B 100% CT/CVT connection Inspection reports
re-connections to obtain required ration. Ensure diagram
that unused secondary cores are correctly shorted.

3.7 Ensure that equipment earthing is as per approved Physical B 100% Equipment earthing Inspection reports
drawings. drawing

3.8 Check relay and meter burden connected to circuit. Physical B 100% Control, metering & Inspection reports
protection scheme

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR COMMISSIONING
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 2 of 7
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Desc. Of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.
3.9 Check cleanliess of insulators Visual B 100% Inspection reports

4 CIRCUIT BREAKER

4..1 Check correct installation of support structure, Visual B 100% Instruction manual, Inspection reports
base frame, circuit breaker operating mechanism, layout drawing
air receiver switch cubicle and compressor.

4.2 Check air piping and valves Physical B 100% Pneumatic diagram Inspection reports

4.3 Check earthing connection Physical B 100% Equipment earthing Inspection reports
drawing

4.4 All pre-commissioning checks as per Test B 100% Instruction manual Inspection reports
manufacturers instruction manual.

5 BUS-BAR, ALUMINIUM TUBE

5.1 Finish Visual B 100% Layout drawing Inspection reports

5.2 Check for proper alignment and tightness Physical Torque B 100% Layout drawing Inspection reports
of connections. wrench

5.3 Check for minimum clearance between phases Measurement B 100% Layout drawing Inspection reports
and phase to ground Section drawing

5.4 Milli volt drop test on main connections / welded Electrical Millivolt 100% Inspection reports
joints meter

5.5 Sag check on conductor Physical Dynamo A 100% Sag-tension chart Inspection reports
meter

6 EARTHING GRID

6.1 Tightness of all connections. Manual Spanners A 100% Inspection reports

check
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR COMMISSIONING
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 3 of 7
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Desc. Of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

6.2 Earth Resistance of grid Electrical Meggar B Whole IEC / GOST Inspection reports
network

6.3 Resistance of driven rods and earth electrodes Electrical Meggar B At each IEC / GOST Inspection reports
location
The earthing resistance of grid shall be measured
using 3 terminal earth tester at two
locations 15M apart.

7 MISCELLANEOUS ITEMS

7.1 Check that wiring and terminal clamps Physical B 100% GA of marshalling Inspection report
the marshalling boxes are all OK. box

7.2 Check that the heater and lamps are working Physical B 100% Inspection reports

7.3 Check ferrule markings on the terminals and Physical B 5% rando Wiring diagram Inspection reports
cable ends and ensure they talley with wiring
diagram.

B COMMISSIONING

1 GENERAL

1.1 Check that all pre-commissioning test have been Record B 100% Test reports Inspection reports
completed

1.2 Check that all the CT secondary circuit are properly Physical B 100% Wiring diagram Inspection reports
connected to the respective relays/instruments
and the cabling is complete in all respects.
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR COMMISSIONING
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 4 of 7
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Desc. Of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

1.3 Check oil levels in instrument transformers Physical B 100% Instruction manual Inspection reports

1.4 Check that the earthing of all equipment and Record B Record register Inspection reports
cubicles are complete in all respects.

1.5 Check for any visual dmage to any of the Visual B 100% Inspection reports
equipment especially porcelain

1.6 Check for tightness of all bolts, clamps Test B 100% Record Inspection reports
and connecting terminals

1.7 Check for cleanliness of insulators and bushings Visual B 100% Record Inspection reports

1.8 Check for lubrication for disconnector Visual B 100% Instruction manual Inspection reports

1.9 Check phase marking for all equipments/buses Visual B 100% Layout drawing Inspection reports
as per layout

1.10 Check that danger boards are fitted Visual B 100% Inspection reports

1.11 Check that Fencing and gates are Visual B 100% Equipment earthing Inspection reports
provided and earthed drawing

1.12 Check marking, equipment identification number Visual B 100% Single Line Diagram Inspection Reports

1.13 Ensure that permission from statutory authorities is B 100% Approval Letter Inspection Reports
obtained to commission the switchyard.

2 CIRCUIT BREAKER

2.1 Control wiring, interlock, tripping circuits, etc. for Test Continuity B 100% Wirining diagram Inspection Reports
correctness of connection and functioning. tester
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR COMMISSIONING
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 5 of 7
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Desc. Of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

2.2 Leaklage test (Air, Gas) Test Leak B 100% Inspection manual Inspection Reports
detector

2.3 Closing, opening and reclosing operation (local Operation B 100% Inspection manual Inspection Reports
remote) at specified pressure

2.4 Check pressure drops during various operations Test B 100% Inspection manual Inspection Reports

2.5 Breaker closing and tripping time at normal Test Synchro B 100% Inspection manual Inspection Reports
voltage and pressure as per IEC 56-4 timer

2.6 Check setting of different switches Test B 100% Inspection manual Inspection Reports

2.7 Check continuity, IR values for entire pole, Test 5 KV B 100% Inspection manual Inspection Reports
control circuit, motor, etc. 500V
Meggars

2.8 Contact resistance and resistance of closing Test Mill B 100% Inspection manual Inspection Reports
and tripping coils Volt
meter,
Multi meter

2.9 Check operation of all auxiliary relays/ Visual B 100% Inspection manual Inspection Reports
contractor/coils

2.10 Any other commissioning test as per Test B 100% Inspection manual Inspection Reports
manufacturer's instruction

3 CURRENT Test B 100% Inspection manual Inspection Reports

TRANSFORMER
3.1 Check magnetisation characteristics of cores Electrical Primary B 100% Inspection manual Inspection Reports
Injection, Kit
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR COMMISSIONING
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 6 of 7
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Desc. Of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

3.2 Measure IR value using meggar

a. Primary to secondary cores and eart with 5kV Electrical Meggar B 100% Inspection manual Inspection Reports
meggar
b. Between secondary cores with 500V meggar Electrical Meggar B 100% Inspection manual Inspection Reports

c. Between secondary to earth with 500V meggar Electrical Meggar B 100% Inspection manual Inspection Reports

3.3 Check polarity Electrical Multimeter B 100% Inspection manual Inspection Reports

3.4 Check for CT ratio by primary injection method Electrical Primary B 100% Inspection manual Inspection Reports
Injection Kit

4 VOLTAGE
4.1 TRANSFORMER Cleanliness of porcelaine insulator Visual B 100% Inspection Reports

4.2 Measure IR value using meggar

a) Primary to secondary cores and eart with 5kV Electrical Meggar B 100% Inspection manual Inspection Reports
meggar
b) Between secondary cores with 500V meggar Electrical Meggar B 100% Inspection manual Inspection Reports

c) Between secondary to earth with 500V meggar Electrical Meggar B 100% Inspection manual Inspection Reports

4.3 Polarity test by induction kick method Electrical Cell B 100% Inspection manual Inspection Reports

4.4 Check for voltage ratio of all cores Electrical Primary B 100% Inspection Reports
Injection Kit

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR COMMISSIONING
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 7 of 7
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

A PRE - ERECTION

1.0 DOCUMENTS

1.1 Check that the instruction/erection manuals for all Physical B 100% Record register
equipments to be erected have een received.

1.2 Check that a schedule of erection drawing is Physical B 100% Record register
available in the instruction manual or is received
separately.

1.3 Check for availability all approved documents Physical B 100% Record register
especially bill of material, packing lists, at
layout drawings, structural arrangement and appropriate
erection drawings as per the schedule stage

1.4 Check that all approved test certificates are Physical B 100% Record register
received for equipment such as CT, PT, LA,
isolators CBs etc.

2.0 CIVIL WORKS

2.1 Check the reference centre lines of complete Visual B 100% Switchyard layout Record register
switchyard installation are permanently and measurement and foundation drg.
clearly marked to given dimensions.

2.2 Check that location and reference centre lines Visual B 100% Switchyard layout Record register
of equipments and towers are marked clearly measurement and foundation drg.
to given dimensions.

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 1 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

2.3 Check that the various levels of different relevant Visual B 100% Switchyard layout Record register
floors and other associated civil aspects like measurement and foundation drg.
inserts, pockets etc. are provided as per
layout drawing.

2.4 Check templates Visual B 100% Template drawing Record register

measurement

2.5 Foundation bolts to be grouted measurement B 100% Foundation drawing Record register
anchor bolt drawing

2.6 Check that the foundation bolts to be grouted are measurement B 100% Foundation drawing Record register
located properly to match correctly with center line, anchor bolt drawing
spacing and Project:PFC-009ion above ground level.

2.7 Check that in case of any deviation required in the Visual B 100% Record register or Record register
point no.2.1 to 2.6 stated above, remedial measures measurement document signed by
are taken with concurrence of competent authority competent authority
well before commencement of erection.

3.0 EARTHING

3.1 Check the earthing scheme and ensure that all Visual B 100% Earthing layout, Record register
necessary points have been brought out from equipment earthing
station eartch mat, for connecting with equipments drawing
towers etc. at required location.

4.0 CHECK OF
THE EQUIPMENT
4.1 Check for the complete receipt of material and Physical B 100% Bill of material Record register
for the completeness of individual assemblies with Site inspection report
all components involved.
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 2 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

4.2 Check that CTs, CVTs, CBs etc. are in good Visual B 100% Record register
conditions and are ready for assemblies/erection

4.3 Check that all terminals are smooth and free Visual B 100% Record register
of dirt, dents etc.

4.4 Check that the surfaces that are to be welded Visual B 100% Welding schedule Record register
such as ends of aluminium tubes, earth before and
conductors etc. are properly cleaned and are free after
from paint, grease or oil. assembly

4.5 Check that all welding materials/eqipment Visual B 100% Welding schedule Record register
including electrodes, filler wire, welding machine
are available at site to required specifications and
they are in order. Also ensure that the welding
electrodes are kept in controlled atmosphere.

4.6 Check for the availability of qualified/approved Physical B 100% Welding schedule Record register
welder at site for aluminium tube welding

4.7 Check that all tools & tackles, instruments etc. Physical B 100% List of tools & tackles Record register
required for erection are availabe at site.

4.8 Check that all necessary testing kits and Physical B 100% Testing instruments/ Record register
accessories are available at site duly calibrated kits, calibration
wherever necessary for carrying out reports
testing during erection.

4.9 Check for the availability of all erection harwares, Physical B 100% Bill of material Record register
foundation bolts, earthing
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 3 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

B ERECTION

1 GENERAL

1.1 Check that the structures are properly tightened/ Physical B 100% Structure and Record register
grouted only after exact alignment layout drawing

1.2 Check that all assemblies required are Visual B 100% Equipment drawing Record register
available at site.

1.3 Check that associated equipments are placed in Visual B 100% Equipment drawing Record register
their proper position during the erection. & layout drawing

1.4 Check the clearances between phases and with Physical/ B 100% Equipment drawing Record register
earth are conforming to design as per layout measurement & layout drawing

1.5 Check that CTs are erected strictly as per layout Visual B 100% Equipment drawing Record register
drawings and in correct order such that the & layout drawing
polarity is OK. Ensure that the secondaries
remain shorted until the secondaries are connected
to their respective instruments/relays.

1.6 Check oil levels Visual B 100% Instruction manual Record register

1.7 Check that earthing of various equipment, structures Visual B 100% Earthing drawing & Record register
etc. are done as per approved earthing drawing. layout drawing

2.0 CIRCUIT BREAKERS

2.1 Ensure that breakers are erected with proper Visual Crane B 100% Instruction manual Record register
handling equipment, preferably with mobile crane
with appropriate boom. Check slings.
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 4 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

2.2 Ensure correct phase sequence and location Visual -- B 100% Equipment drawing Record register
of operating mechnism. & layout drawing

2.3 Check erection of structures Visual Torque B 100% Instruction manual Record register
Wrench

2.4 Check continuity of electrical connections. Electrical Multimeter B 100% Single line diagram, Record register
Continuity continuity breaker schematic
continuity tester diagram

2.5 Ensure that operating mechnism is correctly Visual B 100% Instruction manual Record register
assembled and erected with use of proper
hadener/locktite wherever necessary.

2.6 Check erection of structures Visual B 100% Structure drawing Record register

2.7 Check erection of air receiver Visual B 100% Equipment drawing Record register

2.8 Check mounting of poles, control cubic density Visual B 100% Equipment drawing Record register
monitor, compressor etc.

2.9 Ensure proper tightening of density monitor Physical Torque B 100% Equipment drawing Record register
and SF6 piping. Wrench

3.0 CURRENT
TRANSFORMER
3.1 Check for oil marks, oil level, damage or any Visual B 100% Equipment drawing Record register
other defect of primary and secondary terminals

3.2 Ensure the lifting of CT using lifting lugs Visual sling pads B 100% Instruction manual Record register
only (protect porcelain)
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 5 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

3.3 Check earthing terminal for connection to Visual B 100% Equipment drawing Record register
earthmat at correct location

3.4 Check mounting of CT on structure, ensuring Visual B 100% Rating Plate, Record register
correct polarity and level with Alu Tube. Connection diagram
section drawing

3.5 Check insulation resistance Electrical B Random Instruction manual Record register

3.6 Check CT secondary terminals Visual B 100% Instruction manual Record register

3.7 Check oil level of CT Visual B 100% Instruction manual Record register

4.0 VOLTAGE
TRANSFORMER
4.1 Check case for oil marks/damage Visual B 100% Equipment drawing Record register

4.2 Ensure lifting of CVT using lifting lugs only Visual Sling pads B 100% Instruction manual Record register

4.3 Ensure mounting of base of CVT on the supporting Visual B 100% Equipment drawing, Record register
structure with respect to correct orientation layout drawing
and level.

4.4 Check wiring of secondary terminals and ensure Visual B 100% Rating Plate Record register
that it is done as per the wiring diagram Connection diagram

4.5 Ensure proper connection of secondary terminal Visual B 100% Rating Plate Record register
Connection diagram

4.6 Ensure earthing of HT connection if not utilised. Visual B 100% Instruction manual Record register
Connection diagram
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 6 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

4.7 Check that the wire between primary terminal Visual B 100% Instruction manual Record register
and HT terminal of tank is removed.

4.8 Check secondary fuses for continuity and rating Visual Continuity B 100% Record register
tester

4.9 Check for level of oil in the tank Visual B 100% Instruction manual Record register

4.10 Check removal of breather plug (if any) Visual B 100% Instruction manual Record register

5 ALUMINIUM TUBE
WELDING &
ERECTION OF BUS
5.1 Ensure minimum thickness of tube as per Measurement B 100% Bill of material Record register
specification by measuring ID & OD.

5.2 Inspect the tube visually for damages Visual B 100% Record register

5.3 Check for proper alignment of tube and well Visual B 100% Record register
fiting of sleeve before welding.

5.4 Before commencing the welding check that no Visual B 100% Record register
inflammable material is present around the
work spot.
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 7 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.
5.5 Check that welding is done only by qualified and Visual B 100% Welder qualification Record register
approved welder with recommended welding record, welding
material and welding machine. procedure

5.6 Ensure that the welding of aluminium tube is done Visual B 100% welding procedure Record register
as per instruction and that best quality welding
is achieved.

5.7 Check that alignment is achieved correctly. Physical B 100% Record register

5.8 Check soundness of aluminium pipe joints Die B 10% As per relevant Test report
penetration standard
test
Radiography B 10% As per relevant Test report
standard

5.9 Check joints after cutting the welded piece for voids Testing B 5% As per relevant Test report
standard

6 STRINGING OF MAIN
6.1 BUS BARS Ensure use of correct type of insulator Visual B 100% Bill of material Record register

6.2 Check for tension or sag Measurement Dynamo - B 100% Sag-tension chart Record register
meter

6.3 Check clamping of conductor, tightness of Physical Torque B 100% Layout drawing Record register
clamp. Orientation and looping without loss wrench
of tension.

6.4 Check torque value of bolts of clamps Physical Torque B 100% Record register
and connector wrench

6.5 Check mV drop of the equipment power connectors Measurement Multimeter B 100% Record register
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 8 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

7 UNDER GROUND
CABLING
(UP TO 33 KV)
7.1 Preparation of cable trenches as per
specified drawings

a Check the slope of the trench Visual Measure Major 100% Layout drawing Record register
(not applicable for burried cables) Tape

b Check the drainage possibility Visual Measure Major 100% Layout drawing Record register
(not applicable for burried cables) Tape

c Check grounding in the trench Visual Major 100%

d Check the geometric size with respect to bending Visual Measure Major 100% Layout drawing Record register
radius of the largest size of the cable to be laid Tape

e Check the load capacity / precautionary measure Visual Major 100% Layout drawing
for the raod / culverts / other obstruction in the route

f Check the separation between different types Visual Major 100% Layout drawing Record register
of cables laid nearby

7.2 LAYING OF CABLES

a Check the cable drum / cable to be laid for Visual Major 100% Record register
any external damage

b Check the availability and functionality of the rollers Visual Major 100%

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 9 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / Description of test Type of Instrument Class of Quantum / Reference docu. Format of records Remarks
S.No. Operation check Check frequency & acceptance std.

c Prepare the required earth mat and base in the Visual Major 100% IEC / GOST
trench for the cable to be laid

d Check that cables are protected from the Visual Major

sharp bends while laying

e Check that the power cables are separated Visual Major 100%
from the control cables

f Carry out the straight joints as per the length Visual Jointing Major 100% As per jointing Record register
of the cable and route calls for (try to minimise Mechanical kits and methods specified
the number of joints) associated by the kit
equipment manufacturer

g Check the phase matching at each end after Electrical Multimeter Major 100% Record register
each joint

h Prepare the coffin boxes for the joints Mechanical civil Major 100%
material &
accessory

I Carry out the meggering of the complete laid Electrical Megger Major 100% IEC / GOST Record register
cable and joints made

j Carry out the AC/DC Hipot testing of the Electrical Major 100% IEC / GOST Record register
complete laid cable and joints made

k check cable markers are provided at every Visual Major 100%

20 meter after back filling of the earth.

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 10 of 10
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / items Type of Instrument Class of Quantum / Reference docu. Format of records
S.No. Operation check Check frequency & acceptance std.

1 GENERAL

1.1 Check general ground level, final ground level and Visual Theodolite A 100% Foundation drawing Record register
plinth level. Check permanent bench mark with
theodolite and get confirmation of site officers.

1.2 Check grid lines for whole area Visual Measure A 100% Foundation drawing Record register
tape

1.3 Check subsoil water table, type of soil, level & Physical Field lab B At Soil reort Record register
gradation and soil bearing capacity. Conduct specific
penetration test. locations.

1.4 Check location of individual units / foundation Visual Theodolite B All units Foundation drawing Record register
(Proper location) Mechanical

1.5 Check excavation of pits Visual B 100% Foundation drawing Record register

1.6 Check density of backfilling, and conduc Physical Field lab B 1 sample Record register
moisture content test per 200m3

2 CEMENT

2.1 Check apparent condition of cement prior to Visual C Random IEC / GOST Record register
consumption

2.2 Check initial and final setting time Test Field lab C 1 sample IEC / GOST Record register

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 1 of 6
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / items Type of Instrument Class of Quantum / Reference docu. Format of records
S.No. Operation check Check frequency & acceptance std.

2.3 Check consistancy and soundness of cement Test Field lab C 1 sample IEC / GOST Record register

2.4 Check compressive strength of cement Test Compression C 1 sample IEC / GOST Record register
testing
machine

2.5 Check heat evaluation and hydration of cement Test C 1 sample IEC / GOST Record register

2.6 Conduct sieve analysis Measurement Set of C 1 sample IEC / GOST Record register
IS-sieves

3 CONCRETE MIX

3.1 Check workability of concrete mix Test Slump C Two IEC / GOST Record register
cone samples
from
each
days work

3.2 Check compressive strength of concrete mix Test Compression C 6 test IEC / GOST Record register
testing samples
machine per location
per day

3.3 Conduct slump test and check compaction factor Test Slump C 1 sample IEC / GOST Record register
cone per mix

3.4 Check assembly of reinforcement Measurement C 100% Foundation drawing --do--

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 2 of 6
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / items Type of Instrument Class of Quantum / Reference docu. Format of records
S.No. Operation check Check frequency & acceptance std.

3.5 Check concrete proportioning before actual Test Field lab C One IEC / GOST Record register
consumption. Check water-cement ratio and Sample
proportioning of aggregate cement for required
grade of concrete

4 OPEN FOUNDATIONS

4.1 Check form work Measurement Template C 100% Foundation drawing Record register
Visual Steel tape

4.2 Check levelling Measurement Spirit level C 100% Foundation drawing Record register
Visual Steel tape

4.3 Check insert and their levelling Measurement Spirit level C 100% Foundation drawing Record register
Visual Steel tape

4.4 Check placement, alignment and embedment Measurement Template C 100% Foundation drawing Record register
of anchor bolts Visual Steel tape

4.5 Check stub setting Measurement Stub C 100% Foundation drawing Record register
Visual setting
template

4.6 Check curing Visual C 100% IEC / GOST Record register

5 PILES

5.1 Check the bore Measurement Rods and C 100% Foundation drawing Record register
Visual Mirro

5.2 Check bulb formation Measurement Rods and C 100% Foundation drawing Record register
Visual Mirro
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 3 of 6
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / items Type of Instrument Class of Quantum / Reference docu. Format of records
S.No. Operation check Check frequency & acceptance std.

5.3 Check pile cap Measurement Measure C 100% Foundation drawing Record register
Visual tape

5.4 Conduct routine load test on piles Testing Jack, A As per IEC / GOST Data sheet as per
Steel spec. IS:2911
girder, Record register
dial
gauges

6 COARSE AGGREGATES

6.1 Check moisture content Physical Field lab C Once per IEC / GOST Record register
week*

6.2 Check bulk density Physical Field lab C Once per IEC / GOST Record register
100 m3
per day
during
monsoon

6.3 Check abrasion value Test Field lab C One per IEC / GOST Record register
source

6.4 Check presence of unwanted materials Visual C Random IEC / GOST Record register

6.5 Check crushing value Physical Field lab Once per IEC / GOST Record register
source

6.6 Conduct sieve analysis Test IS-Seaves C 1 sample IEC / GOST Record register
from each
KEC INTERNATIONAL LIMITED
FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 4 of 6
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / items Type of Instrument Class of Quantum / Reference docu. Format of records
S.No. Operation check Check frequency & acceptance std.

6.7 Check impact value Test Field lab C Once for IEC / GOST Record register
source

6.8 Check specific gravity, absorption value and voids Test Gield lab C Once per IEC / GOST Record register
source

6.9 Check organic impurity and deleterious Test Field lab C Once per IEC / GOST Record register
material estimation source

6.10 Check flakiness Test Field lab C Once per IEC / GOST Record register
source

6.11 Check for reaction with acid and alkali Test Field lab C Once per IEC / GOST Record register
source

7 FINE AGGREGATES

7.1 Check for deleterious material, organic impurity, Test Field lab C Once per IEC / GOST Record register
particle size and shape source

7.2 Check absorption, density and voids Test Field lab C Once per IEC / GOST Record register
source

7.3 Check bulkage and moisture Test Field lab C Once per IEC / GOST Record register
source

7.4 Check specific gravity Test Field lab C Once per IEC / GOST Record register
source

7.5 Check for reaction with acid and alkali Test Field lab C Once per IEC / GOST Record register
source

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 5 of 6
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur
 Kazakhstan Electricity Transmission Rehabilitation Project Phase-II

Field Quality Plan for Package-1

Component/ Characteristics / items Type of Instrument Class of Quantum / Reference docu. Format of records
S.No. Operation check Check frequency & acceptance std.

8 WATER

8.1 Make chemical analysis and check pH value, Test Field lab C Once per IEC / GOST Record register
cleanliness source

9 REINFORCEMENT BARS

9.1 Conduct tensile test Mechanical U.T.M. B 1 sample IEC / GOST Record register
per
consignment
per
category

9.2 Conduct bend test and re-bend test Mechanical U.T.M. B 1 sample IEC / GOST Record register
per
consignment
per
category

9.3 Make a visual inspection Visual B 100% IEC / GOST Record register

9.4 Check unit weight Test Scale C 1 sample IEC / GOST Record register
per
consignment
per
category

10 Check for local defects in structural steel inserts Visual 100% Record register

KEC INTERNATIONAL LIMITED

FIELD INSPECTION & TESTING PLAN FOR ERECTION
FQP No. : KX/788/EHV/2011 Date : 06 Sep. 2011 Page : 6 of 6
Prepared by: Mr. Laxmi Narayan Pradhan Approved by : Mr. Rakesh Gaur