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7/28/2019 6-81-1019 Rev 2
http://slidepdf.com/reader/full/6-81-1019-rev-2 1/7
S
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
Page 1 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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Ii5115the i r e , E N G I N E E R Slatargili, WAL I M I T E D
IA Gov of 'Ma unbilakingj
INSPECTIO N AND TEST PLANFOR
B ATTER Y CH AR GER S
S T ANDAR D S P E CI F I CAT ION NO .
6-81-1019 Rev. 2
Page 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
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leZedek NGINEERS
$1g709talrINDIA LIMITED
INSPECTIO N AND TEST PLANFO R
B ATTER Y CH AR GER S
S T ANDAR D S P E CI F I CAT I ON NO.
6-81-1019 Rev. 2
Page 3 of 7
1.0 SCOPE
This Inspection and Test Plan covers the minimum testing requirements of Battery Chargers (DC System consisting of Battery Charger, Cell Booster, DCDB and
Battery).
2.0REFERENCE DOCUMENTS
PO/PR/ Standards referred there in/Job specifications/Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL
NO .STAGE/ ACTIVITY CHARACTERISTICS
AN UMUT
OF CHECKRECORD
SCOPE OF INSPECTION
SU B
SUPPLIERSUPPLIER EIL/TPIA
1.0 Procedures -- -- -- -- -- --
2.0 Material Inspection
2.1
Incoming Material like
Fabricated items, Electronic
components, PCBs, Relays,
Indicating Instruments,
Power Supply Unit,
IGBT/SCRs, etc.
Visual, Dimensional, operational checks, etc.
as applicable 100%
TC's/ Inspection
&
Test records / Lab
Test Records
H II/R R
3 .0 In process Inspection
3 .1PCBs & Electronic
components, Sub-assembliesBurn-in Test for 96 hours at 50deg C 100%
Supplier's Test
RecordsH H R
Format No. 8-00-0001-F7 Rev. 0Copyright EIL — Al l rights reserved
7/28/2019 6-81-1019 Rev 2
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StilalzIeg ea E NGINE E RS$/g7191Pr'aiif I N D I A L I M I TE D
, GON of into Undmtakingl
INSPECTIO N AND TEST PLANFO R
B ATTER Y CH AR GER S
STANDARD SPECIFICATION NO.
6-81-1019 Rev. 2
Page 4 of 7
SL
NO .STAGE/ ACTIVITY CHARACTERISTICS
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
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S a 1 1 5 1 -a e lt h E N G I N E E R S1 1 g 2:1109EDWIV INDIA LIMITEDG.4 of India undenakmoi
INSPECTIO N AND TEST PLANFO R
B ATTER Y CH AR GER S
S T ANDAR D S P E CI F I CAT I ON NO.
6-81-1019 Rev. 2
Page 5 of 7
SL
NO .STAGE/ ACTIVITY CHARACTERISTICS
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
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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
S T ANDAR D S P E CI F I CAT I ON NO.
6-81-1019 Rev. 2
Page 6 of 7
SL
NO .STAGE/ ACTIVITY CHARACTERISTICS
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
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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
B ATTER Y CH AR GER S
S T ANDAR D S P E CI F I CAT I ON NO.
6-81-1019 Rev. 2
Page 7 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
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