inspection at factory works

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Third Party Inspection for Control Panel

The Third Party Inspection for Control Panel article provides you withinformation about the control panel test and control panel inspection in the

manufacturing shop.

You may need to review this article along with the following article:

This content guides you through all the necessary stages in the production of thecontrol panels, including the raw material, final inspection, preservation and packing,and dispatch to site.

You need to take this point into account: this article is written for a typical controlpanel and might not be detailed for special cases.

This content may be useful for second party inspectors, control panel manufacturerquality control personnel, engineering companies, and purchasers, as well.

All control panel inspection and testing is done against the approved drawings,purchase order specifications, purchasers or company standards, and within thepractices and rules of the country, state or province and any government decrees,laws, ordinance or regulation as may apply

The applicable codes and specifications for a control panel that is under theconstruction process is:

Design code Purchase order specification Purchaser's standards Approved drawings

The applicable codes and standards may be based any international standards. Thiscontent is general and can be useful for all recognized standards.

Required Documents for Third Party Inspector Review:

The list of documents normally is agreed upon in the Pre-Inspection meeting, whichis held several weeks before the actual commencement of the inspection work. The

parties that participate in this meeting are the manufacturer, purchaser and thirdparty inspection agency representatives.

This is already explained in the Inspection and Test Plan for Control Panel article.

These are the list of documents that are normally agreed upon to be presented to theinspector:

Control Panel Purchase Order or Contract Control Panel Manufacture Quality Control Plan Control Panel Inspection and Test Plan Control Panel Data Sheet

Arun Pandey (Er.-Planning )


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Control Panel Approved Drawings, (arrangements, schematics, wiring, singleline)

Control Panel Material Test Reports Control Panel Welding Specification Procedures (WPS) and Procedure

Qualification Records(PQR)

Control Panel Welders Qualifications Reports Control Panel Calibration Certificates for Test Equipment Control Panel Special Procedures Control Panel Special Qualifications Control Panel Preparation and Painting Procedure Control Panel Preservation, Packing and Shipping Procedure Control Panel Packing List

Third Party Inspection for Control Panel-Material Inspection

The first actual inspection work in the control panel is the raw materials inspection.

The original or authenticated copies of mill certificates of material normally areavailable at the manufacturer's premises.

The third party inspector examines these certificates for compliance withspecifications, and where appropriate, drawings.

The review includes checks on:

Certificate No. Heat or cast No.

Chemical composition. Mechanical properties. Heat treated condition. NDE applied and results. Surface finish

Then the inspector witnesses the materials identification on the certificates againstthe materials marking. It is also necessary to check these with the control paneldrawing datasheet, material list and other specifications as appropriate.

Visual inspection for surface finish and probable defects is done and dimensional

compliance with specification need to be controlled, as well.

When the third party inspector carries out the material inspection, then provides theinspection visit report (IVR), the report contains the following items:

Confirmation of satisfactory document review Record of the endorsement of certification reviewed/witnessed Record of all non-conformities Record of any tests witnessed and the result

Third Party Inspection for Control Panel Construction



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When the control panel raw material inspection is carried out, and the results weresatisfactory or non-conformities were closed by remedial action, then the controlpanel manufacturer will start fabrication.

The third party inspector checks the following points on the control panel, based on

the inspection and test plan (ITP), which has already been agreed upon between thepurchaser and the control panel manufacturer.

The inspection scope is determined in the ITP. Some purchasers prefer to havestringent controls and assign the TPI for more hold or witness points for inspectionand test activities, and some others prefer less hold or witness points and assignthe TPI much more work in the review document.

This depends in the inspection budget, which purchasers assign for inspection. Muchmore inspection will have a much larger cost and less risk, and conversely, lessinspection will have less cost but more risks.

For more details, review the Inspection and Test Plan for Control Panel article. Thereis a draft of the ITP in this article, which we believe is the best practice for controlpanel inspection.

The third party inspector checks the following items in the control panel casinginspection process:

Paint using specified colour swatch, thickness measurement, if specified Name plate control Outline dimensions, interface dimensions, bus bar dimensions and

Clearances and other specified dimensions Tightness/torque of terminals Degree of protection

It is necessary the results to meet drawings and applicable standards.

Third Party Inspection for Control Panel - General Arrangement Check

The third party inspector checks that all instruments, compartments, control switchesetc. are correctly rated and are correctly located, with specified labelling inaccordance of approved drawings.

If the third party inspector is not in the hold or witness point in the ITP for thisinspection stage, then he/she will review the control panel manufacturer qualitycontrol report in his/her coming visit or on the final inspection day.

Third Party Inspection for Control Panel - Insulation Resistance Test

Insulation resistance is measured between control circuits and earth (with sensitivedevises excluded) with a 500V Megger.

Similarly, insulation resistance is measured in all applicable permutations for anypower circuits, if these are included within the control system, with a Meggerselected to the voltage calculated appropriate to the applicable specification.

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The test result depends to the circuit but would not be acceptable if it is less than 2Megohms.

Similarly, If the third party inspector is not in the hold or witness point in the ITP forthis inspection stage, then he/she will review the control panel manufacturer quality

control report in his/her coming visit or on the final inspection day.

Third Party Inspection for Control Panel - Withstand Voltage Test (DialectricTest)

Power frequency voltage of 1.5 kV is applied between control circuits and earth for 1minute.

Similarly power frequency voltage, calculated appropriate to the applicablespecification, is applied to all applicable permutations for power circuits for 1 minute.

The test would be acceptable if the no flashover and puncture occurs during the test.

Similarly, If the third party inspector is not in the hold or witness point in the ITP forthis inspection stage, then he/she will review the control panel manufacturer qualitycontrol report in his/her coming visit or on the final inspection day.

Third Party Inspection for Control Panel Sequence Test

Control circuitry is functionally tested and circuits proven by appropriate tests.

The test result would be acceptable if meet approved schematic diagrams (includingappropriate, recorded, as built alterations) and project philosophy

Similarly if the third party inspector is not in hold or witness point in the project ITPfor this stage, then will review control panel manufacture quality control report inhis/her coming visit or in the final inspection day.

Third Party Inspection for Control Panel Mechanical Operation Test

The following mechanisms are checked for operation:

Locking Interlocking systems Drawing mechanisms Opening and shutting mechanisms Interchangeability.

The test would be acceptable if all the mechanisms work correctly.

Similarly, If the third party inspector is not in the hold or witness point in the ITP forthis inspection stage, then he/she will review the control panel manufacturer qualitycontrol report in his/her coming visit or on the final inspection day.

Third Party Inspection for Control Panel - Painting and Coating Inspection



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Surface preparation for painting is checked for the following points, according tospecification by third party inspector:

Cleaning method (Blast or scraping and wire brushing) Preparation grades

Freedom from weld spatter, blow-holes and other defects Dry film thickness is checked according to specification

It is necessary surface condition to be free from pin-holes, runs damage and otherdiscontinuity.

Third Party Inspection for Control Panel - Reporting

The third party inspector provides an Inspection Visit Report (IVR) after eachvisit, as well as a final report summarizing the activities carried out during thecontrol panel production in accordance with the contract requirements and

circulated within the time limits specified in the contract.

The report is in the format required by the client and clearly indicates finalacceptance or rejection of the control panel.

Third Party Inspection for Control Panel - Release Note

When required by the contract or purchase order, a release note is issued bythe third party inspection agency and given to the manufacturer when thecontrol panels have been accepted.

Third Party Inspection for Control Panel Packing, Marking and Shipping:

The following points are checked by the third party inspector:

Verify that the packing materials conform to specifications and acceptedpractice for the mode of transport.

Verify protection against humidity, abrasion, distortion and otherdamage.

Verify shipping marks to marking instructions and record. Verify handling marks.



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Third Party Inspection for Bus DuctThis content guides you about all necessary stages in the production of the BusDucts from the examination of the raw material, final inspection, preservation andpacking to dispatch to site.

This content is written for typical Bus Duct and might not be detail for special cases.

This content would be useful for second and third party inspectors, Bus Ductmanufacture quality control personnel, engineering companies, purchasers and anyinterested individuals

Bus Duct inspection and test is done against the approved drawings, purchase orderspecifications, purchasers or company standards, and within the practices and rulesof the country, state or province and any government decrees, laws, ordinance orregulation as may apply.

The applicable codes and specifications for Bus Duct which is under construction orsupply process are:

The applicable codes and standards may be based any international standards. Thiscontent is general and can be useful for all recognized standards.

Design code Purchase order specification Purchaser's standards Approved drawings

The applicable codes and standard may be based any international standards. Thiscontent is general and can be useful for all recognized standards.

Required Documents for Third Party Inspector Review:

The list of documents normally is agreed in the Pre Inspection meeting which is holdseveral weeks before actual commencement of inspection work. The parties whichare participated in this meeting are manufacture, purchaser and third partyinspection agency representatives.

This already explained in the Inspection and Test Plan for Bus Ductarticle.

These are the list of documents which are normally agreed to be presented to theinspector:

Bus Duct Purchase Order or Contract Bus Duct Manufacture Quality Control Plan Bus Duct Inspection and test plan Bus Duct Data Sheet Bus Duct Approved Drawings Bus Duct Material Test Reports

Bus Duct Welding Specification Procedures (WPS) and ProcedureQualification Records(PQR)

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Bus Duct Welders Qualifications Reports Bus Duct NDE procedures Bus Duct NDE Personnel qualifications Reports Bus Duct Calibration Certificates for Test Equipment Bus Duct Special procedures

Bus Duct Special qualifications Bus Duct Preparation and Painting Procedure Bus Duct Preservation, Packing and Shipping Procedure Bus Duct Packing List

Third Party Inspection for Bus Duct - Material Inspection

The first actual inspection work is raw materials inspection. The original orauthenticated copy of mill certificates normally is available at manufacturer'spremises.

The third party inspector examines these certificates for compliance withspecifications and where appropriate with drawings.

The review includes checks on:

Certificate No. Heat or cast No. Chemical composition. Mechanical properties. Heat treated condition. NDE applied and results. Surface finish

Inspector witnesses the materials identification on the certificates against materialsmarking. It is also necessary to check with Bus Duct drawing datasheet, material listand other specification as appropriate.

Visual inspection for surface finish and probable defects are done and dimensionalcompliance with specification need also to be controlled.

When third party inspector carried out the material inspection, then providesinspection visit report (IVR), the report contains following items:

Confirmation of satisfactory document review Record of the endorsement of certification reviewed/witnessed Record of all non-conformities Record of any tests witnessed and the result

Third Party Inspection for Bus Duct Construction

When Bus Duct raw material inspection carried out and results was satisfactory ornon-conformities closed by remedial action, then Bus Duct manufacture will startfabrication.



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The third party Inspector checks following points on Bus Duct based on theinspection and test plan (ITP) which is already agreed between purchaser and BusDuct manufacture.

The inspection scope is determined in the ITP, some purchasers prefer to have

stringent control and assign the TPI inspector in more hold or witness points forinspection and test activities and some others prefer lesser hold or witness pointsand assign TPI much more in thereview document.

This depend to the inspection budget which purchasers assign for inspection, muchmore inspection will have much more costs and less risks and conversely less moreinspection will have less costs but more risks.

For more detail review Inspection and Test Plan for Bus Duct article. There is draftITP in this article which I believe it is the best practice for Bus Duct inspection.

The third party inspector (TPI) checks following in accordance of approved drawingsand applicable standards:

Paint using specified colour swatch, measure thickness, if specified Panel condition Outline dimensions, interface dimensions, bus bar dimensions and clearances

and other specified dimensions Check tightness/torque of terminals Principal dimensions

If TPI is not in the hold or witness point in the ITP for this inspection stage, will

review the Bus Duct manufacture quality control report in coming visit or in the finalinspection day.

Third Party Inspection for Bus Duct General Arrangement Check

The third party inspector checks that all compartments, bars etc., are correctly ratedand are correctly located, with specified labelling in accordance of approveddrawings.

Similarly If TPI is not in the hold or witness point in the ITP for this inspectionstage, will review the Bus Duct manufacture quality control report in the coming visit

or in the final inspection day.

Third Party Inspection for Bus Duct Insulation Resistance Test

Insulation resistance is measured at each circuit with a 500V or (for circuits over500V) a 1000V Megger.

The test would be acceptable if the measured value is not less than 1 Megohm.

Similarly If TPI is not in the hold or witness point in the ITP for this inspectionstage, will review the Bus Duct manufacture quality control report in the coming visitor in the final inspection day.

Third Party Inspection for Bus Duct Withstand Voltage Test (Dialectric Test)

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Power frequency voltage (at specified voltage) is applied between each circuit andearth and between bars, for 1 minute.

The test would be acceptable if no flashover and puncture occurs during the test.

Similarly If TPI is not in the hold or witness point in the ITP for this inspectionstage, will review the Bus Duct manufacture quality control report in the coming visitor in the final inspection day.

Bus Duct Painting and Coating Inspection

Surface preparation and painting is checked according to the specification. Thechecking include to the following items:

Cleaning method (Blast or scraping and wire brushing) Preparation grade

Freedom from weld spatter, blow-holes and other defects Dry film thickness is measured according to specification

It is necessary surface to be free from pin-holes, runs damage and otherdiscontinuity.

Third Party Inspection for Bus Duct - Reporting:

Third party inspector provides Inspection Visit Report (IVR) after each visit as well asa final report summarising the activities carried out during the Bus Duct production inaccordance with the contract requirements and circulated within the time limits

specified in the contract.

The report normally is in the format required by the client and clearly indicates finalacceptance or rejection of the Bus Duct.

Third Party Inspection for Bus Duct - Release Note:

When required by the contract or purchase order a release note is issued by thirdparty agency and given to the manufacturer when the Bus Ducts have been finallyaccepted.

Third Party Inspection for Bus Duct -Bus Duct Packing, Marking andShipping:

The following points are checked by third party inspector:

Verify that the packing materials conform to specifications and acceptedpractice for the mode of transport.

Verify protection against humidity, abrasion, distortion and other damage. Verify shipping marks to marking instructions and record. Verify handling marks.
