INSPECTION SCHEDULE: An inspection is, most generally, an organized examination or formal evaluation exercise.

It involves the measurements, tests, and gauges applied to certain characteristics in regard to an object or activity. The results are usually compared to specified requirements and standards for determining whether the item or activity is in line with these targets. Inspections are usually nondestructive. The schedule is as follows, 1.During preparation of parts and assembly. 2. Dimension inspected after completion. 3. Matching work inspection--For upper and lower tank. Of bushing bosses ,conservator, connection pipes. 4.Final inspection of tanks and parts. 5.Routine Test. 6.Type Test. 7.Blast cleaning. 8.Painting inspection. 9.Check as per drawing used in the fabrication.

Packing and Despatch instructions: Despatched with cover, keeping all openings blanked to avoid dust and rain water collection.

Bush turrets, conservator pipe and other accessories shall be blanked with 5mm thick M.S blanking plates.

Test Methods for Weldable Structural Steel:

1.Tensile Test: Tensile strength , yield strength and percentage elongation of steel will be determined from standard test pieces cut length wise or cross wise from plaes and length wise from sections , flats and bars. 2.Bend Test: Test piece length wise or cross wise from plates and strips. length wise from sections,flats and bars. Rough edges resulting from stearing may be removed by filling machining.

Marking purpose: Marking is done for the identification for re-assembly in

sequential manner and possibility of mismatching is avoided.

Part marking: It is done on detachable fabricated components on all transformers of 5MVA and above and furnace and special transformers. It is not needed for small range because of few detachable components. METHOD: 1.Permanent mild steel tag is prepared. 2.Part marking TAG will bear in information in sequential form. 3. Letter size 10mm height. 4. TAG welded at center of detachable components.

Match marking: Fabricated detachable components have match marking so that there is no mismatch at assembly. It is done for all ratings and all types of transformers.

METHOD: 1. All fixed amd detachable flanges of pipe work should have permanent punch mark. 2. Any pipe ,wherever a possibility exists for reverse matching, one side of such pipe will bear double punch mark. 3. Removable bolted clamps will have match mark at a place such as pipe work, header etc. 4. Marking to be done at time of final assembly before dismantling pipe work. 5. Match marks to be filled by bright red paint.

Defects of Transformer Tanks:

Fabrication of Transformer is basically divided into 4 parts. They are, 1. Winding. 2. Core assembly. 3. Core Coil Assembly (CCA). 4. Tanking.

In this project I have considered the Tanking defects only.

The four defects that arise in Tanking process are, 1. Welding leakages. 2. Stud leakages. 3. Mismatch. 4. Shop Mistake.

Welding defects: These defects are mostly caused by improper welding procedure. Defects usually encountered include incomplete penetration, incomplete fusion, undercutting, porosity, and longitudinal cracking. Incomplete penetration: This type of defect is found in any of three ways: 1) When the weld bead does not penetrate the entire thickness of the base plate. 2) When two opposing weld beads do not interpenetrate. 3) When the weld bead does not penetrate the toe of a fillet weld but only bridges across it. Welding current has the greatest effect on penetration. Incomplete penetration is usually caused by the use of too low a welding current and can be eliminated by simply increasing the amperage. Other causes can be the use of too slow a travel speed and an incorrect torch angle. Both will allow the molten weld metal to roll in front of the arc, acting as a cushion to prevent penetration. The arc must be kept on the leading edge of the weld puddle.

Lack of penetration

Lack of Fusion: Lack of fusion, also called cold lapping or cold shuts, occurs when there is no fusion between the weld metal and the surfaces of the base plate. The most common cause of lack of fusion is a poor welding technique. Either the weld puddle is too large (travel speed too slow) and/or the weld metal has been permitted to roll in front of the arc. Again, the arc must be kept on the leading edge of the puddle. When this is done, the weld puddle will not get too large and cannot cushion the arc. Another cause is the use of a very wide weld joint. If the arc is directed down the center of the joint, the molten weld metal will only flow and cast against the side walls of the base plate without melting them. The heat of the arc must be used to melt the base plate.

Lack of Fusion

Undercutting: Undercutting is a defect that appears as a groove in the parent metal directly along the edges of the weld. It is most common in lap fillet welds, but can also be encountered in fillet and butt joints. This type of defect is most commonly caused by improper welding parameters; particularly the travel speed and arc voltage. When the travel speed is too high, the weld bead will be very peaked because of its extremely fast solidification. The forces of surface tension have drawn the molten metal along the edges of the weld bead and piled it up along the

centre. Melted portions of the base plate are affected in the same way. The undercut groove is where melted base material has been drawn into the weld and not allowed to wet back properly because of the rapid solidification. Decreasing the arc travel speed will gradually reduce the size of the undercut and eventually eliminate it. When only small or intermittent undercuts are present, raising the arc voltage or using a leading torch angle are also corrective actions. In both cases, the weld bead will become flatter and wetting will improve.

Undercutting

Porosity: Porosity is gas pores found in the solidified weld bead. These pores may vary in size and are generally distributed in a random manner. However, it is possible that porosity can only be found at the weld center. Pores can occur either under or on the weld surface. The most common causes of porosity are atmosphere contamination, excessively oxidized work piece surfaces, inadequate deoxidizing alloys in the wire and the presence of foreign matter. Atmospheric contamination can be caused by:

1) Inadequate shielding gas flow. 2) Excessive shielding gas flow. This can cause aspiration of air into the gas stream. 3) Severely clogged gas nozzle or damaged gas supply system (leaking hoses, fittings, etc.) 4) An excessive wind in the welding area. This can blow away the gas shield.

The atmospheric gases that are primarily responsible for porosity in steel are nitrogen and excessive oxygen.

Porosity

Longitudinal Cracking: Longitudinal or centerline cracking, of the weld bead is not often encountered in MIG welding. However, that which does occur can be one of two types: hot cracks and cold cracks. Hot cracks are those that occur while the weld bead is between the liquidus (melting) and solidus (solidifying) temperatures. In this temperature range the weld bead is mushy. Hot cracks usually result from the use of an incorrect wire electrode (particularly in aluminium and stainless steel alloys). The chemistry of the base plate can also promote this defect (an example would be any high carbon stainless steel casting). Any combination of the joint design, welding conditions and welding techniques that results in a weld bead with an excessively concave surface can promote cracking.

Longitudinal Cracking

Some examples of welding leakages found at AREVA DTI,NAINI are, Hand hole leakage Leakage from bottom Radiator Header. Leakage from inspection cover. Leakage from HV Turret. Leakage from Turret Pipeline. Etc.

Some examples of Stud Leakages are, OLG Stud Leakage. Lid Stud Leakage. Inspection covers Stud leakage. CT Stud Leakage. Etc.

Mismatch: A component is said to be a mismatch when it does not match the position it has to occupy. For example, when a pipes flange is of larger diameter whereas the component to be connected is of smaller size (oversize of holes), it is said to be a Mismatching defect. They are generally caused by the problems in bending machines and by using components whose sizes are beyond the tolerances. Some of the examples of mismatching defects are, 1. OLG holes Mismatch. 2. Pipeline Mismatch. 3. Yoke clamp pad fixing problems. 4. Buffer mismatch. 5. Wrong fittings. 6.Under or Oversize of holes Etc.

Shop mistake: They are the mistakes that are committed generally by workmen. Some times they cause a major loss in man hours. Some of the examples are,

1. Earthing links not provided. 2. Screws and LOGO plates not fitted. Etc.

The following are the observations taken at AREVA DTI,NAINI for four months of 2009

Month January February March April

Welding leakages* 11(36) 2(25) 11(43.5)

Stud leakages* 2(8) 2(8) 2(8) 3(12)

Mismatch* 16(100) 3(16) 7(30) 18(81)

Shop mistake* 8(91) 4(32) 9(15)

Total

24(104.5)

9(36)

44(217)

21(138)

*--no. of defects(man hours lost )

As it can be seen, it is interpreted that Mismatch is the major defect which contributes to most of the Man hours lost. Now using a Pareto Chart I have analysed the various Defects in Tanking. As shown below most of defects are due to Mismatch and welding Leakages. A Pareto chart is a special type of chart where the values being plotted are arranged in descending order. The graph is accompanied by a line graph which shows the cumulative totals of each category, left to right. The left vertical axis is the frequency of occurrence, in this case it is the no. of defects. And the right vertical axis is the cumulative percentage. It shows the highest occurring type of defect in this case.

Pareto Chart of Various Defects

100 100

80 no. of defects

80

40

40

20

20

Various Defects no. of defects Percent Cum%

Mism atch 44 44.9 44.9

Welding Leakages Shop Mistake 24 21 24.5 21.4 69.4 90.8

Stud Leakage 9 9.2 100.0

KEY CONTRIBUTORS:

1.Mismatch. 2. Welding Leakages.

Root Cause Analysis: Mismatching

Percent

60

60

Root Cause Analysis: Welding Leakages

In both the above cases, some are controllable and some are non-controllable causes. By controlling the controllable causes, major part of Mismatching Defects can be diminished which subsequently saves time and also improves the quality of the final product.

Effects on Quality:
The above discussed defects in fabricated parts result in increased CONQ (cost of non-quality) and decreased OTIF (On Time and In Full).

OTIF is a roll-up measure. To perform well on OTIF ,everything that goes into it has to be correct. The takeoff and order entries have to be correct, purchasing has to maintain appropriate inventory levels, material has to be handled correctly, pulled correctly, staged and loaded correctly. OTIF is a company wide report card. As discussed, the Mismatching and other defects lead to rework on a particular job which increases the man hours lost and also decreases the efficiency of the company. Moreover rework consumes a lot of time thus resulting in delivery of the product beyond Delivery Date i.e. Late Delivery. So managing OTIF includes reduced time lost to mistakes or time spent on rework of job and increased accuracy and much more. Improving OTIF performance boosts the bottom line by lowering the operating expenses and increasing the revenue generating time. After all, if we are improving the ability to get it right the first time without any defects, we have reduced expenses incurred from getting it right the second time. OTIF results in better Inventory Management, improvements in quoting process, greater process, greater accuracy in manufacturing or loading and more. CONQ (Cost of Non Quality) are the costs of internal and external non-conformities. Internal non-conformities include problems detected prior delivery from administration, marketing, engineering, production, planning, purchasing, shipment and customer services. And external non-conformities includes problems that occur after delivery to customers: product recalls, customer returns, warranties, installation and billing errors, repairs and the time for the correction of this activities. Non quality costs are powerful indicator for quality improvement and for initiation of preventive and corrective actions. However , quantifying these costs is difficult because these costs are hidden and not detailed by the accounting system. The above defects increase the CONQ which are resulted due to increase in internal and external non-conformities.

Conclusion :

According to the observations taken at AREVA DTI,NAINI for four months of the year 2009, it was seen that major effect on Man hour loss and the Efficiency was mainly due to Mismatching Defects and also contributed by Welding Leakages. The root cause analysis for both these defects is done and the causes were discussed. By controlling the controllable causes and by decreasing the no. of non-controllable causes, these defects can be limited to the minimum extent. Anyway these defects tend to increase the CONQ(cost of non quality) and reduce OTIF(On Time and In Full)which increase the amount of rework done, the Operating expenses and also the time taken thus resulting in Late Delivery. So in order to decrease CONQ and increase OTIF, defects in the Fabrication process are to be kept to a minimum, which requires proper material handling, storing the parts to be used at required atmosphere so that rusting is kept to a minimum, proper Lubrication between moving parts and most importantly safe and improvised method of Working.

NOTE: The Data was collected from M/S AREVAs Records and the analysis is solely done by self. The actual analysis /results out of these data, which were part of AREVAs property, were not included in this Report.

REFERENCES:
1.

www.asq.org

2. The Quality Tool box, Second edition, Tague , Nancy. R

3. 4.

www.Wikipedia.org www.eSabna.com/EUWeb/MIG_handbook