Skema tal-Kontroll tal-Kwalità u t-testjar tal-Kabli Elettriku

I. Kontekst tal-Problema
Il-kabelli elettriku huma l-mitjum primarju ta’ trasferiment tal-enerġija fl-isistemi elettriku. Il-prestazzjoni ta’ kwalità tagħhom tiddetermina direttament il-stabbiltà tas-somministru tal-enerġija, is-sigurtà tas-sistema, id-durata tal-ippareggi, u l-abbilta ta’ prevenzjoni ta’ inċidenti ta’ sigurtà bħal l-inċendi. Il-kabelli mhux konformi jgħodd għall-problemi severi, waħda wara l-oħra, li jinkludu r-resistanza magħmula, ħsara tal-ħalib, disintegrazzjoni tal-izolazzjoni, riskju ta’ inċendi aqsm, u interferenza fis-segnali. Għalhekk, huwa importanti li tikteb sistema ta’ kontroll u testjar tal-kwalità scientifica, rigoruża, u komprensiva tal-kwalità li tkoppja mill-materjal raw fiż-ippareggijiet finiti.

II. Objettwi tas-Silġa

Garanzija tas-Sors: Asegura li kull materjal raw imfarrad fil-prodott tal-kabelli ikun konformi mal-standard nazzjonali u industriali ekstrem (pereżempju, GB/T 3956, GB/T 12706, GB/T 19666, etċ.).
Kontroll tal-Proċess: Monitora effettivament parametri u kwalità ta’ fasi intermediatijiet importanti waqt it-twelid.
Affidabilità tal-Prodott: Asegura li l-indikaturi kollha ta’ prestazzjoni ta’ kabelli finiti - inkluż l-elettrika, fizika & mekanika, u l-prestazzjoni tal-inċendi - jiġu raggiunti jew superati skont ir-riqujimenti tad-design u tal-kontratt.
Gestjoni tal-Risiku: Identifika difetti potenzjali permezz ta’ testjar sistematiku biex ippreveni prodotti mhux konformi minn entrata fil-merċat u tneħħi s-risiku ta’ użu.
Traċċjabbiltà: Ikkostituisci sistema ta’ rekordi testjar tal-kwalità kompletta sabiex timma trakkar bittra materiali raw u rezultati tat-testjar tal-ippareggi.

III. Soluzzjonijiet Koresi: Kontroll u Testjar tal-Kwalità tal-Kabelli Elettriku

(A) Kontroll u Testjar tal-Kwalità tal-Materjal Raw (Kontroll tas-Sors)

1. Qualifikazzjoni u Valutazzjoni tal-Fornitur:

Aġġusta fornitori kvalifikati b’Sistema ta’ Gestjoni tal-Kwalità solida (pereżempju, certifikazzjoni ISO 9001), kapabb ta’ somministra stabilment, u reputazzjoni b bona fl-industria.
Effettua inspezzjonijiet samparju periodika mhux avvistati jew verifikazzjoni tal-materjal tal-fornitur permezz ta’ tersa parti.

2. Testjar tal-Materjal Raw Important:

Materjal tal-Kunduttur (Barra/Fil tal-Ramel/tal-Alumini):

Oggetti ta’ Testjar: Analisi tal-kompozizzjoni kemika (kontenut tal-ramel, elementi impuri), proprijetajiet mekanika (forza tensili, elongazzjoni, piegatura ripetuta), misurazzjoni tal-resistanza (fl-20°C).
Riferiment Standard: GB/T 3953 (Fil tal-Ramel Rond għal Użu Elettriku), GB/T 3954 (Barra tal-Alumini għal Użu Elettriku), GB/T 3956 (Kundutturi tal-Kabelli Izolati), etċ.
Metodi ta’ Testjar: Analizzaturi kemiki (pereżempju, spettrometru), mašina ta’ prova tensili, ponte di Wheatstone, jew metru ta’ resistanza preċiż.

Materjal tal-Izolazzjoni u tal-Għabs (PVC, XLPE, PE, LSZH, etċ.):

Oggetti ta’ Testjar:

Proprietajiet Fizika: Aspetto, densità, uniformità tal-spissur, forza tensili & elongazzjoni tal-laqqa, confront tal-prestazzjoni qabel/dop il-baħr.
Proprietajiet Elettrika: Resistanza voluminu/superficiale.
Proprietajiet Termika: Deformazzjoni termika, prova ta’ set hot (għal XLPE), prova ta’ impatt/bieg tal-baħr.
Prestazzjoni tal-Inċendi (għal LSZH/Materjal Retardant tal-Inċendi): Indice tal-okssigen, densusità tal-fum, contenut tal-gas assidi, contenut tal-haloghen (għal requisiti tal-materjal bil-la halogen).

Riferiment Standard: GB/T 8815 (Komposti tal-Policloruri tal-Vinil Non Plasticizzati), GB/T 15065 (Komposti tal-Izolazzjoni tal-Policrossilene), GB/T 18380 (Prove fuq Kabelli Elettriku ta’ Kondizioni ta’ Inċendi - Prova tal-Flam Singola), GB/T 17651 (Misurazzjoni tal-Densusità tal-Fum), GB/T 17650 (Materjal u Prodotti bil-La Halogen, Baxx Densusità tal-Fum), u standards applicabbli oħrajn.
Metodi ta’ Testjar: Mašina ta’ prova materiali universali, furnu ta’ baħr, tester ta’ resistanza, apparatu ta’ prova set hot, analizzatur tal-indice tal-okssigen, kammera tal-densusità tal-fum, analizzaturi kemiki.

Materjal tal-Skerm (Nast tal-Ramel/Fil): Spissur, resistanza, rat ta’ kopriment.
Materjal tal-Talb tal-Baħr: Resistenza tal-ilma (jekk applikabbli), forza mekanika, compatibilità.

3. Requisiti ta’ Testjar:

Kull materjal raw inħarsu hemm għandu esser miktub b’Certifikazzjoni tal-Analisi (COA)/Certifikazzjoni ta’ Konformità (COC) tal-fornitur.
Esegui inspezzjoni samparju permezz ta’ plani ta’ samparju definiti (pereżempju, GB/T 2828.1). Il-frekwenza ta’ samparju tista’ tiżdied jew testjar tal-baħr totali jkun implementat għal materiali kritici (pereżempju, kunduttur, materjal tal-izolazzjoni prinċipali).
Il-materjal raw li jfail il-prova mhux permissibli li jkun użu fil-prodott.

(B) Kontroll tal-Kwalità tal-Proċess ta’ Twelid (Monitoraġġ tal-Proċess)

1. Monitoraġġ ta’ Parametri ta’ Proċess Importanti:

Stranding tal-Kunduttur: Rapport tal-lay, diametru estern, compattazzjoni (kunduttur).
Proċess tal-Estrusione: Impostazzjoni u kontrol tal-temperatura permezz ta’ zoni, pressjoni tal-estrusione, velocità tal-linea, proċess tal-raħeb (effett importantri fuq kristallinità).
Proċess tal-Cross-linking (għal XLPE): Dosaggio tal-irradjazzjoni/tempiratura vulkanizzazzjoni & tempo (kritiku għal grad ta’ cross-linking), kondizzjonijiet tal-raħeb.
Proċess tal-Skerm: Rat ta’ kopriment, kwalità tal-overlap.
Cabling: Lay length, stabilità tal-core.
Sheath Extrusion: Uniformity tal-thickness, quality tal-surface, legibility tal-printing.

2. Samparju tal-Proċess:

Ikkostituisci punti ta’ inspezzjoni online jew offline fid-fasi importanti (pereżempju, metaqbel l-estrusione, cross-linking, cabling, sheathing).
Oggetti ta’ Samparju Komuni: Insulation/sheath thickness and eccentricity, outer diameter, structural dimensions, appearance (surface defects), spark test / withstand voltage test (online/offline), partial physical property sampling (e.g., tensile).

(C) Kontroll u Testjar tal-Kwalità tal-Kabelli Finiti (Verifika Finale)

1. Type Testing (għal prodotti ġodda jew l-ewwel partita ta’ kontratti importanti): Esegui l-oggetti ta’ testjar speċifikati fit-standards relevanti (pereżempju, GB/T 12706.1/2) biex verifika konformità tad-design kompletament.
2. Tests Abitwali (Per Partita / Per Drum / Per Reel):

Oggetti Kern:

Test tal-Resistanza DC tal-Kunduttur: Misura r-resistanza ta’ kull kunduttur biex verifika konformità mal-requisiti nominali ta’ sezzjoni (GB/T 3956). Dan huwa fundamental għal kalkuli ta’ amperaggju u ħalib.
Test tal-Discharge Partial (Essential for MV/HV cables): Iddekteż difetti minut ta’ l-izolazzjoni li jistgħu jiġu għal falliment ta’ long-term (GB/T 3048.8, GB/T 12706). Extremely Important!
Test tal-Voltage (Withstand Voltage Test):

Power Frequency AC Withstand Voltage: Most common. Apply multiple rated voltage (e.g., 2.5U₀) for a specified duration (e.g., 5 min). Insulation must not break down.
DC Withstand Voltage (Specific applications): Used for certain cable types or as a supplement to AC tests.

Measurement of Insulation Resistance: Measure the resistance between conductor and shield/metallic sheath/earth, reflecting the insulation material's basic insulating properties (GB/T 3048.5/6).

3. Sample Tests (Batch Sampling or Periodic Tests):

Electrical Performance:

Capacitance measurement (if applicable).
Dielectric loss tangent (tan δ) measurement (especially for HV cables).

Structural Dimensions and Physical Properties:

Insulation and sheath thickness measurement: Ensure compliance with minimum design requirements.
Outer diameter measurement: Control tolerances.
Physical & Mechanical Performance Tests:

Tensile Strength and Elongation at Break (insulation/sheath) before/after aging: Key indicators, reflecting material's anti-aging capability and toughness (GB/T 2951.1).
Hot Set Test (Essential for XLPE insulation): Verify the degree of cross-linking compliance (GB/T 2951.21).
Low Temperature Impact/Bend Test: Assess material brittleness at low temperatures.
Flexing/Bending Test: Simulate installation and operating conditions to test cable flexibility (GB/T 12527).

Bending Test: Verify the cable's minimum allowable bending radius (usually performed on finished cable).
Fire Performance Tests (As per design requirements):

Single vertical flame test (GB/T 18380.1 series).
Bunched flame test (GB/T 18380.3 series).
Smoke density test (GB/T 17651).
Halogen-free, Low-smoke performance tests (Acid gas content, pH value, conductivity, light transmittance, halogen content - GB/T 17650).

Structural Examination: Conductor structure, shield coverage rate, core arrangement, filling density, metallic armor layer (dimensions, lay length, overlap gap), etc.

4. Testing Process:

Assign unique identification per finished cable batch/drum/reel.
Select representative samples according to defined sampling plans (per GB/T 2828.1 or contract requirements).
Conduct tests in accredited laboratories, adhering to current and valid national standards, industry standards, enterprise standards, or contract technical agreements.
All test items must have clearly defined pass/fail criteria.
Record test results in the finished product test report.

(D) Third-Party Verification and Inspection (Optional but Recommended)

For major projects, high-value cables used in critical locations, or upon specific user request:

Engage accredited independent third-party testing institutions (e.g., with CNAS/CMA accreditation) to perform sampling/re-testing of incoming materials or finished products.
Commission professional inspection agencies to witness and conduct on-site observation (audit/surveillance) during cable production (especially key processes) and final testing.

IV. Quality Testing Agency and Equipment Assurance

Accreditation: Laboratories performing testing tasks must possess relevant accreditation (e.g., CNAS, CMA).
Equipment Requirements: Equipped with comprehensive, fully functional testing equipment of requisite accuracy, regularly calibrated and verified (according to JJG procedures):

High-voltage test equipment (Power Frequency AC, DC, Impulse, Partial Discharge Systems).
Precision Bridges, Resistance Meters.
Universal Material Testing Machines (with high/low temperature chambers and aging ovens).
Hot Set Test Apparatus.
Fire Test Equipment.
Precision Measuring Tools (Calipers, Projectors).
Chemical Analysis Instruments (Spectrometer, Titrator, Ion Chromatograph, etc.).
Thickness Gauges (Laser, Ultrasonic).

Personnel Requirements: Testing personnel must be professionally trained, proficient in standards and operating procedures, and hold valid certification.

V. Non-Conforming Product Handling

Identify and isolate any product found non-conforming during any stage (raw material, process, finished goods).
Conduct non-conformance review to analyze the root cause.
Based on the review conclusion, implement one of the following actions: Re-work/Repair (if feasible upon evaluation and core performance is unaffected), Downgrade/Use as Concession (only for non-critical scenarios with user approval), or Scrap.
Strictly prohibit non-conforming products from reaching the project site in any form.

VI. Records and Traceability

Establish complete electronic and physical backup records of all inspections, including at least:

Raw Material Supplier Information, Batch Number, Purchase Order Number, Raw Material Test Reports.
Production Batch Number, Operation Logs (Key Parameters), Process Inspection Records.
Finished Product Identification (Type, Specification, Length, Manufacturing Date, Batch/Drum/Reel No.), Complete Finished Product Test Report (covering all mandatory and optional test results), Copy of Type Test Report (if applicable).
Third-Party Test/Inspection Reports.

Maintain archives for the defined period (typically not less than the product's expected lifecycle) to ensure product quality traceability. In case of quality issues, enable rapid tracing back to raw material batches, production conditions, and test data.

07/31/2025

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