Inspection and Test Plan (ITP) - Mechanical Works
Qaremy Construction - NSW Solar Farm Project
Document Control
- Document No: QAR-ITP-MEC-001
- Revision: A
- Date: October 2025
- Discipline: Mechanical Works
1. Purpose and Scope
This Inspection and Test Plan defines the inspection and testing requirements for mechanical works associated with the Solar Farm project.
Scope includes:
- Single-axis tracker systems (torque tubes, bearings, motors)
- Fixed-tilt mounting structures (if applicable)
- Module mounting hardware and clamps
- Tracker control systems
- Mechanical commissioning
2. Applicable Standards
- AS/NZS 1170 series - Structural design actions (wind loads, earthquake)
- AS 1252:2016 - High-strength steel bolts with associated nuts and washers
- AS 4100:2020 - Steel structures
- AS/NZS 1163:2016 - Structural steel hollow sections
- AS 2312:2014 - Guide to the protection of structural steel against atmospheric corrosion
- Manufacturer's specifications and installation manuals
3. Inspection Point Definitions
| Symbol | Type | Definition |
|---|---|---|
| 🛑 H | Hold Point | Work must stop until inspection completed and approval given |
| 👁️ W | Witness Point | Inspector must be given opportunity to witness |
| 📋 R | Review Point | Documentation reviewed, work may proceed during review |
4. ITP Table - Single-Axis Tracker Installation
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Pre-Installation | ||||||
| Material certification | Material certificates review | H | QA | AS/NZS 1163, OEM spec | Steel grade certification, galvanizing cert (Z275 min) | Material certificates |
| Component delivery inspection | Visual inspection, quantity | R | QC | Purchase order | No damage, correct quantities, labeled | Delivery checklist |
| Foundation readiness | Civil works sign-off | H | QC | ITP-CIV-001 | Piles installed and tested per civil ITP | Civil completion cert |
| Tracker component layout | Pre-assembly organization | R | SC | Installation manual | Components organized by row/tracker number | Layout verification |
| Tracker Structure Assembly | ||||||
| Purlin installation | Alignment and level | W | QC | Installation manual | Level within ±10mm over row length | Survey report |
| Purlin-to-pile connection | Bolt installation | W | QC | AS 1252, OEM spec | Correct bolt grade (typically 8.8), torque per spec | Torque log (20% sample) |
| Torque tube installation | Alignment and joining | W | QC | Installation manual | Straight alignment, joints per specification | Inspection checklist |
| Torque tube splices | Bolt torque verification | H | QC | AS 1252, OEM spec | Torque per specification (typically 100-200 Nm) | Torque log (20% sample) |
| Bearing and Drive Installation | ||||||
| Bearing mounting | Alignment and fixing | H | QC | Installation manual | Plumb and aligned, correct torque | Torque log (100%) |
| Bearing lubrication | Lubrication verification | R | QC | Installation manual | Correct lubricant type and quantity | Lubrication log |
| Drive motor installation | Mounting and connection | W | QC | Installation manual | Secure mounting, correct alignment | Installation checklist |
| Drive gearbox installation | Alignment check | W | QC | Installation manual | Shaft alignment within tolerance | Alignment report |
| Drive slew bearing installation | Bolt torque | H | QC | AS 1252, OEM spec | Torque per specification, pattern followed | Torque log (100%) |
| Module Mounting | ||||||
| Module clamp installation | Position and torque | R | QC | AS/NZS 5033, OEM spec | Correct position per design, torque per spec (typically 8-12 Nm) | Torque log (10% sample) |
| Anti-theft hardware | Installation verification | R | QC | OEM spec | Installed where specified | Inspection checklist |
| Module alignment | Row and tracker alignment | R | QC | Installation manual | Modules aligned, gaps consistent | Visual inspection |
| Mechanical Systems | ||||||
| Wind sensor installation | Location and mounting | R | QC | Installation manual | Per specification, secure mounting | Installation checklist |
| Limit switches | Installation and adjustment | W | QC | Installation manual | Correct position, proper operation | Test log |
| Dampers/brakes (if applicable) | Installation verification | R | QC | Installation manual | Installed and adjusted per spec | Inspection checklist |
| Electrical/Control | ||||||
| Motor electrical connection | Visual inspection | R | QC | Installation manual | Correct cable, proper termination | Connection checklist |
| Control wiring | Cable routing and termination | R | QC | Installation manual | Protected routing, correct termination | Inspection checklist |
| Tracker controller installation | Mounting and connection | R | QC | Installation manual | Secure mounting, all connections made | Installation checklist |
5. ITP Table - Tracker Commissioning and Testing
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Pre-Commissioning Checks | ||||||
| Visual inspection | Complete system check | R | QC | Installation manual | All components installed, no damage, secure | Pre-commissioning checklist |
| Fastener inspection | Sample torque re-check | W | QC | AS 1252 | Torque maintained (5-10% sample) | Re-torque log |
| Electrical power availability | Voltage verification | H | QC | Installation manual | Correct voltage at motor (typically 24V DC) | Voltage test record |
| Control system power-up | Initial energization | H | QC, OEM | Installation manual | No faults, controllers communicate | Power-up checklist |
| Mechanical Function Tests | ||||||
| Manual rotation test | Hand rotation check (motor disconnected) | H | QC, OEM | Installation manual | Smooth rotation, no binding, full range of motion | Manual test log |
| Motor direction verification | Direction check (slow speed) | H | QC, OEM | Installation manual | Correct rotation direction for positive/negative commands | Direction test log |
| End-stop calibration | Limit adjustment | H | QC, OEM | Installation manual | Stops at correct angles (typically +60° / -60°) | Calibration log |
| Tracking accuracy | Angular position verification | W | OEM, ENG | Installation manual | Within ±1° of commanded position | Accuracy test report |
| Speed and acceleration | Movement timing | W | OEM | Installation manual | Per specification, smooth movement | Movement test log |
| Operational Tests | ||||||
| Normal tracking mode | Daytime operation test | W | OEM | Installation manual | Tracks sun correctly, smooth operation | Operational test log |
| Night stow position | Nighttime positioning | W | OEM | Installation manual | Returns to stow position (typically horizontal or facing east) | Test log |
| Wind stow function | High wind response test | H | OEM, ENG | Installation manual | Stows at wind speed threshold (typically 13-15 m/s) | Wind stow test report |
| Snow/load stow | Load response (if applicable) | W | OEM | Installation manual | Responds to snow load sensor | Test log |
| Communication verification | Tracker-to-controller communication | W | OEM | Installation manual | All trackers respond to commands | Communications test |
| Emergency stop function | E-stop test | H | OEM | Installation manual | Immediate stop on E-stop activation | Safety test log |
| Load and Stress Tests (Sample Basis) | ||||||
| Static load test | Load application (sample trackers) | W | ENG, TP | Structural design | No permanent deformation under 1.5× design load | Load test certificate |
| Dynamic movement test | Repeated cycling (sample trackers) | W | OEM | Installation manual | 100 full cycles, no degradation | Endurance test report |
Testing Frequency:
- Manual rotation: 100% of trackers
- Motor direction and end-stop: 100% of trackers
- Tracking accuracy: 10% sample (minimum 1 per block)
- Load testing: 1% sample or minimum 3 trackers
6. ITP Table - Fixed-Tilt Mounting Structures (If Applicable)
| Activity | Inspection/Test | Type | Party | Reference Standard | Acceptance Criteria | Records |
|---|---|---|---|---|---|---|
| Structure Installation | ||||||
| Foundation readiness | Civil works sign-off | H | QC | ITP-CIV-001 | Foundations per civil ITP | Civil completion cert |
| Material certification | Steel grade and galvanizing | H | QA | AS 4100, AS/NZS 1163 | Certified materials, Z275 galvanizing minimum | Material certificates |
| Structure alignment | Survey check | W | QC | Design drawings | Within ±50mm horizontal, ±20mm vertical | Survey report |
| Tilt angle verification | Angle measurement | H | QC | Design drawings | Correct tilt angle ±1° (typically 20-30° for fixed tilt) | Angle measurement log |
| Bolt installation | Torque verification | H | QC | AS 1252 | Correct bolt grade and torque | Torque log (20% sample) |
| Module rail installation | Alignment and spacing | R | QC | OEM specifications | Rails straight, spacing per module dimensions | Inspection checklist |
| Module clamp installation | Torque check | R | QC | AS/NZS 5033 | Torque per specification | Torque log (10% sample) |
| Earthing bonding | Continuity verification | H | QC | AS/NZS 5033 | Continuous earth path verified | Earth continuity test |
7. Torque Specifications Summary
7.1 Typical Torque Values
| Component | Fastener | Typical Torque | Standard |
|---|---|---|---|
| Module clamps | M8 stainless steel | 8-12 Nm | AS/NZS 5033, OEM spec |
| Purlin-to-pile bolts | M12-M16 Grade 8.8 | 100-150 Nm | AS 1252 |
| Torque tube splices | M12-M16 Grade 8.8 | 150-200 Nm | AS 1252 |
| Bearing mounting bolts | M16-M20 Grade 8.8 | 200-300 Nm | AS 1252, OEM spec |
| Drive motor mounting | M10-M12 Grade 8.8 | 50-80 Nm | OEM specification |
Note: Always refer to manufacturer's specifications and structural drawings for exact values. These are typical ranges only.
7.2 Torque Verification Method
- Calibrated torque wrench (calibration within 12 months)
- Tighten to specified torque
- Mark fastener and adjacent surface
- Document torque value and date
- Re-check sample after 24 hours for settling
8. Material Certification Requirements
All structural materials must have:
- Mill Test Certificates: Confirming steel grade (typically 250-350 MPa yield strength)
- Galvanizing Certificates: Confirming coating thickness (minimum Z275 = 275 g/m²)
- Fastener Certificates: Confirming bolt grade (typically 8.8 or 10.9)
- Traceability: Heat numbers traceable to source
9. Corrosion Protection Inspection
| Item | Check | Acceptance |
|---|---|---|
| Galvanized surfaces | Visual inspection | Uniform coating, no bare steel |
| Cut edges | Protection verification | Touch-up paint or zinc-rich primer applied |
| Fasteners | Material check | Stainless steel or galvanized Grade 8.8 minimum |
| Dissimilar metals | Isolation check | Insulating washers/sleeves where required |
| Damage during installation | Touch-up verification | All damaged areas repaired |
AS 2312 Compliance: All corrosion protection measures must comply with AS 2312:2014.
10. Quality Hold Points Summary
Critical hold points that must have QC approval before proceeding:
- ✅ Foundation readiness (civil sign-off)
- ✅ Material certifications submitted and approved
- ✅ Tracker structure alignment verified
- ✅ Critical bolt torque completed (splices, bearings, drives)
- ✅ Manual rotation test passed
- ✅ Electrical power-up successful
- ✅ End-stop calibration completed
- ✅ Tracking accuracy test passed
- ✅ Wind stow function verified
- ✅ Emergency stop function tested
11. Commissioning Sequence
The following sequence must be followed for tracker commissioning:
Phase 1: Pre-Commissioning
├─ Complete all installation ITPs
├─ Submit as-built documentation
└─ Verify electrical power available
Phase 2: Mechanical Commissioning
├─ Manual rotation test (motor off)
├─ Power-up and controller verification
├─ Motor direction test
├─ End-stop calibration
└─ Tracking accuracy verification
Phase 3: Functional Commissioning
├─ Normal tracking operation (48-hour test)
├─ Wind stow function test
├─ Night stow function test
├─ Communication system test
└─ Emergency stop test
Phase 4: Performance Verification
├─ Load testing (sample basis)
├─ Endurance testing (sample basis)
└─ Final acceptance by Engineer12. Inspection Request Process
12.1 Advance Notice Requirements
| Inspection Type | Notice Required |
|---|---|
| Hold Point (H) | 48 hours minimum |
| Witness Point (W) | 24 hours minimum |
| Review Point (R) | Per submittal schedule |
12.2 Request Procedure
- Subcontractor completes self-inspection
- Submit Request for Inspection (RFI) to QC Inspector
- QC Inspector schedules inspection
- For Hold Points: QA/Engineer notified and must attend
- Inspection completed and documented
- Records distributed within 24 hours
13. Non-Conformance Examples
Common mechanical non-conformances to watch for:
| Issue | Impact | Resolution |
|---|---|---|
| Under-torqued fasteners | Structural integrity | Re-torque all fasteners in area |
| Damaged galvanizing | Corrosion risk | Touch-up with zinc-rich primer |
| Misaligned trackers | Tracking accuracy | Adjust mounting, re-survey |
| Binding during rotation | Mechanical wear, failure | Investigate cause, adjust or replace |
| Incorrect tilt angle | Energy production | Adjust structure angle |
| Missing components | Incomplete installation | Install missing items |
14. Spare Parts and Tools
14.1 Required Spare Parts (Minimum)
- Fasteners: 5% of each type
- Module clamps: 2% of total
- Bearings: 1% of total
- Drive motors: 2% of total
- Limit switches: 5% of total
- Controllers: 2% of total
14.2 Required Tools
- Calibrated torque wrenches (various ranges)
- Angle measurement tools (digital level/inclinometer)
- Survey equipment (total station or GPS)
- Multimeters and electrical test equipment
- Hand tools (per OEM requirements)
15. Quality Records Retention
All mechanical inspection and test records shall be retained for minimum 7 years or life of asset (whichever is longer).
Records include:
- Installation checklists
- Torque logs
- Commissioning reports
- Test certificates
- Non-conformance reports
- As-built documentation
16. Revision History
| Revision | Date | Description | Prepared By | Approved By |
|---|---|---|---|---|
| A | Oct 2025 | Initial Issue | Lead QC Inspector (Mechanical) | QA Manager |
END OF DOCUMENT