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1.1 GENERAL
1.2 SCOPE
1.2.1 This section specifies the general requirements applicable to materials, working
stresses and workmanship involved in the design, Engineering and
manufacture, erection, testing & commissioning of the Ventilation system and
Air Condition System for Power House, Transformer Hall, Down Stream Surge
Gallery(DSSG) and Butterfly valve chamber.
1.2.2 The detailed & specific technical requirements, regarding design, engineering,
manufacture, supply, erection, testing & commissioning etc of the Ventilation
& Air Conditioning Systems mentioned in the above clause are covered
separately in Section –2 of these specifications.
1.3 MATERIALS
All materials forming the equipment shall be of first class commercial quality,
as normally used for these type of equipments, considering mechanical &
electrical strength, ductility, durability, best engineering practice, the normal or
severe operating service to which the equipment will be subjected. The
materials used shall be free from any defects and imperfections of recent
manufacture, unused and of the classifications & grades designated as
specified. The materials not specifically described herein shall be most
suitable for the purpose and shall comply with the latest specifications of
Bureau of Indian Standards, or the American Society for Testing and Materials
(ASTM), or IEC or approved equivalent standards. If the supplier desires to
deviate from or use materials not covered by these specifications, he shall state
the exact nature of the deviation or exception and shall submit complete
specifications of the materials proposed to be used by him along with the
reasons / justifications for such deviation for the approval of the purchaser. All
materials, supplies and articles not manufactured by the supplier shall be the
products of recognized reputable manufacturers.
1.3.3 Materials
1.3.3.1 The Supplier shall be responsible for the suitability of materials to be used in
the construction of the equipment covered in various Sections of these
specifications.
1.3.3.2 To the extent feasible and without adversely affecting the strength and
durability, such materials for field welds shall be used that do not require
preheating or stress-relieving.
1.4.1 All materials, parts and assemblies of the equipment to be supplied under
these specifications shall be tested, unless otherwise directed, according to the
applicable IS, ASTM standards or the best modern approved commercial
methods for the particular type and class of the equipment. The supplier shall
prepare specimens, perform tests and carry out an analysis to demonstrate
conformance of various materials with the specifications given herein. In case
the Supplier desires to use stock materials not manufactured specifically for
the equipment covered by these specifications, he shall submit satisfactory
evidence to the purchaser that such material conforms to the requirements
stated in these specifications, in which case tests on these materials may be
waived. Certified mill test reports of plates will be acceptable. Routine test
reports for minor components will be acceptable.
1.4.2 Five certified copies of test reports shall be furnished to purchaser as soon as
possible after the tests are carried out. The results of these tests shall be in
such form so that checking compliance with the applicable specifications for
the material tested is easy. When required, all tests or trials shall be made in
the presence of the representative(s) of the purchaser. The supplier shall keep
Purchaser informed in advance regarding time of starting and the progress of
the manufacturing of the equipment to be supplied in its various stages so that
arrangements can be made for inspection. No materials shall be despatched
until all tests, analysis and inspection have been completed and certified
copies of tests reports have been accepted.
1.4.3 The costs of all the tests, trials and samples shall be borne by the supplier and
shall be included in the prices stated in the Schedule of Prices.
1.4.4 The acceptance of materials, parts and assemblies, or the waiving of the
inspection by the Purchaser, shall in no way relieve the supplier from the
responsibility of furnishing equipment in accordance with the requirements of
these specifications.
1.5 DESIGN STRESSES
Liberal factors of safety shall be used throughout the design, especially in the
design of all such parts, which are likely to be subjected to alternating stresses
or to shock loading or to most severe operational loadings including those due
to short circuit faults. The supplier shall furnish complete information and
computations regarding the maximum unit stresses used in the design for
reference and record of the purchaser.
1.5.2.1 Under the most severe operating conditions, the unit stresses in the materials
shall not exceed the values shown in Table 1.1:
TABLE - 1.1
Maximum Unit Stress in
Material Tension Compression
Cast Iron One-tenth (1/10) of the 700 kg/cm2
ultimate strength
Steel Forgings, One fifth (1/5) of the One-fifth (1/5) of the
Cast Steel and Alloy ultimate ultimate
Cast Steel strength or one-third (1/3) strength or one-third (1/3)
of the yield strength, of the yield strength,
whichever is lower whichever is lower
Plate Steel for One-fourth (1/4) of the One-fourth (1/4) of the
principal parts subject ultimate strength but ultimate strength but
2
to hydraulic stresses. limited to 1050 kg/cm limited to 1050 kg/cm2
1.5.2.2 The maximum stresses for the materials not covered in the Table 1.1 in tension
or compression used in the construction of VAC system/ equipments due to the
most severe conditions occurring in normal operation shall neither exceed one-
third of the yield strength nor one-fifth of the ultimate strength of the material.
Maximum stresses in shear shall not exceed 210 kg/cm 2 in components made
from cast iron and 60 percent of the allowable stresses in tension for other
materials.
1.6 WORKMANSHIP
1.6.1.1 Workmanship shall be of the highest grade and in accordance with the best
modern practice for the manufacture of Ventilation and Air Condition Systems
and distribution panels, control/ special cables, communication equipment and
accessories not withstanding any omissions from these specifications or
associated drawings. All work shall be performed by workmen skilled in their
respective trades.
ii) The re-entrant cuts shall be made in a workmanlike manner. Where these
cuts cannot be made by shearing, a rectangular punch may be used.
These cuts shall be filleted, unless otherwise approved by the purchaser.
iii) The bends, except for minor details, shall be made by approved dies or
bending tools. When heating is required for the satisfactory working of
the metal, it shall be allowed to cool under conditions that will not
destroy the original properties.
iv) The steels with welds other than those indicated in the shop /
manufacturing drawings, or specified or otherwise called for, will not be
acceptable. All bolts, nuts, and screws shall be adequately tight.
ii) All nuts, bolts & pins shall be locked in position. If bolts & nuts are placed
so that they are inaccessible by means of ordinary spanners, suitable
special spanners shall be provided by the supplier.
iii)All threads shall be clean and accurately cut before assembling. Screwed
parts shall be lightly lubricated or coated with jointing compound as may
be applicable before connection. All screwed connections shall be made
adequately and no such force shall be used which may permanently
deform the material. Metric threads shall be provided.
i) Fastening elements for the equipment viz the bolts, studs, nuts, screws,
washers shall be of material most suited for the operating conditions and
the frequency of removal for dismantling of the respective components,
parts. These items shall conform to relevant national or international
standards.
ii) The material of the fastening elements shall be selected as per the
following considerations:
iii) The fasteners (nuts and bolts) used for the parts subjected to pressure
shall be machined on the shank, under the head and nut.
iv) Wherever necessary, the fastening elements shall have locking devices
and anti-vibration devices. The washers shall be of the taper type.
v) Where there is a risk of corrosion, bolts and studs shall be finished flush
with the surface of the nuts.
vi) With the exception of high strength friction grip bolts, the bolts shall be
designed so that with the nuts fully tightened, the stress intensity at the
bottom of the thread shall not exceed one half (1/2) of the yield point of
the bolt material under all conditions.
vii) In case, nuts and bolts are as per manufacturer’s own standards, which
are different from the usual national or international standards, the
supplier shall supply taps & dies for the threads and special spanners for
the nuts & bolts.
viii) The supplier shall state the standards to which offered fastening elements
conform.
ii) All machined parts shall be accurately machined and identical parts shall
be interchangeable. Drilled holes for bolts shall be accurately located and
drilled to templates when necessary or specified. The holes for fit-up
bolts or dowels shall be carefully reamed and the bolt or dowel shall
enter with a light driving fit. Bolt and screw threads shall conform to
applicable IS or to ISO standard R68.
iii) Surfaces in sliding or rotating contact, where motion is slow and loads
are light, shall have a maximum roughness value of 3 microns.
iv) Surfaces in sliding or rotating contact, when loads and speeds are
moderate, shall have a maximum roughness value of 1.6 microns.
v) Surfaces in sliding or rotating contact, where loads are heavy and/or the
motion is rapid, shall have a maximum roughness value of 0.8 microns.
1.6.2.8 Unfinished Surfaces
As far as practicable, all parts shall be laid out to secure proper matching of
adjoining unfinished surfaces. Where there is a large discrepancy between
adjoining unfinished surfaces, they shall be chipped and ground or machined
to secure reasonable alignment. Unfinished surfaces shall be true to the lines
& dimensions shown on the drawings and shall be chipped or ground to free
the various surfaces from projections or rough spots. Depressions or holes not
affecting the strength or usefulness of the parts may be filled in a manner
approved by the purchaser.
1.6.3 Galvanizing
1.6.3.1 All drilling, punching, tapping, cutting & bending of parts shall be completed
& all burrs removed prior to galvanizing.
1.6.3.2 Galvanizing shall be applied by the hot dipped process & shall consist of the
smooth, clean zinc coating free from defects & of uniform thickness. Original
blast-furnace raw-zinc (minimum purity 98%) shall be used. Sherardizing or
other alternative process shall not be used without the approval of the
purchaser & / or consultant.
1.6.3.3 Material on which galvanizing has been damaged shall be re-dipped unless, in
the opinion of the purchaser, the damage is local & can be repaired by
applying a coat of galvanizing repair paint.
The design of welded joints and the welding procedures for both field welds &
shop welds, in addition to conforming to the requirements set forth in the
applicable code and/or in these specifications, shall meet the following
requirements for workmanship and visual quality:
i) Butt welds shall be slightly convex with uniform height and shall have
full penetration.
ii) Fillet welds shall be of the specified size with full throat and with legs of
equal length.
The castings shall be free from injurious defects and foundry irregularities
such as projections, ridges, hollows, honey-combing, pock marks, or chip
marks, so that they will not require surface smoothing operations in the field
prior to painting. The location of existing defects shall be determined and they
shall be completely removed to sound metal. The structure of the castings
shall be homogenous and free from excessive non-metallic inclusions. An
excessive segregation of impurities or alloys at critical points in a casting shall
not be permissible and such casing shall be rejected. All castings involving
welded fabrication shall be stress-relieved.
ii) The test pieces / specimens for tension and bend shall be removed from
the castings at the time of inspection. Certified copies of the test reports
shall be furnished as specified in clause 1.4.2. The supplier shall carryout
the non-destructive tests for important load carrying castings as
appropriate prior to final machining. The radiographic or magnetic
particle inspection, ultrasonic or other non-destructive tests, may be
required by the purchaser when it is desired to conduct such tests as a
means of judging acceptability of castings which contain defects of
apparent borderline seriousness or to determine that repair welds have
been properly made. Any such tests shall be carried out at by the supplier
at without any extra cost to the purchaser.
iv) The repairs carried on the castings by the welding of major defects at any
stage of manufacture after the first heat treatment (annealing) shall be
stress-relieved. The minor defects or imperfections that may not impair
the strength or service ability of the castings may be repaired by welding
in accordance with accepted commercial casting practice without
obtaining the approval of the purchaser. However, an accumulation of
minor defects which in the opinion of purchaser casts serious doubt as to
the general quality of the casting may constitute cause for rejection.
1. 6.5.4 Dimensions
The thickness and other dimensions of the castings shall conform substantially
to the dimensions on the drawings and shall not be reduced by shop or foundry
practices to the extent that the resulting stresses in the metal will exceed the
stresses allowed under these specifications. The castings shall not be warped
or otherwise distorted, nor shall their dimensions be oversize to such an extent
as to interfere with proper fit with other parts.
(a) The surface finish shall be indicated on the detailed drawings and shall
conform to the requirements of relevant IS or ANSI B46.1 "Surface
Roughness, Waviness and Lay", or other approved equal standards.
(b) All parts shall be free from burrs, sharp edges and imperfections in
cutting, machining and welding. All visible parts shall receive special
attention in order to ensure pleasing appearance of the completed
machine.
The supplier shall furnish to purchaser for approval the names of the
manufacturers or sub-suppliers of all such machinery and equipment from
whom he intends to procure some items of the offered equipments together
with performance, capacities, and other significant information including the
performance reports pertaining to the equipment or similar equipment supplied
elsewhere by him. The drawings and bills of materials submitted for approval
shall clearly indicate the type of quality of material, & the name of
manufacturer. The samples of materials shall be submitted for approval when
so directed. The equipment, materials and articles installed or used without
such approval shall be at the risk of subsequent rejection.
a. All surfaces shall be thoroughly cleaned of rust, mill scale, oil, grease
and dirt prior to shipment and before painting. The paint shall only be
applied to dry & clean surfaces.
e. The minimum total dry film thickness shall be 1.5 mils (38 microns) for
prime finishes, 2 mils (50 microns) for lacquer finishes and 3 mils (75
microns) for enamel finishes.
The supplier shall submit the specifications and the names of manufacturers of
all paints which will be incorporated into the work for approval of the
purchaser. Colour scheme will be approved by the purchaser.
1.9.1.1 All motors shall comply with relevant National or International Standards.
1.9.1.2 Supplier shall be fully responsible for ensuring that the motor duty cycle,
rating, performance, tests and mechanical arrangements are all entirely
relevant, suitable for compliance with the above standards for the application at
the station in the extreme environmental and conditions specified.
1.9.1.3 The preferred type of A.C. motor is squirrel cage, totally enclosed, fan-cooled,
except for single-phase motor with rating less than 0.5 kW. The standard types
of motors would be subject to approval of purchaser. Motors above 1.0 kW
shall be 3-phase type.
1.9.1.4 The stator insulation system shall be Class-F or a higher class but in each case,
temperature rises shall be limited to Class-F wherever practicable on full
continuous rated load.
1.9.1.5 All A.C. motors shall be capable of direct on-line starting and of continuous
operation at rated output under abnormal frequency conditions. These shall
also be capable of operation for a period of not less than 5 minutes, with a
voltage of 25 percent below nominal voltage at nominal frequency, without
injurious overheating. The starting current at full voltage shall not exceed six
times the full load current. Each motor shall be tested at Manufacturer’s works
to confirm compliance with this requirement.
1.9.1.6 Ball or roller bearings shall be used. Vertical shaft motors shall have approved
thrust bearings. Lubrication fittings shall be provided for the bearings.
1.9.1.7 The terminal box shall be weatherproof and firmly fixed to the motor frame.
The terminal studs shall be adequately sized for the current duty required and
shall be identified. All terminal boxes shall have approved cable adapter
plates, sealing chambers or conduit entries.
1.9.1.8 The arrangement of the terminal box shall be such as to facilitate installation
of cables and allow interchanging of any two phase leads without disturbing
the sealing compound, if this is used at cable terminations.
1.9.1.9 Where practicable, the motor end cover shall be removable from the driving
end and shall have a removable plug to allow the speed to be checked by
means of a portable tachometer.
1.9.1.10 All motors having a mass of 50 kg or more shall be fitted with lifting lugs.
1.9.2 Instruments / Meters
1.9.2.1 Instruments mounted on panels shall be of the semi flush type, back
connected, matching pattern, shape and of approved finish to present neat and
fitting appearance consistent with the functional requirements.
1.9.2.2 Mechanical quantity measuring instruments which are directly mounted on
equipment shall have circular dials and shall be properly supported and
guarded against accident injury/breakage. These shall be placed in convenient
location.
1.9.2.3 Contact making instruments shall have contacts suitable for 250V AC or 220V
DC circuits.
1.9.2.5 The instruments shall accurately measure and indicate the quantity under all
conditions of operation with minimum instrument errors. Changes in ambient
temperature within the range prevailing at site shall not affect the accuracy.
1.9.2.6 The coils of electrical instruments shall be designed for continuous operation
at 110% of the full load current at instrument potential. The coil rating of the
measuring instruments shall be co-ordinated with those of the associated
Instrument transformers (i.e. CTS, PTs, etc.) by the Contractor. The VA burden
of the instruments shall be as low as possible. The meters shall be of the first
grade in respect of accuracy classification.
1.9.3.2 Cubicles shall be fitted with close fitting, gasketed, hinged, lift-off doors
capable of being opened through 1800. The doors shall be provided with
integral lock and master key.
1.9.3.3 Cubicles and disconnecting chambers shall be vermin-proof. Removable gland
plates shall be provided with adequate working clearance for the termination
of cables. Under no circumstances shall the floor/roof plate be used as a gland
plate. The cables, bus-bars and wiring shall enter the cubicles from bottom or
top as approved or directed by purchaser as per site requirements.
1.9.3.4 All electrical devices, control knobs and indicating lamps shall be flush
mounted on the panels. Relays and other devices sensitive to vibration shall
not be installed on doors or hinged panels and no equipment shall be installed
on rear access doors.
1.9.3.5 The instrument and control wiring including all electrical interlocks and all
interconnecting wiring between sections shall be completely installed and
connected to terminal blocks by the supplier.
1.9.3.6 The arrangement of control and protection devices on the panels and the
exterior finish of the panels shall be subject to the approval of purchaser. The
interior of all cubicles and disconnecting chambers shall have a matt white
finish unless specified otherwise.
1.9.3.7 Switched interior light and socket outlets shall be provided for all cubicles and
control panels.
1.9.3.8 All cubicles and control panels shall be provided with name plates, identifying
the purpose of the panel & all its components.
1.9.4.1 All terminal blocks shall be mounted in an accessible position with the spacing
between adjacent blocks not less than 100 mm and that between the bottom
blocks and the cable gland plate being a minimum of 250 mm. Sufficient
terminals shall be provided to allow for the connection of all incoming and
outgoing cables, including spare conductors. In addition, 20 percent spare
terminals shall be provided in enclosed cubicles. The terminal blocks provided
shall be inclined towards the door for facilitating terminations.
1.9.4.2 The blocks shall meet the requirements of IEC-947-7-1. The insulating
material of terminal blocks shall be polyamide 6.6, V0 class, unbreakable, fire
retardant meeting inflammability requirements of UL94. All metal parts shall
be of copper alloy, captive and touch proof. The terminal block should
withstand vibration level up to 5g. The terminal blocks shall be touch proof,
suitable for Din and G-rail mounting
1.9.4.3 Terminal blocks shall be provided with shorting links & paralleling links,
wherever applicable, and mounted identification numbers and/or letters.
1.9.4.4 The smallest size to be used shall be designed for 2.5mm 2 wire and not more
than two conductors shall be connected under one terminal clamp. Terminal
blocks shall be suitable for connection of purchaser’s 16 mm2 Aluminum
cables (for AC/DC power supply to panels).
1.9.4.6 Standard warning labels with red letters shall be mounted thereon in a
conspicuous position.
1.9.5.2 The markers may be typed individually or made up from sets of numbers and
letters firmly held in place. Open markers will not be accepted.
1.9.5.3 The markers must withstand a tropical environment and high humidity. Only
fungus proof materials will be accepted. Ferrules of adhesive type are not
acceptable.
1.9.5.4 All the trip circuits shall employ markers having a red background.
1.9.5.6 All wiring connections shall be readily accessible and removable for test or
other purposes. The wiring between the terminals of the various devices shall
be point to point.
1.9.5.7 Splices or tee connections between terminal points are not acceptable.
Longitudinal troughs extending throughout the full length of the panel held
against the ceiling shall be preferred. Whenever possible, unused areas of the
panels shall be kept free of wiring to facilitate the installation of future
equipment.
1.9.6.1 Wherever applicable, all alarm contacts shall be of galvanically isolated type
and provide inputs to the following devices:
i) Local annunciator
ii) Station annunciator
iii) Supervisory control and sequence of events / fault recorder system.
1.9.7.2 All alarm contacts shall be changeover type. Wherever required, relays shall
be provided as contact multiplier.
1.9.8 Earthing
1.9.8.1 The earthing terminals for equipment of these specifications shall form part of
equipment supplies. The supplier shall connect the earthing conductors to the
required terminals.
1.9.8.2 The earthing risers from the station earthing bus near the equipment will be
arranged by the purchaser unless specified otherwise.
1.9.9.1 Power, control and special cables required for this package shall be supplied
for cabling between equipment & devices covered in this package. However,
terminations of cables are to be made to the equipment & devices covered by
this package only.
1.9.9.2 LT AC power cables (single core and multiple cores as per site conditions)
shall be of 1.1kV grade, stranded aluminum conductor, PVC insulated,
armoured / unarmoured (as required) & FRLS type. These AC power cables
shall have copper conductor where conductor dia is 10mm or below. DC
power cables shall have stranded tinned copper conductor having minimum 7
(seven) strands.
1.9.9.5 The cables will have current rating and de-rating factors as per relevant
standards. The current rating shall be based on maximum conductor
temperature depending on the type of insulation for 10% continuous overload.
Further, all cables shall be designed to cope with the short-circuit conditions.
The cables shall be capable of satisfactory operation under a power supply
system voltage variation of ± 10% and frequency variation of ± 5% and a
combined frequency voltage variation of 10% (absolute sum). The cables
shall have heat and moisture resistant properties.
1.9.9.6 The contractor shall submit the following for approval of the purchaser:
Calculations for short circuit & rated current for selecting the cable size.
Cable schedule.
Cable routing drgs.
1.9.9.7 The conductor, PVC insulation, fillers, insulation shield, armour, PVC sheath,
etc., of the cables shall be as per relevant Indian standards. All material shall
be new, unused and of finest quality. The cables shall be manufactured as per
relevant standards. During manufacture of cables, manufacturer’s standard
tests shall be performed and copies of test certificates shall be furnished.
1.9.9.8 After manufacture of cables, type, routine and acceptance tests shall be
performed strictly as per applicable standard/specifications and copies of test
certificates shall be furnished.
1.9.9.9 The purchaser reserves the right to witness all tests and the supplier shall
provide all facilities to the purchaser in this regard and shall inform the
purchaser sufficiently in advance to enable the purchaser to depute his
representative to witness the same. The test reports on the cables shall be got
approved from the purchaser before dispatch of the cables.
1.9.9.10 The cables shall be wound on suitable sized wooden, non-returnable drum for
each length of cable as per IS: 10418.
1.9.9.11 The contractor shall supply required quantities of cable lugs, cable glands,
compression type terminals (for control wiring), button-type strap & stud,
aluminium strip lugs and other accessories. All above accessories and PVC
tapes, cotton tapes and any other accessories required for laying, termination,
testing and commissioning shall also be supplied and shall be of good quality
as per relevant standards.
1.9.9.12 Full technical details and descriptive literature shall be furnished indicating
construction details, standards applicable for the components of the cable and
the current rating of the cables in air and ground. De-rating factors to be
considered for the ambient temperature and ground temperature for laying of
cables in air and ground shall be furnished. The certificate for the type tests
conducted on cables, similar to the cables to be supplied, shall be submitted
during design stage.
1.10.1.1 The bidder shall submit the various drawings, technical data/documents/
literature & also the drawings as per Clause No. 2.17.1 of Section – 2 of these
specifications and as called for in other sections of this document, with their
bid.
1.10.1.2 The drawings, data & information shall be elaborate enough to enable the
purchaser to comprehend and assess the vital details, features, capabilities and
functioning of the equipment and their arrangements.
1.10.1.3 Non-compliance of the above stipulation by the bidder shall render their bids
unresponsive and shall be liable to rejection.
1.10.2.1 The contractor shall submit to the purchaser the various drawings/documents
after the award of contract as per Clause No. 2.17 of Section-2 of these
specifications expeditiously in a sequential manner. All measurements and
dimensions given on drawings submitted for approval shall be expressed in the
metric system (millimeters, meters, kg. & sec. as the case may be).
1.10.2.3 When drawings are revised, the number of prints of revised drawings,
documents to be furnished shall be same as above. The prints shall be clear
and legible. Faint unreadable prints will be returned by purchaser and the
supplier shall be responsible for any loss of time for the same.
1.10.2.5 The revisions carried out shall be identified on the prints suitably giving serial
number of revision, date and details in the revision block. The locations of
revisions carried out in the drawings may be marked / stamped by light
colour arrows.
1.10.2.6 It shall be obligatory for the supplier to carry out such modifications and
changes in the designs and drawings which in the opinion of the purchaser,
may be necessary to conform the design to the provisions & intent of these
specifications without any extra cost to the purchaser.
1.10.2.7 The approval of the supplier's drawings by the purchaser shall not be
construed held to relieve the supplier from any part of his obligations to meet
all the requirements of these specifications or of the responsibility of
correctness of the supplier's drawings.
1.10.2.8 The prints of drawings submitted shall in general be examined and commented
upon or approved as the case may be within forty-five days of their receipt.
Seven prints of all such drawings shall invariably be submitted for
examination.
After completion of the erection work the supplier shall furnish 5 copies (3
copies of A1size and 2 copies of A3 size duly bound) and one copy on tracing
cloth or velograph of final as built drawings of equipment along with 2 sets of
CD’s. Each set shall include an index showing the Drawing No., Revision No.
and Titles.
(iv) The procedure for the purchase of materials, parts, components and
selection of sub-supplier’s including vendor analysis, source inspection,
incoming raw-material inspection, testing and verification of materials
purchased.
(vi) System for process control, fabrication and assembly control during shop
manufacturing and site erection.
(iii) The inspection plan with verification, inspection plan check points,
verification sketches, if used, alongwith methods used to verify that the
inspection and testing points in the inspection plan were performed
satisfactorily.
iv) Factory test results for tests carried out as per the relevant codes and
standards.
(b) The repair work remains part of the accepted product quality.
1.11.3.2 The contractor shall also furnish copies of the reference documents/plant
standards/acceptance norms/test and inspection procedure etc. as referred in
quality plans. These quality plans/reference documents/standard etc. will be
subject to approval of PHPA-I, without which manufacturer shall not proceed.
PHPA reserves the right to add any inspection or test which is felt necessary
for completion of the work. These approved documents shall form a part of the
contract. In these approved quality plans, PHPA-I shall identify customer hold
points (CHP’s) i.e. test checks which shall be carried out in the presence of the
PHPA’s Engineer or his authorized representative and beyond which the work
will not proceed without the consent of PHPA/authorized representative in
writing. All deviations to these specifications, approved quality plans and
applicable standards must be documented and referred to PHPA-I alongwith
technical justification for approval and dispositioning.
1.11.3.3 The contractor shall furnish field quality plans which will detail out for all the
equipments, the quality practices & procedures etc. to be followed by the
contractor’s site quality control organization during various stages of site
activities from receipt of material/equipment at site. The field quality plans
shall also be approved by the PHPA-I
1.11.3.4 No material shall be dispatched from the manufacturer’s works before the
same is accepted prior to pre-despatch / final inspection including verification
of records of all previous tests/inspection by PHPA-I’s Engineer or his
authorized representative duly authorized for despatch.
1.11.3.7 PHPA-I reserves the right to carry out quality audit & quality surveillance of
the system and procedures of the tenderer. The contractor shall provide all
necessary assistance to enable PHPA-I to carry out such details & surveillance
including quality manuals.
1.11.3.8 All welding and brazing shall be carried out as per procedure drawn and
qualified in accordance with requirement of ASME section-IX or other
International equivalent standard acceptable to PHPA-I. All welding/brazing
procedures shall be submitted to the PHPA-I for approval prior to carrying out
the welding/brazing.
1.11.3.9 All brazers, welders and welding operators employed on any part of the
contract either in contractor’s/his sub-contractor’s works or at site or
elsewhere shall be qualified as per ASME section-IX or other equivalent
international standards acceptable to the PHPA-I.
1.11.3.10 The quality requirements as agreed for the main equipment supply shall be
applicable for the replacement items and all the spares as required.
1.11.3.12 Before subcontracting any portion of work, the supplier will take prior
approval of PHPA-I.
1.11.3.13 All materials used or supplied shall be accompanied by valid & approved
material certificates &tests and inspection reports. These certificates and
reports shall indicate the acceptable identification numbers of the material.
The material certified shall also have the identification details stamped on it.
1.11.4.2 Non destructive examination shall be carried out for the principal parts of
materials and the weld seams of fabricated components in accordance with the
requirements of applicable IS specifications or A.S.T.M. standards as
approved.
1.11.4.3 Material mill certificates and material identification record for important
components shall be submitted after completion of fabrication.
1.11.4.4 The test and inspection certificates shall be submitted to the purchaser prior to
dispatch of components/assembly concerned.
1.11.4.5 To ensure implementation of quality assurance plan, all inspection and tests on
various materials, components, assembly and equipment shall be subdivided
into following categories:
i) Tests by manufacturer’s inspector at his or vendor/sub-supplier’s work.
ii) Tests by manufacturer’s inspector and witness by purchaser’s
representative.
iii) Test certificates/reports are required to be furnished by the supplier to the
purchaser for both (i)&(ii) above.
iv) All the Inspection / tests are subject to purchaser’s review.
1.11.4.6 Quality assurance plan shall be offered for all the items covered under the
contract.
1.11.4.7 As far as practicable, provisions and guidelines of IS:14001 or ISO 9001 will
be applicable and implemented for quality control & assurance.
1.12.1 In each case of witnessing of test, the supplier shall furnish, well in advance
test plan/procedures to be followed, all the relevant drawings and documents
including test proforma for all the elements to be tested during the witnessing,
designed values and permissible tolerances for on the spot comparison of
tested values. The purchaser will depute the engineers of PHPA-I &
consultants (including CEA/ WAPCOS) for witnessing of tests.
1.12.2 The supplier shall declare readiness of material and equipment for testing well
in advance. Notice of inspection shall be given minimum 30 days prior to the
date of testing. Such tests shall be to the supplier’s account and all the
expenses relating to or connected with the test shall be deemed to have been
included in contract price. Purchaser or his representatives shall attend such
tests at the time so notified unless inspection is waived off by the purchaser in
writing. Supplier shall thereafter forward five (5) copies of duly certified test
reports in to the purchaser.
1.12.3 When the factory tests have been completed at the supplier’s or sub-supplier’s
works and the tests witnessed by the purchaser, the supplier shall submit the
tests reports to the purchaser for his approval. If the purchaser fails to
communicate his approval / comments within 60 days of receipt of test report,
the report shall be deemed to have been approved by the purchaser and failure
of the purchaser to issue such a certificate shall not prevent the supplier to
continue with the next stage of manufacturing / despatch. The completion of
these tests, or the issue of the certificate shall not bind the purchaser to accept
the equipment should it, on future tests after erection, be found not to comply
with the contract specifications.
1.12.4 The purchaser shall communicate his views within 30 days from the date of
inspection in writing to supplier for any objection to any test report &/or
drawings & any equipment and workmanship which in his opinion is not in
accordance with the contract. The supplier shall give due consideration to
such objections, shall make the modifications that may be necessary to meet
the said objections and shall submit a report to the purchaser.
1.12.5 Should any inspected or tested goods fail to conform to the specification, the
purchaser may reject them and the supplier shall either replace the rejected
goods or make all alterations necessary to meet the requirements of technical
specification free of cost to the purchaser. No extension in the delivery period
shall be given on this account.
1.12.6 The purchaser's right to inspect, test and, wherever necessary, reject the goods
after arrival in the purchaser's country shall in no way be limited or waived
due to reasons of the goods having previously been inspected, tested and
passed by the purchaser or his representative prior to the despatch from the
country of origin.
1.12.7 Nothing in Clause 1.12 shall in any way relieve the supplier from any
warranty or other obligations under this contract.
1.12.8 Training
The successful supplier shall have to impart training to the power house O&M
staff in the proper function and use of the Ventilation & Air Conditioning
System during Erection, Testing & Commissioning of the equipment at site so
that these can be handled safely during operation.