9.section - 9 QAP

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STANDARD TECHNICAL SPECIFICATION FOR RETROFIT OF WET LIMESTONE BASED FLUE GAS DESULPHURISATION (FGD)
SYSTEM IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT
SECTION 9.0
QUALITY ASSURANCE PLAN

The testing and inspection requirements of major equipment of FGD system to be
followed by the bidder over and above the respective code/ standard requirements
are given hereunder:
9.1 MECHANICAL SYSTEMS
9.1.1 Flue Gas System

9.1.1.1 Booster fans
i) Rotor components shall be subjected to ultrasonic test at mill and
magnetic particle examination/dye penetration examination after rough
machining.
ii) Butt welds in rotor components shall be subjected to 100% UT and all
welds shall be subjected to MPE or DPT after stress relieving.
iii) All rotating components of fans shall be dynamically balanced to quality
grade 2.5 of ISO 1940.
iv) Test for natural frequency of all fan components, including fan blades
shall be carried out for the fans.
v) Full range performance test shall be carried out on one fan as per BS
848, Part-1.
vi) Hydraulic coupling of booster fan shall be checked for string test i.e.,
operational check of one fan assembly using hydraulic coupling to
check temperature rise, smooth operation, vibration and noise level. Dry
run test shall preferably be carried out during string test.
9.1.1.2 Thermal insulation
i) Thermal insulation
a) Pre-formed fibrous pipe insulation and LRB mattresses/ sections of

rock wool/ mineral wool from approved manufacturing sources
conforming to and tested as per relevant standards shall be used.
b) For resin bonded mineral wool insulation, testing shall be carried

out as per IS: 8183.
c) For resin bonded rock wool insulation, testing shall be carried out
as per IS: 9842.
d) Type tests except thermal conductivity shall be regularly carried

out once in three months.
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e) Type test for thermal conductivity shall be carried out by the

manufacturer minimum once in six months. Thermal conductivity
(K value) shall be measured in line with IS: 3346.
9.1.1.3 Dampers
i) All the dampers shall be subjected to operational test/checks.
ii) Gas tight dampers shall be subjected to shop leakage test to

demonstrate the guaranteed tightness (minimum one damper of each
type and size offered). In case such type test is already done, the
reports of the same shall be submitted for review.
iii) All dampers shall be checked for sealing dimensions to establish

guaranteed tightness.
9.1.1.4 Structure, Ducts, Hoppers

i) All materials shall be tested for chemical and mechanical properties as
per relevant standard. All plates above 40mm shall be 100%
Ultrasonically tested.
ii) Visual inspection of all welds shall be performed in accordance with

AWSDI .1.
iii) NDT requirements of structural steel welds shall be as under:
a) 100% RT/UT on butt-welds of plate thickness ≥ 32mm.
b) For plates of 25mm ≤ thickness<32mm: 10% RT and 100% MPI.

c) For plates of thickness <25mm: 10% MPI/LPI.
iv) Edge for shop and field weld shall be examined by MPI for plate
thickness ≥ 32mm.
9.1.2 Absorber
9.1.2.1 Metal Structures
i) Only material which has been identified against mill sheet or test
certificates shall be used for construction. Check testing shall be carried
out in the absence of MTC. All plates above 40mm shall be 100%
Ultrasonically tested.
ii) Visual inspection of all welds shall be performed in accordance with

AWSDI .1.
iii) NDT requirements of structural steel welds shall be as under:
a) 100% RT/UT on butt-welds of plate thickness>= 32mm.
b) For plates of 25mm<=thickness<32mm-10% RT and 100% MPI.
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c) For plates of thickness <25mm-10% MPI/LPI.
iv) Edge for shop and field weld shall be examined by MPI for plate
thickness >= 32mm.
9.1.2.2 Spray Nozzles

i) Spray nozzles shall be tested for physical properties.
ii) Spray nozzles also shall be subjected to performance test.
91..2.3 Agitators
i) Rubber lining shall be tested for hardness and spark test.
ii) Impellers shall be tested for dimensional and balancing check.
iii) Gear Boxes shall be tested for run test as per standard practice.
9.1.2.4 Other Critical Equipment
Checks/ NDTs shall be done as per relevant Indian Standards or equivalent

International Standards.
9.1.3 Limestone & Gypsum Handling System
9.1.3.1 Crushers
The details of the checks to be carried out for various components are to be
submitted by the Contractor for Owner's approval. However, some indicative
checks on different items are given below which should necessarily form part
of the Quality Assurance Plan to be agreed with the Owner.
i) All plates equal to or above 25mm thickness shall be ultrasonically

tested.
ii) Shaft forgings and suspension bars to be checked for ultrasonic testing
in addition to check for chemical, mechanical, hardness, microstructure
etc. as per applicable material specification.
iii) Following minimum NDT requirements to be ensured for welds:
a) Butt welds UT/RT and 100% MPI/DPT.
b) Fillet Welds 10% MPI/DPT.
iv) Crusher rotor to be dynamically balanced. Procedure to be submitted for

approval.
v) No-load trial run test to be carried out at shop to check for speed(RPM),
temperature rise, noise level and vibration.
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9.1.3.2 Metal Detectors
i) Functional test including sensitivity, Burn in test, operation of liquid

spray marker, detection of smallest piece of different materials as
specified.
ii) Test report for Degree of protection test to be furnished.
9.1.3.3 Belt Conveyor System

The details of the checks to be carried out in the various equipment are to be
submitted by the Contractor for Owner's approval. However, some indicative
checks on different items are given below which should necessarily form a
part of the Quality Assurance Plan to be agreed with the Owner.
9.1.3.3.1 Idlers
i) Check for run out and free movement shall be carried out on idlers. Run
out shall be restricted as per IS:8598
ii) Test for dust proofness, water proofness and dynamic friction factor of
the Idlers shall be conducted at shop. The detailed procedures for the
same shall be submitted for review and approval.
9.1.3.3.2 Belting
i) Rubber cover of finished belt shall be checked for tensile strength and
elongation at break before and after ageing. Rubber cover shall also be
checked for abrasion, tear strength and hardness.
ii) For finished belts, checks for elongation at 10% nominal tensile strength
tensile and elongation at break in longitudinal (warp) direction and
tensile in transverse (weft) direction shall be carried out.
iii) Adhesion test between ply to ply and cover to ply shall be carried out.
iv) Troughability test and Test for fire resistance shall be carried out.
v) Test for procedure qualification for belt vulcanizing joint (at site) shall be
done. Procedure for belt vulcanizing joint shall be discussed and
finalized during FQP finalization.
vi) There will be a limitation on the no. of repairs allowed on the belts.
Following will be the acceptance norm for the cover repairs.
a) The maximum size of a repair shall be limited to a size equivalent to

one fifth the belt width. No single dimension shall exceed one fifth
(1/5) of belt width.
b) Small local repair by dough filling of size 25mm x 25mm to a limited

extent shall not be counted of repairs. However, in case of cluster of
repairs, same shall be counted as a patch repair.
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c) The maximum number of patch repair shall not exceed 5 per 100
meter. However, the total number of patch and dough filling repairs
shall not exceed 10 per 100 meters.
vii) In addition to above, Steel Cord belt shall be tested for following also:
a) Cord dia and breaking strength
b) Finished belt shall be tested for cord pull-out strength before and
after aeging, peeling resistance.
c) Dynamic cord pull out test
d) Cord dia, pitch and number of cords

viii) In no case shall the cover thickness or the width of belt be less than that
given in specification.
ix) For testing purpose, belt sample shall be taken from anywhere of the
belt roll length offered
9.1.3.3.3 Belt vulcanizing machine
i) Check for tensile strength shall be carried out on a sample vulcanized

belt joint for each type of belt in shop. However, if such test has been
done earlier, the report for same shall be submitted for verification.
ii) Complete assembly shall be tested at shop for temp. and pressure
developed.
9.1.3.3.4 Pulleys
i) In addition to chemical, mechanical, hardness, microstructure as per

applicable material specification, pulleys shaft forgings shall be
subjected to ultrasonic testing.
ii) 100% MPI/DPT on all welds shall be conducted and RT/UT on butt
welds shall be conducted.
iii) Static balancing of pulleys shall be carried out after rubber lagging.
iv) Checks on rubber lagging to include abrasion loss, shore hardness test,
peel-off strength test and physical properties. Peel-off strength shall be
10 kg/cm, Abrasion loss shall be less than 250 cubic mm when tested
as per DIN 53516.
9.1.3.3.5 Pull chord & belt sway switches
The following tests shall be carried out:
i) Over all dimension and functional test.
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ii) HV & IR test
iii) Degree of protection test report.
9.1.3.3.6 Zero speed switch, under belt switch and chute blockage switch
The following tests shall be carried out:
i) Burn in test at 50 deg C for 48 hours shall be done for electronic

switches.
ii) Over all dimension and functional tests.
iii) HV & IR
iv) Degree of protection test
9.1.3.3.7 Drive Equipment

i) Gear Boxes
(a) In addition to checks for physical, chemical, hardness,
microstructure as per relevant standard, the shaft and gear/pinion
forgings shall be subjected to ultrasonic testing
(b) MPI to be carried out on Gears/Pinions after machining. Case

depth, hardness and MPI after hard facing shall be checked to
ensure freedom from defects.
(c) Gear reducer shall be checked for reduction ratio, backlash and
contact pattern. No load shop trial run to be conducted on gear
boxes to check for oil leakage, temperature rise, noise level and
vibration.
ii) Flexible Coupling
(a) Ultrasonic testing shall be conducted on forgings for gear sleeve

and gear hub, if gear coupling is provided.
(b) MPI shall be carried out after machining to ensure freedom from
cracks.
iii) Fluid Coupling

(a) Dynamic balancing shall be carried out for the rotating parts.
(b) Check for leak tightness of the coupling shall be carried out.
(c) Functional test on fusible plug for each type of coupling shall be
conducted at shop.
(d) All couplings to be run tested at shop on no load.
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(e) Check for temperature rise, torque-speed, torque-slip characteristics

and over speed test shall be included during performance test of
one coupling of each type preferably at full load.
9.1.3.3.8 Belt Scales

The details of the checks to be carried out in the various equipment are to be
submitted by the Contractor for Employer's approval. However, some
indicative checks are given below which should necessarily form a part of the
quality assurance plan to be agreed with the Employer.
i) Mounting arrangement/Overall dimensional check shall be carried out

on the Belt Scales.
ii) Belt scale shall be calibrated with test weight/test chain in static at
works and with test weight for dynamic condition at site.
iii) All electronic modules shall be subjected to burn in test at 50 Deg C

for 48 hours.
iv) General check for load cell shall be carried out.
v) Test report for degree of protection on enclosure shall be furnished.
vi) Accuracy/performance check shall be demonstrated at site.
9.1.4 Dust Suppression & Dry Fog Dust Suppression System
The details of the checks to be carried out on the various equipment are to be
submitted by the Contractor for Owners approval. However, some indicative
checks on different items are given below which should necessarily form a
part of the Quality Assurance Plan to be agreed with by the Owner.
i) Pumps
Refer clause 9.10.6
ii) Piping, valves, and fillings
Refer clause 9.10.3
iii) Air Compressor

Refer clause 9.12.9
9.1.5 Bucket Elevator
i) All plates equal to or above 25 mm thickness shall be ultrasonically
tested.
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ii) Castings and forgings, forged/rolled bar/section shall be subjected to

ultrasonically test in addition to check for chemical, mechanical,
hardness, microstructure etc. as per applicable material specification.
iii) Machined and hard faced surface of casting/forging and other hardened,
stellited parts shall be subjected to DPT/MPI in addition to check for
case depth, hardness as applicable for chain/sprocket/gear
reducer/rollers/wheel/pan etc.
iv) Following minimum NDT requirements shall be followed for welds:
a) Butt Welds in Tension- 100% UT/RT and 100% MPI/DPT.
b) Butt Welds in Compression - UT/RT and MPI/DPT.

c) Fillet Welds MPI/DPT.
v) For other items like drive system, motor, pulley, belt etc relevant portion of
specification shall be applicable.
vi) No load trial run test shall be carried out at shop on completely assembled
Bucket Elevator to check for trouble free operation, temperature rise, Noise
& vibration. The procedure for the No load trial run shall be submitted for
approval.
9.1.6 Silos/ Bunkers

i) All material shall be tested for Chemical & Mechanical properties as per
relevant standard. MPI/DP test on welding shall be carried out. Fit up
assembly checks shall be carried out at shop for all despatchable
segments.
ii) Bag Filters: Bag Leakage test shall be carried out for pressure parts.
Pulsing and sequential test on bag filter shall be done.
9.1.7 Ball Mills

i) Raw material for shaft, coupling, gears and pinions, top and bottom
races and other rotating components shall be subjected to UT. MPI/LPI
shall be carried out to check surface soundness.
ii) Wear-resistant parts shall be UT/RT tested to check soundness after

suitable heat treatment. Check for chemical composition, hardness and
microstructure shall be carried out.
iii) Butt welds in the tube/separator/body casing of the mill shall be tested
by RT and MP'. All other welds in main tube/separator shall be tested by
MPI/LPI for acceptance. The tube shall be statically balanced.
iv) All gearboxes shall be run tested for adequate duration to check rise in
oil temperature, noise level and vibration. Check for leak tightness of
gear case also shall be performed.
9.1.7.1 Gravimetric Feeders
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i) Any welds in the casing/pulley fabrication shall be checked with MPI.

ii) Routine tests shall be done as per relevant Indian Standards or
equivalent International Standards.
iii) All major items like plates for casing, head pulley, tail pulley, pulley shaft
and major castings shall be procured with respective material test
certificates.
iv) Calibration check shall be carried out on all feeders.
9.1.3.7.2 Lubricating oil systems
Complete lub oil system shall be checked suitably as per standard practice.
9.1.8 Vacuum Belt Filter System
i) Impeller, casing and shaft of vacuum pumps shall be tested for

chemical and mechanical properties as per relevant standard. All plates
above 40mm shall be 100% Ultrasonically tested.
ii) UT on shaft (if greater or equal to 40mm) and impeller shall be carried
out.
iii) All vacuum pumps shall be tested at shop for capacity, power, pressure,
efficiency, noise and vibration etc.
iv) Filter cloths and belts shall be tested for physical properties as per
relevant standard
v) Hydro cyclones shall be checked by visual, dimensional etc.
9.1.9 Monorail and Hoists
9.1.9.1 Hooks
i) All tests including proof load test as per relevant IS shall be carried out.
ii) MPE or DPT shall be done after proof load test.
9..1.9.2 Steels castings
Steel castings shall be subjected to DPT on machined surface.
9.1.9.3 Forgings
i) All forgings (wheel, gears, pinions, axles, hooks and hook trunion)
greater than or equal to 50mm diameter or thickness shall be subjected
to ultrasonic testing.
ii) DPT or MPE shall be done after hard facing and machining.
91.9.4 Wire rope
Wire rope shall be tested as per relevant standard.
9.1.9.5 Electric hoists
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All electric hoists shall be tested as per IS-3938 and chain pulley blocks
shall be tested as per IS-3832.
9.1.10 Ventilation System

i) Fans
a) 20% DPT of welding on fan hub, blades, casing and impeller as
applicable shall be carried out.
b) DPT of fan shafts shall be carried out after machining.
c) UT of fan shafts (diameter greater than or equal to 50mm) shall be
carried out.
d) Rotating components of all fans shall be statically and dynamically
balanced to ISO-1940 Gr. 6.3.
e) All centrifugal fans shall be subjected to run test for 4 hour or till
temperature stabilization is reached. Vibration, noise level,
temperature rise and current drawn shall be measured during the
run test.
f) One fan of each type and size will be performance tested as per
corresponding IS code for airflow, static pressure, total pressure,
speed, efficiency, power consumption, noise, vibration and
temperature rise.
g) Piping Valves and fillings
Refer clause 9.10.3
9.1.11 Packaged, split and window air conditioners

i) Compressor of packaged air conditioner (PAC) shall be tested as per
relevant code/standard.
ii) PAC shall be subjected to production routine test in accordance with IS:
8148 for the following.
a) General running test.
b) Pressure or leakage test of refrigerant.
c) Insulation resistance test.
d) High voltage test.
e) Performance test on one PAC of each type/size at ambient
condition to check for following.
 DBT and WBT of supply and return air.
 Air flow
 Current, voltage measurement and power consumption
 Noise and vibration measurement
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iii) Manufacturer’s standard test certificate or guarantee certificate shall be

submitted for split and window air conditioners.
9.1.12 Elevators
i) The details of the checks to be carried out in the various equipment are
to be submitted by the contractor for owner's approval. However, some
indicative checks on different items are given below which should
necessarily form part of the quality assurance plan to be agreed with the
owner.
ii) All forgings shall be subjected to ultrasonic test to ensure free from
internal defects in addition to check for chemical and mechanical
properties.
iii) 10% of the welds selected at random shall be subject to DP test.
iv) All forged components shall be subjected to DPI/MPI after machining.
v) Gear Reducer shall be checked for gear ratio, backlash, contact pattern.
No load shop trial run shall be conducted on gear boxes to check for oil
leakage, temperature rise, noise and vibration.
vi) Buffer springs shall be subjected to load test as per relevant

specifications. Material certificates for springs shall also be furnished
vii) All components prior to assembly shall be checked for dimensions.
viii) Car sling and car body in assembled condition shall be checked for
position of all major components i.e. car sling, inside depth, width,
height, positions of push box, indicator box lights, fans etc.
ix) Function test of Elevator assembly shall be carried out.
x) All electrical equipment shall be of proven quality.
xi) Galvanized components/parts shall be checked for weight of Zn coating,

thickness of coating, uniformity of coating and adhesion test and visual
examination as per IS 2633 and IS 2629.
9.1.13 Fire Detection & Protection System
i) Hydrant System: Shop Tests
a) Hydrant Valve:
 All valves shall be hydro tested for body and seat.
 Capacity test / flow test shall be done as per relevant standard.

b) Water Monitor, Hoses, Branch Pipes, Couplings and Nozzles:
 All tests including hydraulic test shall be done as per relevant
Indian / International standard.
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ii) High/ medium velocity water spray: shop tests
a) For Pipes, Fittings, Valves and specialties, requirements are

indicated separately.
b) Deluge Valves and Spray Nozzles

 All valves shall be hydro tested for body and seat.
 Performance test / functional test of 'Deluge Valves' and 'Spray
Nozzles' shall be carried out.
iii) Detectors: All 'Detectors' shall be tested as per relevant Indian /

International Standards. Detectors shall also meet the requirements
of UL / FM / LPC/VDS etc.
iv) Piping, valve and specialties
Refer clause 9.12.4
v) Portable & mobile fire extinguishers

a. All fire extinguishers shall be tested as per relevant standard.
b. Performance / function test shall be carried out on sampling basis
as per relevant code / standard.
vi) Site tests.
a) Fire Extinguishers: A performance demonstration test at site of five
(5) percent or one (1) number, whichever is higher, of each type and
capacity of the extinguisher shall be carried out by the contractor. All
consumables and replaceable items require for the contractor
without any extra cost to employer would supply this test would be
supplied by the Contractor without any extra cost to employer.
b) Piping Protection:
 Thickness, Holiday by spark test, Adhesion test shall be carried
out as per relevant standard.
 Complete piping shall be Hydro pressure tested, at 1.5 X DP or 2
X MWP whichever is higher, before protection.
c) Welding of Pipes:
 ERW Black / rolled welded:
-100% DPT on root of butt and finish weld of butt and fillet.
-RT on 10% randomly selected joints shall be carried out (for
underground piping).
 Gl Pipes
Welding on Gl Pipes in general shall not be done. Welding of
Gl Pipes, if permitted by design, (butt / socket / fillet weld)
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shall be done strictly as per approved drawing and procedure

approved by NTPC Engineering. For all such welds 100% DP
test and random 1% RT shall be done.
9.1.14 Miscellaneous Equipment

9.1.14.1 Pressure Vessels
i) NDT on weld joint shall be as per respective code requirements or the
minimum as specified as below:
a) 100% DPT on root run of butt weld, nozzle welds and finished fillet
welds.
b) 10% DPT on all finished butt welds.
c) 10% RT (covering all 'T'/cross joints) of butt welds.
iv) Butt welds of dished ends shall be stress relieved and subjected to
100% RT.
v) Each finished vessels shall be hydraulically tested to 150% of the
design pressure for a duration of 30 minutes.
9.1.14.2 Tanks
i) Tests shall be carried out on the materials of the tanks to establish their
mechanical properties, and chemical compositions
ii) Plates shall be subject to 100% ultrasonic testing.
iii) Welding
a) Root run of butt welds shall be examined by 100% DPT or MPE.
b) Butt welds, full penetration joints and nozzle welds shall be

checked by 100% RT and 100% MPE or DPT.
c) Fillet welds shall be checked by 100% MPE or DPT.
iv) Rubber lining shall be subject to hardness and spark test, as applicable.
v) Visual check and dimensional measurement shall be carried out on the
completed equipment.
vi) The fabricated tank shall be subject to water fill test to check for the
leakage.
9.1.15 Low Pressure Piping, Valves and Fittings etc.
9.1.15.1 Pipes, fittings
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i) Tests shall be carried out on the materials on various components to

establish their mechanical properties and chemical composition.
Further, heat treatment shall be carried out for materials as required.
ii) Dye penetration test of welds of pipes and fittings (including welds of
rolled and welded pipes) shall be carried out.
iii) All pipes and fittings shall be tested as per applicable codes/ standards
at manufacturer’s works.
9.1.15.2 Valves
i) Tests shall be carried out on the materials on various components to

establish their mechanical properties and chemical composition.
Further, heat treatment shall be carried out for materials as required.
ii) Shaft/ spindle of size ≥ 50 mm diameter shall be subjected to ultrasonic

test.
iii) Machined surfaces of casing, disc and shaft shall be subjected to 100%
MPI or DPT as applicable.
iv) All valves shall be hydraulically tested for body, seat and back seat
(wherever provided) at 1.5 times the maximum pressure to which
respective valves can be subjected during plant operation. Check
valves shall also be tested for leak tightness test at 25% of the specified
seat test pressure. For rubber lined valves, hydraulic test shall be
carried out before rubber lining.
v) For butterfly valves, hydraulic test, seat and disc string test and proof of
design test (if not carried out earlier) shall be carried out in accordance
with latest edition of AWWA-C-504 standard.
vi) Visual and dimensional check shall be carried out for all valves as per
relevant code/ approved drawing.
vii) Functional/ operational checks for and check for smooth opening and
closing of the valves shall be carried out.
viii) Gate, globe and swing check valves
a) Machined surfaces of castings and butt welds shall be subjected to

MPE or DPT.
b) Blue matching, wear travel for gates, valves, pneumatic seat

leakage, reduced pressure test for check valves shall be done as
per relevant standard.
vii) Diaphragm valves
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a) Seat leakage test for actuator operated valves, shall be done with
by closing the valves with actuator.
b) Tests on rubber parts per batch of rubber mix such as hardness,

adhesion, spark test, bleed test and flex test on diaphragm, type
test for diaphragm for 50,000 cycles.
viii) Cast butterfly valves
a) Machined surfaces of casing, disc and shaft shall be subjected to

MPE or DPT.
b) Actuator operated valves shall be checked for seat leakage by

closing the valves with actuator. Seat leakage test shall be carried
out in both directions.
ix) Fabricated butterfly valves
a. UT shall be carried out on plate material for body and disc.
b. Machined surfaces of casing, disc and shaft shall be subjected to

MPE or DPT.
c. Butt welds of thickness above 30mm on body and disc shall be

subject to 100% RT along with and post weld heat treatment for
stress relieving.
d. Actuator operated valves shall be checked for seat leakage by

closing the valves with actuator. Seat leakage test shall be carried
out in both directions.
x) Dual plate check valves
a. Dry cycle test (spring cycle test) for one lakh cycles shall be
carried out as a type test.
b. Machined surfaces of casing, disc and shaft shall be subjected to

MPE or DPT.
9.1.15.3 Rubber lining of pipes and valves
i) For rubber lining, the following tests shall be carried out as per IS-4682
part-I or acceptable equivalent standard:
i. Adhesion test
ii. Measurement of thickness
iii. Shore hardness test
iv. Visual examination and spark test at 5 kV/mm of thickness
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v. Bleeding resistance test (as applicable) with keeping the sample in

33% HCl, 48% NaOH and DM water for 72 hours.
vi. Bleeding test and ozone resistance test shall be done on rubber
material.
ii) Dimensional check shall be carried out as per relevant code/ approved
drawing.
9.1.15.4 Coating and wrapping of pipes
Spark test, adhesion test and material test for primer and enameled and coal
tar tapes, as applicable, shall be carried out as per AWWA-C-203-91.
9.1.15.5 Rubber expansion joints
i) Rubber compound test slab after valcanising shall be tested for tensile
strength, elongation and shore hardness. Tests on rubber compound
shall also include hydro stability test as per ASTM D-3137 and ozone
resistance test as per ASTM D- 380.
ii) Fabric strength of synthetic fibre for reinforcement shall be checked,
and test for rubber to fabric adhesion as per IS: 3400 or ASTM D- 413,
rubber to metal adhesion as per IS 3100 or ASTM D-429 shall be
carried out.
iii) All expansion joints in assembled condition shall be subjected to
vacuum test at 730 mm Hg under conditions to ensure its suitability to
withstand deflection in each axial transverse and longitudinal direction.
Duration of test shall be of minimum 10 minutes.
ii) All bare bellows shall be subjected to hydraulic pressure test in normal
condition at twice the design pressure for a duration of 30 minutes.
Additionally, all bare bellows shall be subjected to deflection tests under
pressure, pressure being raised from zero to the design value in regular
steps and deflection measured at each step.
iii) All expansion joints in assembled condition along with control rod
assembly shall be subjected to deflection test under design pressure.
iv) Either during the hydraulic test or during the vacuum test, change in
circumference at the top position of the arch shall not exceed 1.5% of
measured circumference at normal position.
v) Twenty four (24) hours after the above tests, the permanent set
(variation in dimensions with respect to its original dimension) shall be
measured and recorded. The permanent set shall not be more than
0.5%.
vi) Life cycle test and burst test shall be carried out on bellows of each
type, design and size.
9.1.15.6 Dosing pumps/ metering pumps
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i) Tests shall be carried out on the materials of the pumps to establish

their properties, and chemical compositions
ii) Pump casings shall be subject to hydraulic test at 1.5 times the shut off
pressure or 2 times the working pressure whichever is higher.
iii) Pumps shall be performance tested as per HIS, USA.
9.1.15.7 Horizontal centrifugal pumps

i) Tests shall be carried out on the materials of the pumps to establish
their properties, and chemical compositions.
ii) 100% DPT or MPE shall be carried out for the rotor and machined
surfaces of casing and impellers.
iii) UT on pump shaft (diameter greater than or equal to 50mm), MPI or
DPT on pump shaft and impeller after machining shall be carried out.
iv) All rotating components of the pumps shall be statically and dynamically
balanced to ISO-1940 Gr. 6.3.
v) Assembly fit up check, and dimensional check shall be carried out for
the completed pump assembly.
vii) Pump casings shall be subject to hydraulic test at 1.5 times the shut off
pressure or 2 times the working pressure whichever is higher for a
minimum duration of 30 minutes.
viii) All pumps shall be tested at manufacturer’s works for head, capacity,
power and efficiency as per requirements of HIS, USA or equivalent
standard. Pump shall be given running test over the entire operating
range covering from the shut-off head to the maximum flow. Acceptance
shall be as per approved datasheet and HIS only.
viii) Pumps shall be subjected to strip down examination visually to check
for mechanical damages after testing at shop in case abnormal noise
level and/or excessive vibration are observed during the shop test.
9.1.1.5.8 Vertical sump pumps
i) All materials should be of tested quality and test certificates to be
provided.
ii) Shaft forgings to be subjected to ultrasonic testing.
iii) DPT to be done on machined shaft and impeller.
iv) Impellers to be dynamically balanced to ISO 1940 Gr.6.3.
v) All pressure parts shall be hydraulically tested at 150% of the shut-off

head or 200% of rated head, whichever is higher for 30 minutes. No
leakage is allowed.
17
DRAFT
vi) All pumps to be performance tested as per Hydraulic Institute Standard/

Indian Standard. Performance test to include check for noise, vibration
level and bearing temperature rise.
9.1.15.9 Blowers
i) Tests shall be carried out on the materials of the rotary blowers/

compressors to establish their properties, and chemical compositions.
ii) 100% DPT or MPE shall be carried out for the rotor and machined
surfaces of casing and impellers.
iii) The shaft and impellers shall be dynamically balanced.
iv) Assembly fit up check, and dimensional check shall be carried out for
the completed blower assembly.
v) The blower/ compressor casing shall be subject to hydraulic test at 1.5
times the shut off pressure or 2 times the working pressure whichever is
higher.
vi) The blowers/ compressor shall be performance tested as per relevant
code/ standard.
9.1.15.10 Air Compressors
i) All pressure parts shall be hydraulically tested at not less than 150%
of design pressure for a duration of 30 minutes prior to painting.
ii) All other parts including inter-connecting piping shall be hydraulically
tested wherever possible, as per relevant codes.
iii) Ultrasonic testing shall be carried out on all forgings and rotor for dia
50mm and above. MPI/DPT shall be done on machined area of the
components.
iv) During assembly all clearances and alignments shall also be checked
and recorded
v) Rotor shall be statically and dynamically balanced.
vi) Performance test on the compressor shall be carried out in

accordance with ISO: 1217/Eq. The test shall also include
demonstration of loading and unloading mechanism (Capacity
control) and operation of safety valve.
vii) Vibration and Noise level measurement shall be done during shop
performance test.
viii) Air Receiver
a) Each finished vessel shall be hydraulically tested at 150% of the

design pressure for a duration of 30 minutes
18
DRAFT
b) NDT on weld joints shall be as per respective code requirements

or the minimum as specified below:
 100% DPT on root run of butt welds

 100% DPT on all finished butt welds and fillet welds
 10% RT on butt welds which shall include all T-Joints
9.1.16 Hangers and Supports
i) All raw materials used shall have co-related mill test certificate meeting
mandatory checks of material specification.
ii) Completed springs shall be tested for sagging test and load versus
deflection test. For diameter more than 25mm, MPE shall also be
carried out.
iii) Butt welds of thickness 32mm and above shall be tested for UT, and for
butt welds of thickness less than 32mm MPE shall be done. Fillet welds
shall be tested for MPE.
iii) Dampers with viscous fluids shall be checked for viscosity of liquid
used, damping resistance of the damper, stiffness of the damper etc.
iv) Turn-buckle, pipe clamps and hangers of thickness greater than 25mm
shall be checked by MPE or DPT on bent portions.
v) One hanger of each type and size shall be checked for variation in
deflection and travel versus load test.
19
DRAFT
9.2 ELECTRICAL SYSTEMS
9.2.1 HT Busduct
11kV, 6.6kV & 3.3kV Segregated Phase Bus ducts
Tests/ Checks
physical inspectionMake, Type, Rating, Model, TC, General

Galvanizing Test as per IS: 2629/ 2633/ 6745
Electrical, Mechanical, Chemical properties
Routine tests on complete busduct

Electrical clearance and creepage
Visual and Dimensional Checks
Paint shade and Adhesion test
Functional/ Operational check

NDT, DP or MPI, RT
WPS and PQR
Items/ Components/ Sub-
systems
Enclosure/ cubicle Y Y Y Y Y Y
Busbar flexible connector
Y Y Y
and disconnect or link
Steel structure and plate
Y Y
IS:2062
Bushing, post and support
Y Y Y Y Y
insulator (IS:9431 and 2544)
Welding of enclosure and
Y Y Y
conductor
Gasket, silicagel breather Y Y
Complete busduct IS:8084 Y Y Y Y
Y =Test applicable
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other
tests/ checks as per the manufacturer’s recommendation shall also be carried
out
a) Power frequency voltage withstand test

b) Air leakage test
c) Water tightness test on outdoor portion of bus-duct
d) Insulation resistant measurement of equipment and all wiring
e) Milli-volt drop
20
DRAFT
9.2.2 Auxiliary Service Transformers

9.2.2.1 Oil-filled Outdoor Transformers
Tests/ Checks
SpotCore Loss (on first Job) Hot
TC,Make, Type, Rating, Model,

checksVisual and Dimensional
andVoltage Ratio, Vector Group
Vacuum and Pressure Test

Chemical Composition
Mechanical properties
NDT, DP or MPI, UT
Compatibility with oil
Thermal properties
Electrical strength
WPS and PQR
Routine Tests
Ageing Test
Items/ Components/
Sub-systems
Tank, HV and LV Cable

Y Y Y Y
Box/ Flange throat
Conservator/ Radiator/
Y Y Y
Cooler/ Pipes
Copper Conductor
Y Y Y Y
(IS:191)
Insulating Material Y Y Y Y Y Y
CRGO Lamination and
Y Y Y Y Y Y
Built Core
Bushing / Insulator
Y Y Y Y
( IS:2544/ 5621)
Gasket Y Y Y Y
Transformer oil
Y
( IS:335)
Off-circuit tap changer Y Y
Core coil assembly and
Y Y
pre-tanking
Marshalling box Y Y Y
WTI, OTI, MOG, PRD,
Breather, Terminal
Connector, Bucholz Y Y
Relay, Globe and Gate
Valve,
Welding (ASME Sect-
Y Y
IX)
Complete Transformer
Y Y
(IS:2026)
Y =Test applicable
21
DRAFT
9.2.2.2 Dry Type Indoor Transformers

Tests/ Checks
polarityVoltage ratio, vector group and
tan delta between windingMeasurement of capacitance and

General physical inspectionMake, Type, Rating, Model, TC,
Core loss (on first job), Hot Spot
Visual and dimensional check
Chemical properties
Thermal properties
Electrical strength
NDT, DP or MPI
WPS and PQR
Routine tests
systems
Enclosure door, HV and LV

Y Y Y
Cable box/ Flange throat
Copper conductor Y Y Y Y
Insulating material Y Y Y
CRGO lamination and built
Y Y
core
Bushing/ Insulator ( IS:2544/
Y Y Y
5621)
Gasket Y Y Y
Off-circuit tap changer Y Y
Core coil assembly Y Y
Marshalling box Y
WTI, Thermister, Terminal
Y Y
connector
Welding Y
Complete transformer
Y Y Y
(IS:11171)
Y =Test applicable
Site tests :
out
a) Dry out test

b) Resistance measurement of windings
c) Ratio test
d) Vector group test
e) Tap changer test
f) Buchholz relay test
g) Low oil level alarm.
h) Temperature indicators
i) Marshalling kiosk
j) Protective relays
22
DRAFT
k) Magnetizing current
23
9.2.3 Motors
Tests/ Checks
inspectionMake,Type,Rating,TC,General physical
index testTan delta, shaft voltage and polarisation

DRAFT
All tests as per IS:325/ IS:4722/ IS:9283

Mechanical, Chemical properties
Welding/ Brazing (WPS/ PQR)
Hydraulic, Leak, Pressure test

Electrical characteristics
Magnetic characteristics
Thermal characteristics
NDT, DP or MPI, UT
Dynamic balancing
Heat treatment
Metallography
Dimensional
Over speed
Item/ Components/
Vibration
Run out
Visual
Sub-system
Plates for stator

frame, end shield, Y Y Y Y Y
spider etc.
Shaft Y Y Y Y Y Y Y
Magnetic material Y Y Y Y Y Y Y Y
Rotor copper/
Y Y Y Y Y Y Y
Aluminium
Stator copper Y Y Y Y Y Y Y
SC ring Y Y Y Y Y Y Y Y Y
Insulating material Y Y Y Y Y
Tubes for cooler Y Y Y Y Y Y Y
Sleeve bearing Y Y Y Y Y Y Y
Stator, Rotor coils Y Y Y Y Y
Castings, stator
frame, terminal box
Y Y Y Y Y Y
and bearing
housing etc.
Fabrication and
machining of
Y Y Y Y
stator, rotor,
terminal box
Wound stator Y Y Y Y
Rotor complete Y Y Y Y Y
Stator, Rotor,
Terminal Box Y Y Y
assembly
Accessories, RTD,
BTD,CT, Brushes,
Diodes, space
heater, antifriction Y Y Y
bearing, cable
glands, lugs,
gaskets etc.
Complete motor 24
Y
(IS: 325/ IS:4722/ Y Y Y Y Y Y
1
IS:9283)
Y =Test applicable, Y1 = for 11kV and 3.3kV motors only
DRAFT
Site Tests :
out
i) Measurement of vibration.
ii) Measurement of insulation resistance and polarization index
iii) Measurement of full load current.
iv) Test running of the motors, checking the temperature rise and
identifying the hot spot etc.
25
DRAFT
9.2.4 11kV, 6.6kV and 3.3kV Switchgear (Table 1/2)

Tests/ Checks
Paint shade, thickness, adhesion and finish
All Routine Tests as per relevant standards

Item to conform to relevant Standards
Make, Type, Model, Rating and TC
Functional and operational features
Degree of Protection - Routine test

Pretreatment as per IS 6005
CB Operation timing check

Dimensions and Finish
Electrical Properties
Chemical properties
Functional Checks
HV and IR Test
systems
Aluminum busbar material

Y Y Y Y Y Y
(IS: 5082)
Copper busbar material
Y Y Y Y Y Y
(IS :613 )
Bus bar support insulation
Y Y Y Y Y Y
(IS:9431)
HT Circuit Breaker
Y Y Y Y Y Y Y
(IEC:56 )
HT Contactors ( IS:9046 ) Y Y Y Y Y Y
Protection and auxiliary
relays (IS:3231/ Y Y Y Y Y Y
8686 )
HT CT’s and PT’s (IS:2705/
Y Y Y Y
3156)
HT Fuses ( IS:9385 ) Y Y Y Y
Surge arrester ( IEC:99-4 ) Y Y Y Y
LT Contactors ( IS:13947) Y Y Y Y Y
Control and selector
Y Y Y Y Y
switches (IS:6875)
Indicating meters (IS:1248) Y Y Y Y Y Y
Indicating lamps (IS:13947) Y Y Y Y Y
Push buttons (IS: 4794) Y Y Y Y Y
Control transformer
Y Y Y Y Y
( IS:12021 )
LT fuses (IS:13703) Y Y Y Y
Energy meters (IS:722 ) Y Y Y Y Y
Transducers (IEC:60688) Y Y Y Y Y
Y =Test applicable
26
DRAFT
9.2.4 11kV, 6.6kV and 3.3kV Switchgear (Table 2/2)

Tests/ Checks
All Routine Tests as per relevant standard

finishPaint shade, thickness, adhesion and
Item to conform to relevant standards
Functional and Operational features

Pretreatment as per IS: 6005
CB Operation timing check

Chemical properties
Electrical properties
Functional checks
HV and IR Test
Items/ Components,/ Sub-
system
Diodes Y Y Y Y Y
Terminal Blocks Y Y Y Y
Synthetic Rubber Gasket
Y Y Y Y
( IS:11149/ 3400 )
Breaker Handling Trolley Y Y Y Y Y
HT Switchgear Panel
Y Y Y Y Y Y Y Y Y Y Y
( IS:3427)
Y =Test applicable
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out.
a) General
i) HV test on complete switchboard with CT and breaker/ contactor in
position
ii) Check continuity and IR value of space heater
iii) Check earth continuity for the complete switchgear board
b) Circuit Breaker/ Contactors

i) Check control wiring for correctness of connections, continuity and IR
values
ii) IR values, resistance and minimum pick up voltage of coils
iii) All functional checks and electrical & mechanical interlocks provided
iv) Checks on spring charging motor, correct operation of limit switches and
time of charging
c) Current and Voltage Transformers

i) Insulation resistance test
ii) Ratio test on all cores
iii) Polarity test
27
DRAFT
d) Relays
i) Insulation resistance between AC to DC terminals and between all
terminals and body
ii) Check minimum pick up voltage of DC coils
iii) Relay settings
28
DRAFT
9.2.5 415V Switchgear and Busduct

9.2.5.1 415V Switchgear (Table 1/2)
(MCC, PCC, ACDB, DCDB, Local push button station, Local motor
starters)
Tests/ Checks
Paint shade, adhesion, thickness and finish
All Routine tests as per relevant standards

Functional and Operational features
Make, Model, Type, Rating and TC
Degree of protection Routine test

Pretreatment as per IS 6005
Chemical properties
Milli-volt drop Test

Functional checks
IR – HV – IR Test
system
Sheet steel (IS:513) Y Y Y Y Y

Aluminum bus bar material
Y Y Y Y Y Y
(IS:5082)
Copper bus bar material
Y Y Y Y Y Y
(IS:613)
Support insulator
Y Y Y Y Y
(IS:943, IS:10912, IEC: 660 )
Air circuit breaker
Y Y Y Y Y Y Y
(IS:13947)
Energy meters ( IS:722 ) Y Y Y Y Y Y
Power and auxiliary contactor
Y Y Y Y Y
(IS:13947)
Protection and auxiliary
Y Y Y Y Y Y
relays (IS:3231)
Control and selector switches
Y Y Y Y Y
(IS:6875)
CT and VT (IS 2705/ 3156) Y Y Y Y
MCCB ( IS:13947 ) Y Y Y Y
Indicating meters (IS:1248) Y Y Y Y Y Y
Indicating lamps (IS:13947) Y Y Y Y Y
Air break switches
Y Y Y Y Y
( IS:13947 )
Control terminal blocks Y Y Y Y
Y =Test applicable
29
DRAFT
9.2.5.1 415V Switchgear (Table 2/2)

(MCC, PCC, ACDB, DCDB, Local push button station, Local motor
starters)
Tests/ Checks
standards andAll Routine tests as per relevant

FinishPaint Shade, Adhesion, Thickness and
Functional and Operational Features
Make, Model, Type, Rating and TC

Pretreatment as per IS: 6005
Chemical properties
Milli-volt drop Test

Functional checks
IR – HV – IR Test
Items/
Components/
Sub-system
Fuse (IS:13703) Y Y Y Y Y
Control
transformer Y Y Y Y Y Y
(IS:12021)
Push Buttons
Y Y Y Y Y
(IS:4794)
Transducer
Y Y Y Y Y Y
(IEC:60688)
MCB (IS:8828) Y Y Y Y Y
Breaker
Y Y Y Y Y Y
handling trolley
Synthetic rubber
gasket Y Y Y Y Y
(IS:11149)
415V
Switchgear Y Y Y Y Y Y Y Y Y Y Y
(IS:8623 )
Y =Test applicable
30
DRAFT
9.2.5.2 415V Busduct

Tests/ Checks
Weld quality check ( DP test and X-ray)
IR – HV – IR test
Degree of protection routine test

Item to conform to relevant IS
Paint shade, Thickness, Adhesion and finish
Galvanizing test as per IS 2629/ 2633

Chemical properties
Electrical clearances
Phase sequence check

Tightness by torque measurement
Dimension and surface finish
WPS approval, Welder qualification

Make, Type, Rating and Test certificate (TC)
Items/
Components
Aluminum sheets/
plates/ strips /
Y Y Y Y Y Y Y
flexibles/ tubes
(IS:5082/ 737)
CRCA flats/ ISMC
Y Y Y Y Y
(IS:2062)
Neoprene/
synthetic rubber
Y Y Y Y
gaskets (IS:11149/
3400)
Rubber bellows
Y Y Y Y
(IS:3400)
Support insulator
(BS:2782,
Y Y Y Y
IEC:660,
IS:10912 )
Galvanized
structure and GI
earthing flat Y Y Y Y
(IS:2629/ 2633/
4749)
Space heater and
Y Y
Thermostat
LT busduct
(IS:8623 Part 2)
Y = Test applicable
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out.
31
DRAFT
a) General
i) HV test on complete switchboard with CT and breaker/ contactor in
position
ii) Check continuity and IR value of space heater
iii) Check earth continuity for the complete switchgear board
b) Circuit Breaker/ Contactors

i) Check control wiring for correctness of connections, continuity and IR
values
ii) IR values, resistance and minimum pick up voltage of coils
iii) All functional checks and electrical & mechanical interlocks provided
iv) Checks on spring charging motor, correct operation of limit switches and
time of charging
c) Current and Voltage Transformers

i) Insulation resistance test
ii) Ratio test on all cores
iii) Polarity test
d) Relays
i) Insulation resistance between AC to DC terminals and between all
terminals and body
ii) Check minimum pick up voltage of DC coils
iii) Relay settings
e) Bus duct
i) Power frequency voltage withstand test
ii) Insulation resistant measurement of equipment and all wiring
iii) Milli-volt drop test
32
DRAFT
9.2.6 Power and Control Cables

9.2.6.1 11kV, 6.6kV and 3.3kV Power Cables (Table 1/2)
Item/ Components/ Sub- Tests/ Checks
system
after ageing on outer sheath and insulationTensile strength and elongation before and
gap between two wireArmour coverage, cross over, looseness,
lengthSequential marking/ surface finish/ cable

Hot set test, Eccentricity and Ovality
Metallic screening ( if applicable)

Thermal stability on outer sheath
Make, Type, Rating and TC
Lay length and sequence

Dimension/ surface finish
Chemical composition
Curing properties
Spark test
Aluminium (IS-8130) Y Y Y Y Y
Semi conducting
Y Y Y Y
compound
XLPE compound
Y Y Y Y Y
(IS-7098- Part-II)
FRLS PVC compound
(IS-5831, ASTM-D2843,
Y Y Y Y
ASTM-2863, IEC-754
Part-1)
Triple extrusion and
curing/ Manufacturing of Y Y Y Y
core
Copper tape Y Y Y Y
Polyster tape Y Y
Armour wire/strip Y Y Y
Copper tapping Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer sheathing Y Y Y Y
Power cable (Finished)
(IS : 7098 Part-II)
IEC:332, IS-5831, Y Y Y Y Y Y
ASTM-D2843, ASTM-
2863,IEC-754 Part-1)
Wooden
drum(IS:10418)/ Y
Steel drum
Y =Test applicable
33
DRAFT
9.2.6.1 11kV, 6.6kV and 3.3kV Power cables (Table 2/2)

Tests/ Checks
perRoutine and acceptance test as

drumsAnti termite coating on wooden
featureConstructional requirements
FRLS tests
Item/ Components/ Sub-system
Aluminium (IS-8130)
Semi conducting compound
XLPE compound (IS-7098- Part-II)
FRLS PVC compound (IS-5831, ASTM-D2843, ASTM-
Y
2863, IEC-754 Part-1)
Triple extrusion and curing/ Manufacturing of core
Copper tape
Polyster tape
Armour wire/strip
Copper tapping
Inner sheath
Armouring
Outer sheathing Y Y
Power cable (Finished) (IS : 7098 Part-II) IEC: 332, IS-
Y Y Y
5831, ASTM-D2843, ASTM-2863,IEC-754 Part-1)
Wooden drum(IS-10418) /Steel Drum Y
Y =Test applicable
Notes
1) Additional acceptance tests like FRLS, thermal stability, tensile strength and
elongation after ageing shall be done on one sample/ lot
2) Length measurement/ surface finish/ eccentricity/ ovality shall be checked on
one length/ size/ lot
3) Routine test shall be carried out on each drum length as per specifications.
34
DRAFT
9.2.6.2 1.1 kV PVC and XLPE cables (Table 1/2)

Tests/ Checks
after ageing of insulation and outer Tensile strength, elongation before and
Gap between two armour wire/ stripArmour coverage, cross over, looseness,
sheath *Thermal stability of insulation and outer

Make, Rating, Type and TC
Dimension/surface finish
Lay length/ sequence

Hot set test (XLPE)

Spark test
Item/ Components/ Sub-
system
Aluminum (IS-8130) Y Y Y Y Y
PVC compound (IS-5831) Y Y Y Y
XLPE compound (IS-7098
Y Y Y Y Y
Pt-I)
FRLS PVC compound (IS-
5831 ) ASTM-D-2843/
Y Y Y
ASTM-D-2863 IEC-754
Part-I
Armour wire/strip (IS-3975) Y Y Y
Insulated core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y
Finish cable (IS-1554 and
7098 – Part-1) ASTM-D-
2843/ ASTM- D-2863 IEC-
754 Part-I Swedish Y Y Y Y Y Y
Chimney SS 4241475 for
(F3 category) Flammability
test IEC-332 Part –3 Cat-B
Wooden drum (IS-10418) /
Y
Steel drum
Y =Test applicable
35
DRAFT
9.2.6.2 1.1 kV PVC and XLPE Cables (Table 2/2)

Tests/ Checks
drumsAnti termite treatment on wooden

specificationConstructional/ requirement as per
relevant standard and specification

Routine and acceptance test as per
FRLS Tests
Aluminum (IS-8130)
PVC Compound (IS-5831)
XLPE Compound (IS-7098 Pt-I)
FRLS PVC Compound (IS-5831 ) ASTM-D-
Y
2843/ ASTM-D-2863 IEC-754 Part-I
Armour wire/strip (IS-3975)
Insulated Core
Laid up core
PVC Inner sheath
Armouring
Outer sheath Y
Finish cable (IS-1554 & 7098 – Part-1) ASTM-
D-2843/ ASTM- D-2863 IEC-754 Part-I Swedish
Y Y Y
Chimney SS 4241475 for (F3 category)
Flammability test IEC-332 Part –3 Cat-B
Wooden drum (IS-10418) / Steel drum Y
Y =Test applicable
Notes
1) (*) Not applicable for XLPE insulation
2) Additional acceptance tests like FRLS, thermal stability, tensile
strength and elongation after ageing shall be done on one sample /
lot.
3) Length measurement / surface finish shall be checked on one length/
size/ lot
4) Routine test shall be carried out on each drum length as per
specifications.
36
DRAFT
9.2.6.3 1.1 kV PVC Control cables

(Table 1/2)
Tests/ Checks
after ageing of insulation and outer sheathTensile strength, elongation before and
gap between two armour wireArmour coverage, cross over, looseness,
sheathThermal stability of insulation and outer

Make, Type, Rating, Test certificate (TC)
Dimension/ surface finish
Lay length/ sequence

Spark test
Item/ Components/ Sub-
system
Copper conductor (IS-8130) Y Y Y Y Y

PVC compound (IS-5831) Y Y Y Y
FRLS PVC compound IS-
5831 ASTM-D-2843/
Y Y Y
ASTM-D-2863 IEC-754
Part-1
Armour wire/strip (IS-3975) Y Y Y
Insulated core Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y
Finished cable (IS-1554)
ASTM-D-2843/ ASTM-D-
2863 IEC-754 Part-1
Swedish Chimney: SEN SS Y Y Y Y Y Y
424-1475( F3 category)
Flammability test IEC-332
Part-3 Cat-B
Wooden drum( IS:10418)/
Y
Steel drum
Y =Test applicable
37
DRAFT
9.2.6.3 1.1 kV PVC Control cables

(Table 2/2)
Tests/ Checks
per relevant standard and Routine and Acceptance test as

drumsAnti termite treatment on wooden
specificationConstructional feature as per
FRLS test
Copper conductor (IS-8130)

PVC compound (IS-5831)
FRLS PVC compound IS-5831 ASTM-D-2843/
Y
ASTM-D-2863 IEC-754 Part-1
Armour wire/strip (IS-3975)
Insulated core
Laid up core
PVC Inner sheath
Armouring
Outer sheath Y
Finished cable (IS-1554) ASTM-D-2843/ ASTM-D-
2863 IEC-754 Part-1 Swedish Chimney: SEN SS
Y Y Y
424-1475 ( F3 category) Flammability test IEC-
332 Part-3 Cat-B
Wooden drum( IS : 10418) / Steel drum Y
Y =Test applicable
Notes
1) Additional acceptance tests like FRLS, thermal stability, tensile
strength and elongation after ageing shall be done on one
sample/ lot
2) Length measurement / surface finish shall be checked on one
length/ size/ lot
3) Routine test shall be carried out on each drum length as per
specifications.
38
DRAFT
9.2.7 Installation of Cables, Earthing system and Lightning Protection

system
Tests/ Checks
specificationConstructional feature as per

Paint shade, paint thickness, adhesion
Functional test as per specification
Item conform to relevant standard

All Routine and acceptance tests
Bought out items/ Bill of material
Pre-treatment of sheet
Galvanize test
Deflection test
IP protection
Dimension
HV and IR
Proof load
systems
Switch box/ Junction box/

Receptacles (IS-513, IS:5,
IS:2629, IS:2633,
IS:6745)
Cable glands (BS:6121) Y Y Y
Cable lug (IS:8309) Y Y Y
Lighting wire (IS:694) Y Y Y Y
Flexible conduits Y Y Y Y
Conduits (Galvanize and
Epoxy) IS:9537, IS:2629, Y Y Y Y Y
IS:2633 and IS:6745
RCC hume pipe (IS:458) Y Y Y
Cable termination and
Straight through joint Y Y Y Y Y Y
(VDE-0278)
Cable Trays, Flexible
supports system and
accessories IS:513, Y Y Y Y Y Y Y Y Y
IS:2629, IS:2633 and
IS:6745
Trefoil clamp Y Y Y
GI flats for earthing and
lightning protection
Y Y Y Y Y
(IS:2062, IS:2629,
IS:6745 and IS:2633)
GI wire (IS-280) Y Y Y Y Y
Y =Test applicable
39
DRAFT
Site tests :
out
i) Cables
a) Check for physical damage
b) Check for insulation resistance before and after termination/
jointing.
c) HT cables shall be pressure tested (test voltage as per IS:7098)
before commissioning
d) Check of continuity of all cores of the cables.
e) Check for correctness of all connections as per relevant wiring
diagrams. Any minor modification to the panel wiring like
removing/ inserting, shorting, change in terminal connections,
etc. shall be carried out
f) Check for correct polarity and phasing of cable connections
g) Check for proper earth connections for cable glands, cable
boxes, cable armour, screens, etc.
h) Check for provision of correct cable tags, core ferrules, tightness
of connections
ii) Cable trays/ supports and accessories

a) Check for proper galvanizing/ painting and identification number
of the cable trays/ supports and accessories.
b) Check for continuity of cable trays over the entire route.
c) Check that all sharp corners, burrs, and waste materials have
been removed from the trays supports.
d) Check for earth continuity and earth connection of cable trays
iii) Earthing and Lightning protection system

a) Earth continuity checks
b) Earth resistance of the complete system as well as sub-system.
40
DRAFT
9.2.8 DC Storage Battery

9.2.8.1 Lead-Acid type battery
Tests/ Checks
with the test for voltage during dischargeTest for capacities for 10 hours discharge rate along
(Routine and Acceptance test)Checking of polarity and absence of short circuit
adhesionPaint process checks, paint shade, thickness,
Conformance to CPWD Specification for teak wood
Constructional requirements as per specification

Lead coating thickness (minimum 25 microns,
Marking ( Routine and Acceptance test)

Conformance to relevant drawing
IS:6848 and Adhesion check

Dimensions and finish
Insulation Resistance
Item/ Components/
Sub-system
Container and Lids

Y Y
( IS:1146)
Vent plugs Y Y
Sealing compound
Y Y
(IS:3116)
Positive and
Y Y
Negative plates
Separators
Y Y
( IS:6071 )
Electrolyte (water/
sulphuric acid ) Y Y
(IS:1069/ 266)
Inter-cell connectors
Y Y Y
and fasteners
Battery stand Y Y Y Y
Cell insulators Y Y Y
Stack assembly Y Y
Lead-Acid battery
Y Y Y Y Y
(IS:1652 )
Y =Test applicable
41
DRAFT
9.2.8.2 Ni - Cd type battery

(Table 1/2)
Tests/ Checks
Conformance to relevant part drawing and
Marking and mass (Routine and Acceptance test)

Paint shade, thickness, adhesion and finish
Air pressure test (Acceptance test)

Air pressure test after heat sealing
Nickle plating thickness
Dimensions and finish
Resistance to alkali
Impact strength
system assembly
Manufacturer’s standards
Container and Lids ( IS:1146) Y Y Y Y

Vent Plugs Y Y Y
Perforated steel strips Y Y Y Y
Active material for positive and
Y Y
negative Plates
Separators Y Y Y
Electrolyte Y Y
Inter-cell connectors and
Y Y Y Y
fasteners
Battery stand Y Y Y
Cell Insulators Y Y Y
Stack assembly Y Y Y Y
Ni-Cd Battery (IS:10918 ) Y Y Y
Y =Test applicable
42
DRAFT
9.2.8.2 Ni- Cd type battery (Table

2/2)
Tests/ Checks
(Routine and Acceptance test)Polarity and absence of short circuit

Insulation Resistance (Acceptance test)
AH test (Acceptance test)
test)Retention of charge test (Acceptance
system assembly
Container and Lids ( IS:1146)

Vent Plugs
Perforated steel strips
Active material for positive and
negative Plates
Separators
Electrolyte
Inter-cell connectors and
fasteners
Battery stand
Cell Insulators
Stack assembly Y Y
Ni-Cd Battery (IS:10918 ) Y Y Y Y
Y =Test applicable
Site tests :
out.
i) Physical examination
ii) Dimensions, mass and layout
iii) Marking
iv) Polarity and absence of short circuit.
v) Insulation resistance
vi) Ampere - hour capacity
vii) Retention of charge
viii) Air pressure test
43
DRAFT
9.2.9 Battery Charger

Tests/ Checks
Annunciator and AVR operation testRipple content test, load limiter and
process checksSheet steel pretreatment and painting
constructionalComplete physical examination for

thickness,Dimensional check and paint shade,
Make, Model, Type, Rating and Finish
Operational and functional checks

Chemical and Mechanical tests
Burn-in test at 500C for 48 hrs

Conform to relevant standard
Degree of protection test .

Dynamic response test
Temperature rise test
HV and IR test
Rectifier transformer (IS:2026) Y Y Y Y

Electronic components
including potentiometer Y Y
( vernier type)
PCB and electronic cards Y Y
19”standard racks for electronic
Y Y
card
Control and selector switches
Y Y Y
(IS:6875)
Indicating meters (IS:1248 ) Y Y Y
Indicating lamps (IS:13947) Y Y Y
Air break switches/ Fuses
Y Y Y
(IS:13947/13703)
Control terminal blocks
Y Y
(IS:13947)
Control transformer ( IS:12021) Y Y Y
Push buttons ( IS:4794 ) Y Y Y
MCB ( IS:8828) Y Y Y
PVC insulated copper control
Y Y
wires (IS:694)
Sheet steel ( IS:513 ) Y Y Y Y
Synthetic rubber gaskets Y Y Y
Annunciator Y Y Y
Battery charger Y Y Y Y Y Y Y Y Y
Y =Test applicable
44
DRAFT
Site tests :
out
i) Complete physical examination
ii) Checking of proper operation of annunciation system
ii) Temperature rise test at full load
iv) Insulation resistance test
v) Automatic voltage regulator operation
vi) Load limiter operation
vii) Dynamic response test
9.2.10 VFD Module

Attributes/ Visual & Make / Final Remarks
Characteristics Dimensional Type/ Inspection
checks Rating etc. as per IS/
IEC
Items/
Components/
Sub-system
assembly
HT Breaker Y Y Y
(IEC-56)
For details refer table
DC Reactor Y Y
for DC Reactor
Transformer Y Y
for Transformer
For details refer
Motor Y Y
separate table for Motor
VFD Panel Y Y
for VFD Panel
Note: 1) This is an indicative list of tests/checks. The manufacture is to furnish a

detailed Quality Plan indicating the practices & Procedure followed alongwith relevant
supporting documents during QP finalization
2) Make of all major Bought-out Items will be subject to purchaser’s approval
45
DRAFT
9.2.10.1 DC Reactor
ATTRIBUTES/
Mechanical and Chemical Property

CHARACTERISTICS
Final inspection as per IS:2026

Painting by Stove Enamelling
Pretreatment by seven tank
Electrical Characteristics
Welding/ NDT
Dimensional
Visual
ITEMS/ COMPONENTS,
SUB_SYSTEM ASSEMBLY
1. Winding Material (Aluminium) Y Y Y Y

2. Insulation Material Y Y Y
3. Sheet Steel Y Y Y
4. Winding Y Y Y
5. Fabrication of Enclosures Y Y Y Y Y
6. Assembly Y Y
7. Routine Tests Y Y Y
(R) - Routine Test (A) - Acceptance Test Y – Test

applicable
Note:
1) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted along
with relevant supporting documents during QP finalization of all items.
2) All major Bought-out items shall be subject to purchaser’s approval.
46
DRAFT
9.2.10.2 Transformer (Oil Filled)
NDT/ DPT/ MPI/ UT

Mechanical Properties
Compatibility with oil
Routine Test as per relevant test

Visual & Dimensional Checks
general Physical Inspection Make/ Type/ rating/ Model/ TC/

Voltage Ratio, Vector Group &
Attributes /
Characteristics
Thermal Properties
Electrical Strength
WPS & PQR

Ageing Test
Routine test
Items/Components
Sub Systems
Polarity, Magnetic Balance Test

Tank, H.V. & L.V.
Y Y
Cable Box / Flange Y
throat
Conservator / Radiator Y Y
Y
/ Cooler / Pipes
Copper Conductor Y Y Y Y
(IS:191)
Insulating Material Y Y Y Y Y Y
CRGO Lamination & Y Y Y Y Y

Built Core
Bushing /
Y
Insulator Y Y Y
(IS:2544 / 5621)
Gasket Y Y Y Y Y
Transformer Oil Y
( IS:335 / IEC296)
Off-Circuit Tap Y Y
Changer
Core Coil Assembly & Y Y
Pre-tanking
Marshalling Box Y Y Y Y
WTI, OTI, MOG, PRD,

Breather, Terminal
Connector, Bucholz Y Y
Relay, Globe & Gate
Valve,
Welding (ASME Sect- Y Y
IX)
Complete Transformer Y
Y
(IS:2026/ IEC-60076)
47
DRAFT
Note: 1) This is an indicative list of tests / checks. The manufacturer is to furnish a

detailed Quality Plan indicating the practice and procedure along with relevant
supporting documents.
2) All major Bought Out Items will be subject to Purchaser’s approval.
48
DRAFT
9.2.10.3 Dry Type Transformer
NDT/ DPT/ MPI/ UT

Visual & Dimensional Checks
WPS & PQR
Routine Test as per relevant Standard
Routine test
Chemical Properties
Voltage Ratio, Vector Group & Polarity

Physical Inspection Make/ Type/ rating/ Model/ TC/ general
delta between winding Measurement of Capacitance and tan

Attributes /
Characteristics
Thermal Properties
Electrical Strength
Items/Components
Sub Systems
Enclosure door, H.V. &

Y Y
L.V. Cable Box / Y
Flange Throat
Copper Conductor Y Y Y Y
Insulating Material Y Y Y
CRGO Lamination & Y

Built Core
Bushing /Insulator Y
Y Y
( IS:2544 / 5621)
Gasket Y Y Y
Off-Circuit Tap Y Y
Changer
Core Coil Assembly Y Y
Marshalling Box Y Y
WTI, Thermister, Y
Y
Terminal Connector
Welding Y
Complete Transformer
Y
(IS:11171 / IEC Y Y
60076)
Notes: 1) This is an indicative List of test/checks. The manufacturer is to furnish a
detailed Quality Plan indicating his practice and procedure along with
relevant supporting documents during QP finalization for all item.
2) All major Bought out Items will be subject to Purchaser’s approval.
49
DRAFT
9.2.10.4 VFD Panel

Attributes
Simulation check Interlock functional & operation testing/

Routine Test as per relevant Standard
Mounting/ BOM/ Make, Completeness
Final testing as per relevant standard

Characteristics
Type/ Rating/ Functional Check
Paint finish/ Shade/ Thickness

IS : 6005, Seven tank process
Degree of Protection Test

Constructional Features
Dimension/ Finish
Electrical Properties
Chemical properties
HV/ IR
Item/ Components/
Sub-system/ Assembly
Sheet Steel (IS-513) Y Y Y
Aluminum / Copper Y Y Y Y
Busbar (IS-5082/IS-
613/IS-1987)
Support Insulator (BS- Y Y Y Y
2782/IEC-660/IS-10912)
Control / Selector Y Y Y
Switch(IS6875)
Contactor/ MCB (IS- Y Y Y
13947)
O/L Protection relays(IS- Y Y
3231)
C.T /V.T/ Indicating Y Y Y
Meter(IS2705/3156/124
8)
Fuse/ Fuse carrier (IS- Y Y Y
13703)
Terminals/lugs/PVC Y Y Y Y Y
wires(IS13947//IS-694)
Timers (IS-3231) Y Y Y
Push Button/ Lamp/ (IS- Y Y Y
6875)
Control Transformer Y Y Y
(IS12021)
Mimic, Annunciator Y Y
GASKET(IS-11149) Y Y Y Y Y
Fabrication Y
Pretreatment & Painting Y Y
VFD panel Y Y Y Y Y
50
DRAFT
NOTE:
1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed

Quality Plan indicating the practice and procedure along with relevant supporting
documents.
2. All major Bought-out items will be subject to Purchaser’s approval.
51
DRAFT
9.2.11 Station Lighting
Item to conform to relevant standard

Finish Paint shade thickness Adhesion &
standard & spec.. Routine tests as per relevant
standard & spec. Acceptance tests as per relevant

Constructional feature as per spec.
Attributes /
Bought-out items/ Bill of Material
Functional check as per spec.

Characteristics
Make, Type, Rating/ TC
Pre-treatment of sheet
Galvanization Tests
Dimension
HV & IR
IP Test
Items/Components
Sub Systems
Luminaries (IS:10322
Y
Pt.5 Sec.1 (Non-LED Y Y Y Y Y
type)
Electronic Ballast Y Y Y Y
Lighting wire (IS:694) Y Y
Fans (IS:374) Y Y
Pole (IS:2713) Y Y Y Y Y
Lamps (IS:9800,
Y Y Y
IS:9974)
Lighting Mast (with
raise & lower lantern Y Y Y Y Y Y
type)
Wall mounted Lighting Y
Panel (IS:513, IS:5)
Switch Box/ Junction
Box/ Receptacles/
Local Push Button
Y Y Y Y Y Y Y Y Y Y Y Y
Station/ Lighting Panel
(IS:513, 2629, 2633,
4759,6745)
Cable Gland
Y Y Y
(BS:6121)
Cable lug (IS:8309) Y Y Y
Flexible Conduit Y Y
Lighting Transformer
Y Y Y
(IS:11171)
Epoxy & Galvanised
Conduit (IS:9537,
Y Y Y Y
2629, 2633, 4759,
6745)
52
DRAFT
53
DRAFT
9.3 CONTROL AND INSTRUMENTATION (C& I) SYSTEM

9.3.1 Measuring Instruments (Primary & Secondary)
TESTS
Make, Model, Type and Rating (R)
IBR Certification (if applicable) (R)

Process/ Electrical Connection (R)
Material Test Certificate (R)

Test as per Standard (R)
Insulation Resistance (R)

Dimensions (R)
Calibration (R)
Hydro Test (R)

ITEMS
1. PR Gauge (IS-3624) Y Y Y Y Y
2. Temp. Gauge (BS-5235) Y Y Y Y Y
3. Pr./ D.P.Switch (BS-6134) Y Y Y Y Y Y
4. Electronic Transmitter(IEC- 60770) Y Y Y Y Y Y
5. Temp. Switch Y Y Y Y Y Y
6. Recorder(IS-9319/ANSI C-39.4) Y Y Y Y Y Y
7. Vertical indicators Y Y Y Y Y
8. Digital Indicators Y Y Y Y Y
9. Integrators Y Y Y Y
10. Electrical Metering Instrument Y Y Y Y Y Y
(IS-1248)
11. Transducer (IEC-688) Y Y Y Y Y Y
12. Thermocouples (IEC–754/ ANSI- Y Y Y Y Y Y
MC-96.1)
13. RTD (IEC-751) Y Y Y Y Y Y
14. Thermowell Y Y Y Y Y
R-Routine Test A- Acceptance Test Y – Test applicable
Note:
This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted along with
relevant supporting documents.
54
DRAFT
TESTS
IBR Certification (as applicable) (R)

Make, Model, Type and Rating (R)
Process/ Electrical Connection (R)
Requirement as per Standard (R)
Calculation for accuracy (R)
Material Test Certificate (R)

Non-destructive testing (R)
Insulation Resistance (R)

WPS approval (A)
Dimensions (R)
Hydro Test (R)

Calibration (R)
ITEMS
15. Cold junction Y Y Y Y Y
compensation box
16. Orifice plate (BS-1042) Y Y Y Y Y Y Y Y Y* Y
* ** ** *
17. Flow nozzle (BS-1042) Y Y Y Y Y Y Y Y Y Y
*
18. Impact head type Y Y Y Y Y
element
19. Level transmitter/ float Y Y Y Y Y Y Y Y
type switch
20. Analysers Y Y Y Y
21. Dust emission monitors Y Y Y Y
* Calibration to be carried out on one flow element of each type and size if calibration
carried out as type test same shall be repeated.
** if applicable
R-Routine Test A- Acceptance Test Y – Test applicable

Note:
detailed quality plan indicating the Practices and Procedure adopted along with
55
DRAFT
9.3.2 Process, Connection & Piping for C&I Systems

TESTS
Standard Flattening, Flariing, Hydro test, Hardness check as per ASTM
Proof Pressure test Dismentaling and reassembly test,

GA, BoM, Layout of components & construction feature (R)
Chemical/ Physical Properties of material (A)

Review of TCs for instruments/ devices (R)
Tests as per Standards and Specification

Accessability of TBs/ Devices (R)
Paint Shades/ Thicknesses (R)
Make, Model, Type, Rating (R)
Illumination Grounding (R)

Component Ratings (R)
Leak/ Hydro Test (A)

Dimension (R)
IR & HV (R)
Tubing (R)
Wiring (R)
Visual (R)
Hydraulic impulse and vibration test (R)

ITEMS
Local Instrument Y Y Y Y Y Y Y Y Y Y Y Y Y
enclosure
Local instruments Y Y Y Y Y Y Y Y Y Y Y Y Y
racks
Junction Box Y Y Y Y Y Y Y
*
Gauge Board Y Y Y Y Y Y Y Y Y
Impulse pipes and Y Y Y Y Y
tubes
Socket weld fittings Y Y Y Y Y
ANSI B-
16.11
Compression fittings Y Y Y Y Y Y
Instrument valves & Y Y Y Y Y
Valve manifolds
Copper tubings Y Y Y
ASTM B75
* applicable for painted junction boxes.
R-Routine Test A- Acceptance Test Y – Test
applicable
Note: This is an indicative list of tests/checks. The manufacturer is to furnish a detailed
quality plan indicating the Practices and Procedure adopted alongwith relevant supporting
documents.
56
DRAFT
9.3.3 Instrumentation Cable
(A) ++ Tensile & Elongation before & after ageing

++ Swedish chimney Test (SS 4241475) (A)
(A) ++ Vol. Resistivity at room & elevated temp.

(A) Outer Sheath/ Core marking, end sealing
Constructional detail, Dimensions (A)
TESTS
Overall/ Coverage/ Continuity (A)

Conductor Resistance (R) & (A)
Insulation Resistance (R) & (A)
Electrical Parameters ** (A) +
Spark Test report review (R)

Visual, Surface finish (A) +
Persulphate Test (A) +

High Voltage (R) & (A)
Thermal Stability (A) +
FRLS Test * (A) ++

Instrument cable twisted and
ITEMS
shielded
Conductor(IS-8130) Y Y Y
Insulation(VDE-207) Y Y Y Y Y Y
Pairing/Twisting Y Y Y
Shielding Y Y Y
Drain wire Y Y Y Y Y
Inner Sheath Y Y Y Y Y Y
Outer Sheath Y Y Y Y Y Y
Over all cable Y Y Y Y Y Y Y Y Y

Cable Drums(IS-10418) Y Y
(R) - Routine Test (A) - Acceptance Test (Y) - Test Applicable
Note :
1. High Temp. cables shall be subjected to tests as per VDE-207 (Part-6)
Compensating cables shall be checked for Thermal EMF/ Endurance test as per
IS 8784.
2. This is an indicative list of tests/checks. The manufacture is to furnish a detailed
Quality Plan indicating his practice & Procedure along with relevant supporting
documents during QP finalization for all items.
3. Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable)
* FRLS Tests: Oxygen/ Temp Index (ASTM D-2863), Smoke Density Rating
(ASTM–D 2843), HCL Emission ( IEC-754-1)
** Characteristic Impedance, Attenuation, Mutual Capacitance, Cross Talk (As
applicable)
+ Sample size will be One No. of each size/ type per lot.
++ Sample size will be One No. sample for complete lot offered irrespective of size/ type
57
DRAFT
9.3.4 Control Desk, Plc Panel, Smoke Detector, Fire Alarm & Control
System
TESTS
Review of TCs for instruments/ devices/ Recorders,

indicators/ osaic items/ Transducers (R)
Component Ratings/ Make/ Type (R)
Functional Check for control element

GA, BoM, Layout of components (R)
Accessability of TBs/ Devices (R)
Tests as per Standards (R) & (A)

Paint Shades/ Thicknesses (R)
Test as per IEC 1131 (R) *

Alignment of section (R)
Illumination (R)
Dimension (R)
IR & HV (R)
Wiring (R)
Visual (R)
Mimic (R)
ITEMS
1. Control Desk Y Y Y Y Y Y Y Y Y Y Y Y Y
2. Annunciation/ Control/ Y Y Y Y Y Y Y Y Y Y Y Y
PLC
Panel
3.Smoke Detectors Y
(UL-268,EN-54 PT-7), Heat
Detectors( UL-521/ EN54
PT-5 ) Annunciation/
Control
Panel (UL -864, EN-54, PT-
2)
* Applicable for PLC
(R) - Routine Test (A) - Acceptance Test Y - Test Applicable

Note:
This is an indicative list of test/ checks. The manufacturer is to furnish a
detailed quality plan indicating the Practice and Procedure alongwith relevant
58
DRAFT
9.3.5 Power Supply For C&I Systems (UPS/ Voltage Stabilizer)
thickness (R) Visual/ Dimension/ Rating/ Paint adhesion/
Mimic (R) General arrangement/ BoM/ Make of components/
Restart with PRI A.C and battery (separately) (R)

TESTS
Output voltage & frequency adj. range (A)
Parallel operation and current division (R)
System transfer and retransfer (R) *

AC input failure and return test (R)
Load transfer retransfer test (R) *
Tests as per Standards (R) & (A)

Relative harmonic content (R)
Preliminary light load test (R)
Asynchronous transfer (R)

Input voltage variation (A)
Load limiter operation (R)

Efficiency, regulation (R)
Ripple content (R)
IR/ HV (R)
ITEMS
UPS/CONVERTER
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
(IEC-146 PT-4)
VOLTAGE STABILISER Y Y Y Y Y Y Y Y
LEAD ACID BATTERY
Y
(TUBLER) IS:1651
LEAD ACID BATTERY
Y
(PLANTE) IS:1652
NICKEL-CADMIUM
Y
BATTERY (IS:!)(!*/ IEC-623)
* Transfer time and Over shoot /under shoot during load & system transfer shall be
recorded
(R)-Routine Test (A)- Acceptance Test (Y) – Test

applicable
Note:
detailed quality plan indicating the Practices and Procedure adopted alongwith
59
DRAFT
9.3.6 Control Valve Actuators and Accessories.

TESTS
accessories (R) Functional test, review for make and TC for

UT/ radiography for > 900lb rating (R)
Material test certificates (R)
Pressure resistance (R)
Linearity/ hysteresis (R)

Timing open/ close (R)
Make, Model, Tag (R)
IBR certificates (R)

Heat treatment (R)
Surface finish (R)
Hydraulic test (R)
Seat leakage (R)

Dimension (R)
Mpi/ dp (R)
ITEMS
CONTROL VALVE
AND ACTUATOR
Overall Y Y Y Y Y Y Y Y Y
Body Y Y Y Y Y Y Y
Bonnet Y Y Y Y
Trim Y Y Y*
Pneumatic actuator Y Y Y
Electro pneumatic Y Y
positioner
Y* - UT ON SPINDLE DIA ≥ 40 MM.
(R) - ROUTINE TEST (A) - ACCEPTANCE TEST
(Y) - TEST APPLICABLE
NOTE :
This is an indicative list of tests/checks. the manufacture is to furnish a detailed
quality plan indicating his practice & procedure along with relevant supporting
documents during QP finalisation for all item.
60
DRAFT
9.3.7 Electrical Actuators With Integral Starters
Test/ Attributes
All routine test as per Standard & Specification (R)
(R) Operation & setting of limit switch/ torque switch
(R) Function of Aux. like potentiometer, space heater

Hand wheel operation/ Auto de clutch function (A)
Safety check (Single phasing, Phase correction,

Characteristics
Local/ Remote (open-stop-close) operation (R),

Correct Phase Sequence (R)
Mounting Dimension (R)
Stall torque/ current (R)

No Load current (R)
Grease leakage (R)

IR & HV Test (R)
Tripping etc.) (A)

EPT output (R)
RPM (R)
ITEMS/
COMPONE
NT/ SUB-
ELECTRICAL
SYSTEM
ACTUATOR
ASSEMBLY/ WITH
INTEGRAL
TESTING
STARTERS
(IS:9334)
Motor Y Y Y Y Y
Final Testing Y Y Y Y Y Y Y Y Y Y Y Y Y
(R) - ROUTINE TEST (A) - ACCEPTANCE TEST

(Y) - TEST APPLICABLE
NOTE :
detailed quality plan indicating the practices & procedure along with relevant
61
DRAFT
9.4 CIVIL WORKS

9.4.1 Sampling, Testing and Quality Assurance for Civil Works
9.4.1.1 General
i) This part of the specification covers the sampling, testing and

quality assurance requirement for all civil and structural works
including excavation and filling, cast in situ concrete and allied
works, fabrication and erection of structural steel works, masonry /
sheeting and allied works, finishing items, etc.
ii) The Contractor shall carry out all sampling and testing in
accordance with the relevant Indian standards and / or international
standards and this technical specification. Where no specific testing
procedure is mentioned, the tests shall be carried out as per the best
prevalent engineering practices and to the directions of the Purchaser.
The Contractor shall establish the QA&QC laboratory at site. All
sampling and all field tests shall be done in the presence of the
Purchaser or his authorised representative. The tests which cannot
be carried out in the field laboratory shall be done at a laboratory of
repute such as CSMRS, NCBM, IITs, National Test House, Kolkata
etc. as agreed by the Engineer. The cost of transportation and
other associative cost including the test charges shall be borne by
the contractor and be shall deem to be included in his contract price.
iii) The recommendations and suitability of material for concreting and
other building materials like brick, cement, aggregates etc., shall be
ascertained by contractor prior to start of work. Preliminary evaluation
of aggregate and its evaluation for potential alkali-aggregate
reactivity as per following shall be done:-
A. Evaluation of Aggregates:
 To carry out different tests on coarse aggregate sample i.e.

specific gravity, water absorption, sieve analysis, deleterious
material; soundness, crushing value, impact value, abrasion
value, elongation index and flakiness index, as per IS: 2386.
 To carry out different tests on fine aggregate sample i.e.

specific gravity, water absorption, sieve analysis, soundness,
deleterious material, silt content, clay content and organic
impurities as per IS: 2386.
B. Evaluation of Aggregates for Potential Alkali-Aggregate

Reactivity:
 To carry out petrographic analysis and accelerated Mortar bar
62
DRAFT
Test on aggregate samples (1N NaOH at 80 deg. Centigrade for

14 days as per ASTM 1260, or the method established/
developed by CSMRS for 22days test.
All records shall be submitted, unless specified otherwise, as per the

format developed by the Contractor and approved by the Engineer.
iv) The Contractor shall enclose a comprehensive list of bought out
items (BOIs) envisaged in the contract for carrying out fabrication/
manufacturing/ erection/ construction/ commissioning activities,
procurement of forged, cast, semi-finished and finished
components/equipment etc. and shall indicate the names of
reputed manufacturers for each of them in their bid proposal.
v) The list of manufacturers / sub-vendors of each of the BOIs
identified/ indicated by the Contractor shall be discussed/ reviewed
by the Purchaser during post bid discussions and the list of proposed
manufacturers / sub-vendors shall be agreed/ approved. The
Contractor’s proposal shall include vendor’s site facilities,
expertise, facilities established at the respective works, the process
capability, process stabilization, QC systems followed, experience
list, etc. along with his own technical evaluation for identified sub-
Contractors proposed. The formats for furnishing above details shall
be given to the Contractor at post bid discussion stage.
vi) Structural steel supply if in the scope of the contractor shall be
procured from Main Steel Producers like SAIL, TISCO, RINL, Essar
Steel, Ispat Industries, JSW Steel, Lloyds Steel Industries, Jindal
Steel & Power and Sunflag Steel & Iron Co., Bhandara [only for
rounds (15-105 mm), flats (45-120 mm width & 4.75-28 mm thick),
hex rods (15.5-42 mm) and wire rods (5.5-38 mm)].
Reinforcement steel supply if in the scope of the contractor shall be
procured from Main Steel Producers like SAIL, TISCO, RINL, Essar
Steel, Ispat Industries, JSW Steel, Lloyds Steel Industries, Jindal
Steel & Power and Jai Balaji Industries Ltd, Durgapur (for 8-40mm
reinforcement steel).
vii) The Field Quality Plans shall detail out all the equipment, the quality
practices and procedures etc. to be followed by the Contractor’s “Site
Quality Control Organization", during various stages of site activities
starting from receipt of materials/equipment at site.
The contractor shall furnish complete QA & QC programme (QAP) for the
work envisaged which may include the following :-
 The organisation structure for the management and implementation of
the proposed Quality Assurance Programme.
 Document Control system
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 The procedure for procurement of materials and source inspection.

 System for site controls including process controls.
 Control of non-conforming items and systems for corrective action
 Inspection and test procedures for site activities
 System for indication and appraisal of inspection status
 System for maintenance of records
 System for handling, storage and delivery.
 Quality Plan detailing out quality practices and procedures,
relevant standards and acceptance levels for all types of work
under the scope of this contract.
Based on the schedule of work agreed with the Purchaser and the
approved FQP, the Contractor shall prepare a schedule of tests and
submit them to the Purchaser and organise to carry out the tests as
scheduled/ agreed.
viii) The contractor shall prepare and obtain approval of the Owner of the
Field Quality Plan (FQP) well before the start of the work. This FQP
shall cover for all the items / activities covered in the contract/schedule
of items and required for completion of the work.
ix) All materials / components and equipment covered under the scope
of work which are to be manufactured at shop/ factory of the
vendor/subvendor shall be covered under a comprehensive quality
assurance programme. Manufacturing Quality Plan (MQP) shall detail
out all the components and equipment, various test/inspection, to be
carried out as per the requirements of this specification and standards
mentioned therein.
x) All the equipment shall be duly calibrated by NABL/ NPL
accredited laboratories/accreditation agencies.
xi) The Contractor shall submit to the Purchaser Field Welding
Schedule for field welding activities, the format for Field Welding
Schedule shall be furnished to the Contractor at pre-award stage.
The field-welding schedule shall be submitted to the Purchaser along
with all supporting documents, like welding procedures, heat
treatment procedures, NDT procedures etc. at least ninety days
before schedule start of erection work at site. The Contractor shall
submit Welding Procedure Specification (WPS) for Purchaser
approval/ acceptance, the format for the WPS shall be furnished to
the Contractor during post bid discussion stage.
All welding and brazing shall be carried out as per procedure drawn
and qualified in accordance with requirements of ASME Section
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IX/BS-4870 or other International equivalent standard acceptable to

the Purchaser. All welding/brazing procedures shall be submitted to
the Purchaser or its authorized representative for approval prior to
carrying out the welding/brazing.
All brazers, welders and welding operators employed on any part of

the contract either in the Contractor’s/ sub-Contractor’s works or at site
or elsewhere shall be qualified as per AWSD1.1/ASME Section-IX or
BS-4871 or other equivalent International Standards acceptable to
the Purchaser.
Welding procedure qualification and Welder qualification test results
shall be furnished to the Purchaser for approval. However, where
required by the Purchaser, tests shall be conducted in presence of
Purchaser /authorized representative.
No welding shall be carried out on cast iron components for repair.

All the heat treatment results shall be recorded on time
temperature charts and verified with recommended regimes.
All Non-destructive examination shall be performed in accordance
with written procedures as per International Standards and as
mentioned elsewhere in the technical specification; The NDT operator
shall be qualified as per SNT-TC-IA (of the American Society of non-
destructive examination). NDT shall be recorded in a report, which
includes details of methods and equipment used, result/evaluation, job
data and identification of personnel employed and details of co-relation
of the test report with the job. The records of RT (Films) and UT
(inspection records or printed reports if possible) shall be documented
and produced to Purchaser.
xii) The Contractor shall associate themselves with the reputed
specialized blasting agency such as CMRI, NIRM for trials blasts,
design blasts, blasting pattern, monitoring of blast during the blasting
operations at site. All blasting work shall be done as per approved
blasting scheme/ design/ pattern in line with the technical
specification requirements and all statutory laws, rules, regulations,
relevant standards pertaining to the acquisition, transport, storage,
handling along with use of explosives shall be strictly followed by the
Contractor.
xiii) The Contractor shall install and operate equipments (such as tri-axial
seismograph) for continuous monitoring and control of blast induced
vibrations, noise level/ air pressure, dust, silica and noxious gases
during all blasting operations in line with the Technical Specification
requirements in association with the specialized blasting agency.
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9.4.2 General QA Requirements
9.4.2.1 Storage and handling of common building materials
All materials shall be stacked and stored by the Contractor as per IS-
4082 and as per the requirements specified in Purchaser Technical
Specification.
9.4.2.2 Excavation and filling works
i) The contractor shall submit a work methodology covering various

items of works for all stages of excavation and filling works. This
methodology shall broadly include the quantity wise and classification
wise identification of source of excavation and filling, suitability tests
as per specification requirements, method of stockpiling,
transportation, placement, spreading, compaction, equipment, list of
protocols, in- situ tests, third party lab test if required, acceptance
checks for final clearance.
ii) Tolerance for finished surface level shall be within 20 mm of the level
shown in the drawing. For an unimportant area, tolerance up to
+75mm shall be acceptable at the discretion of the engineer.
However, these tolerances shall be applicable for localized areas
only.
Acceptance criteria shall be:
a) When only one set of sample is tested, then all individual samples
collected and tested should pass without any deviation
b) For retest of any sample two additional samples shall be collected
and tested, and both should pass without any deviation.
c) Where a large number of samples are tested for a particular
test then 9 samples out of every 10 consecutive samples tested
shall meet the specification requirement.
9.4.2.3 Masonry and allied works
Unless specified otherwise the tolerances in construction of masonry works

shall be as below:
. Type of Check Tolerance

Deviation in verticality in Shall not exceed 12.5mm
total height of any wall of a (more than one storey)
building
6mm per 3m height (within
a storey)
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Deviation from the position Shall not exceed 12.5mm

shown on the plan of any (more than one storey)
brickwork
Relative displacement between Shall not exceed 6mm
load bearing walls in adjacent
storeys intended to be in
vertical alignment
Deviation of bed joint from Shall not exceed 6mm (upto
horizontal in any length, and it 12m)
Shall not exceed 12.0 mm

total (in any length over 12m)
Deviation from the specified Shall not exceed 1/5th of the
thickness of bed-joints, cross- specified thickness
joints or perpends
Finished plastered surface Deviation not more than 4
mm when checked with a
straight edge of 2 m length
placed against the surface
Not be less than the
The average thickness of plaster
specified thickness
Not less than the specified
The minimum thickness over any
thickness by more than 3 mm
portion of the surface
for plaster thickness above
12mm and 1 mm for ceiling
plaster
9.4.2.4 Concrete works
For concreting works provisions of technical specifications and IS: 456 shall
apply. A detailed methodology for concrete works shall be submitted by
the contractor to Purchaser for approval.
The methodology for concrete works shall broadly contain the suitability of
source of aggregates, cement, admixture, water and reinforcement steel,
etc. t he available concrete mix design, results of trial mix carried out at
site, method / control of batching, mixing, transportation, layer wise
placement, compaction, fixing / removal of form work, staging, fixing of
water stops at appropriate locations along with specials, expansion joints,
contraction joints and construction joints, cover blocks and method of
curing, methodology of repair of newly placed hardened concrete, testing
and sampling of concrete during production and placement and acceptance
checks for final clearance.
Exposed surfaces of concrete shall be kept continuously in a damp or wet
condition for at least seven days from the date of placing concrete in case
of ordinary Portland cement, not be less than 10 days for concrete
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exposed to dry and hot weather conditions, at least 10 days or period

may be extended to 14 days where mineral admixtures or blended
cements are used. Approved curing compounds may be used in lieu of
moist curing with the permission of purchaser.
Reinforcement steel shall conform to relevant IS codes. Lapping / spacing

of reinforcement shall be so staggered that under no circumstances more
than 50% of bars at any cross section shall be lapped. Corrosion
resistance Steel shall be used for the foundations wherever specified in
the technical specification. Sample test for 3% of the number of
mechanical bars grips subject to a minimum of three, shall be carried out
up to the yield strength of reinforcement of bars.
Test shall be conducted for the water tightness of the liquid retaining
structures as per technical specifications, IS 3370 and IS 6494.
All the materials, equipment, processes used in pre cast concrete work
shall conform to the requirements for the cast-in-situ concrete.
If fly ash is used in concrete, source of supply shall be checked for
suitability as per IS 3812 (Part-I). Routine tests for retention of particles
on 45µ sieve and loss on ignition shall be carried out on each lot of fly
ash before its use. The storage of fly ash shall be similar to that of
cement. Separate Silo for fly ash shall be provided in the batching plant.
Validation of Mix design using fly ash shall be carried out by an approved
specialist agency, before start of concrete production.
The acceptance criteria of concrete shall be in accordance with IS 456.
All records of concreting, reinforcement, testing of materials, as-built
dimensions, the details of the rectification, etc. shall be maintained as
given below. Four copies of such record in a bound form shall be
submitted to owner for their record and future reference.
i. Testing data / report of aggregates including petrographic
examination & potential reactivity of aggregate and repeated
temperature cycle tests wherever specified.
ii. Testing records of admixture as per IS-9103 / ASTM C494 including
third party test reports.
iii. Approved scheme for concreting
iv. Hourly records of concreting including pour card
v. Protocol indicating the dimensional tolerance and details of inserts
vi. Records giving the details of rectification giving the location of grouting,
the quantity of grout used at each location, type of grout used
vii. Bar bending schedule
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viii. Location and details of mechanical anchoring used for

reinforcement
ix. Protocol giving the details of checking of reinforcements before

concreting and conformance to the reinforcement details as shown in
the construction drawings
x. Photographs showing the areas where rectification works have been

carried out. Photographs should be taken before and after rectification
xi. Temperature control record of concrete at the time of placement if

applicable.
xii. Detailsof curing, staging and fixing / removal of formwork, checklist for
formwork as per IS 14687 including all machine foundations
xiii. Batching Plant shall be calibrated regularly at least once in a

3 months. Computerized output shall be taken for each batch of
production of concrete. Production and supply of concrete from batching
plant shall conform to the provisions of IS 4926.
xiv. Dimensions (length, cross sectional dimensions, straightness,

squareness, and flatness) and tolerances for pre cast members as per
Technical Specification. Load test on Pre cast members (except pre-
cast tiles to be laid in the reservoir) shall be carried out @ 1% up to
1000 nos., @0.5% from more than 1000 nos. precast members of
one type. The load test shall be carried out as per the provisions of IS-
456 and relevant IS code.
9.4.2.5 Structural steel work
For structural steel works provisions of technical specifications and IS:

800 shall apply. A detailed methodology for structural steel works shall
be submitted by the contractor to Purchaser for approval.
The contractor shall submit the welding procedures specification (WPS),

heat treatment procedures, NDT procedures etc. at least ninety days
before scheduled start of erection work at site. All welding and brazing shall
be submitted to the Purchaser and carried out as per procedure drawn
and qualified in accordance with requirements of ASME Section IX/BS-
4870 or other International equivalent standard acceptable to the Purchaser.
All brazers, welders and welding operators employed on any part of the
contract either in the contractor’s / sub-contractor’s works or at site or
elsewhere shall be qualified as per AWSD1.1/ASME Section-IX or BS-
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4871 or other equivalent International Standards acceptable to the

Purchaser.
The records of welding procedure qualification and welder qualification

test results shall be furnished to the Purchaser for approval. However,
where required by the Purchaser, the tests shall be conducted in presence
of Purchaser / authorized representative.
No welding shall be carried out on cast iron components for repair. All
the heat treatment results shall be recorded on time temperature charts
and verified with recommended regimes.
All Non-destructive examination shall be performed in accordance with
written procedures as per International Standards and as mentioned
elsewhere in the technical specification. The NDT operator shall be qualified
as per SNT-TC-IA (of the American Society of non-destructive examination).
NDT shall be recorded in a report, which includes details of methods and
equipment used, result/evaluation, job data and identification of personnel
employed and details of co-relation of the test report with the job. The
records of RT (Films) and UT (inspection records or printed reports if
possible) shall be documented and produced to Purchaser.
Low hydrogen electrode (AWS E-7018) for welding of High/Medium tensile

steel, for M.S (IS 2062 Gr. A/Gr. B, IS 8500) sections thickness above
20mm shall be used. Preheating and Post weld heat treatment
requirements shall be complied as specified in the technical specification /
approved WPS.
The requirements of pre-heating shall be as below:
Thickness of Welding using Welding using low
thickest part at the other than low hydrogen welding
area of welding/ hydrogen welding electrodes or submerged
heat affected zone electrodes IS 2062 arc welding IS 2062
Upto 20 mm None None
(including)
Over 20 mm to 40 Not allowed 200 C
mm (including)
Over 40 mm to 63 Not allowed 660 C
mm (including)
Over 63 mm Not allowed 1100 C
The following tests/ checks shall be carried out for structural steel works:
TESTS / CHECKS QUANTUM / STANDARD
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Physical and chemical As per relevant codes,

properties of material if supply review of correlated mill
in the scope of contractor test certificates or check
testing in absence of MTC
Ultrasonic test on plates above As per ASTM A435

40mm
Welding procedure & welders AWSD1.1/ASME Section-IX

qualification test or BS-4871 or other
equivalent International
Standards
Fillet Weld
Macro-etch examination on Minimum one joint per built

production test coupons for up beams, columns and
main fillet welds crane girder etc.
Tension member of crane girder Dye penetration test on

25% weld length
All other fillet welds DPT on 5% of weld length

with minimum 300mm at
each location
Butt Weld
DPT 100% after back gouging

on all butt welds
Mechanical testing of Minimum one joint per
production test coupons built up beam, column and
crane girder.
Radiography test on butt 100% RT on butt welds of
welds tension flange (bottom
flange) of crane girders
(In case of failure of any welds
in SPOT/RT or UT the % of 10% RT weld length of
retesting shall be doubled at each welder on butt welds,
that particular location.
Acceptance criteria of NDT on
welds shall be as per AWS D1.1.
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Ultrasonic testing on full 100% UT on the web to

penetration welds (other than flange joint of crane girder
butt welds)
10% UT on other full
penetration joints
Control assembly check in 1st and further every 10th

shop before erection set of identical structure
Dimensional tolerances during as per IS-7215 and IS-12843

fabrication and erection
Surface Preparation and Paint SA 2 1/2 , By elcometer
thickness random after each coat,
each member
9.4.2.6 Painting works
Painting works shall be carried out as per the provisions of technical

specifications. A detailed methodology for painting works shall be
submitted by the contractor to Purchaser for approval.
The methodology for painting works shall broadly contain the source of
approved brand of paints, shot / sand blasting as specified, minimum
acceptable size of shot used for blasting, application of primer,
intermediate coat and final coat, experience of applicator, etc. testing of
painting work and acceptance checks for final clearance.
9.4.2.7 Sheeting works

All bought out items shall be procured from the manufacturer’s
approved by engineer and tested as per relevant IS Codes/ Specification.
Raw material of colour coated sheets shall meet the chemical & physical
properties as per relevant standards / codes referred in the approved data
sheet. It shall be tested for colour match, bare metal thickness, weight of
Z/AZ coating, thickness of painting system, reverse impact, T-Bend
adhesion, scratch resistance, salt spray test for 1000 Hrs and any other
test / properties as specified in the technical specifications. Colour coated
sheets shall be marked with video jet printing at the interval not more than
2m bearing manufacturer’s name, date and time of manufacturing.
Fasteners shall also be tested for 1000 hrs salt spray test as per the
requirement of technical specifications.
Bonded Mineral Wool Insulation shall meet the requirements of thickness,
density, thermal Conductivity, all other tests as per the technical
specifications and IS-8183.
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For sheet installation no gas cut opening shall be allowed at the site,
whenever opening is specified these shall be properly cut in the factory and
shall be filled with lipping / flashing for true shape / dimension etc. The
sheets/ packets shall be stacked neatly clear off the ground at an angle to
the ground, over a base pallet to provide drainage. Water / moisture should
not be allowed to stagnate on surface, or in between layers. This can
damage the coating, and cause corrosion.
9.4.2.7 Tile works
The contractor shall submit the work methodology which shall include
the type, grade and make of materials along with their technical data
sheets, details, etc., clearance from E-I-C regarding leak proofness and
damp proofness of parent concrete surface, surface preparation, the
procedure of application, curing, testing and acceptance.
The tests shall be carried out on acid resistant bricks / tile- water
absorption, compressive strength, resistance to acid, flexural strength,
dimensions and all other tests as per IS 4860 and IS 4457, bitumastic
ready mixed paint as per IS 158, bitumastic as per IS 9510, potassium
silicate, resin type and sulphur type mortars as per IS 4832, part I, II and
III, surface preparation for painting as per IS 2395, epoxy painting shall be
carried for required coating thickness and dry film thickness.
9.4.2.8 Fire proof doors
Fire Proof doors shall be tested for the requirements mentioned in the
Technical Specification. The type test of the doors shall be carried out at
CBRI Roorkee for minimum 2 hours fire rating and its Fabrication drawing
shall also be approved by CBRI, Roorkee. DFT of paint of Fire Proof
Doors and its fittings and fixtures as per BOQ shall be checked. The doors
shall be finished with suitable fire retardant painting system
9.4.2.9 Water proofing
Water proofing shall be tested for water tightness by creating a pond of

water minimum 25 mm height on area of 6 m x 6 m, for the period of 48
hrs on fully dried elastomeric membrane surfaces. Minimum 5% area of the
roof shall be subjected to water tightness test. Such test necessarily be
conducted on vulnerable areas like drain channel / drain head. No
dampness shall be visible on the underneath side of roof (i.e. ceiling),
parapet and well junctions etc. which have been subjected for testing.
The above testing shall be carried out prior to application of wearing course.
9.4.3 Piling Work (If Applicable)
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A detailed methodology for piling works shall be submitted by the

contractor to Purchaser for approval. The methodology shall broadly
contain the method of boring, stability of bore hole, termination criteria,
tests / checks for termination level, fabrication of cage, cage lowering,
concrete batching / mixing, transportation, placing, recording of the time of
construction operations, method of conducting initial and routine load
tests, testing and sampling of concrete during production and placement
and acceptance checks on piles for final clearance.
The piling works shall be executed as per the technical specifications,
approved drawings, relevant codes / standards, FQP and BOQ. In addition
to the requirements of technical specifications, the following shall also be
ensured while execution of piling works:
a) Time gap between completion of pile boring and start of concreting

should be kept to the minimum. However, the maximum time gap shall
not be more than 6 hours.
b) Muck Debris should be removed from the pile bore by air lift
technique (by keeping the tremie & air pipe as close as to bottom of
pile bore) i.e. after completion of boring, after completion of SPT
(wherever applicable), after lowering reinforcement cage, but before
start of concreting.
c) Density of bentonite slurry shall be checked from the sample taken

from the bottom of pile bore (not at 1.0 m above the bottom of the pile
bore)
d) While lowering the R/F cage into the pile bore, two hooks shall
always be used to ensure balanced/symmetrical insertion of cage into
the pile bore.
e) Concrete cover blocks at the junction of two R/F cage shall be

ensured before lowering the second segment.
f) Surge concreting of about 1.0 cum shall be ensured at the start of

concreting
(i.e. in the first pour), by suddenly allowing to fall through the tremie
pipe from the funnel. This will help in displacing left out muck/debris in
the pile bore (by the impact).
g) Continuous feeding of concrete shall be ensured by deploying at

least two transit concrete mixers (if required to be deployed) and
mixing done through concrete batching plant (if deployed). Cold joints
in the pile shall be avoided.
h) In a pile group, SPT shall be carried out at termination level in the
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pile, taken up first.
i) Bentonite slurry circulation to be ensured from start of boring to start of

concreting.
j) Properties of drilling mud shall be checked prior to commencement

of the piling work and thereafter, minimum once per week or as found
necessary by the engineer. One sample consisting of 3 specimens
shall be tested for the above.
k) Low strain pile integrity test on all job piles and test piles shall be
conducted as specified in the Technical Specification. This test shall
be suitably used to identify the piles for routine tests. High Strain
dynamic test shall be done as per the technical specification. The
frequency of the test shall be as per the BOQ
l) For Working Piles: Minimum one sample consisting of 6 test cubes

shall be made for first ten piles. Out of these 3 shall be tested for
7 days’ cube strength and 3 for 28 days cube strength. Minimum
one sample of 6 test cubes for every 25 nos. of piles shall be tested,
out of these 3 shall be tested for 7 days’ cube strength and 3 for 28
days’ cube strength
9.4.3.1 Pile load test
Pile load testing shall conform to the requirements of IS-2911 (Part IV)
and the technical specification. Initial load tests as specified in the contract
documents shall be conducted to assess the safe load carrying capacity of
pile before start of work. To verify the load carrying capacity of the
working piles, routine load test shall be conducted.
Pile load-testing procedure and the test setup / scheme shall be
submitted for approval of Purchaser.
All the gauges and instruments shall be calibrated before the start of the
tests on test piles and working piles and the calibration record shall be
verified before start of execution of the test.
9.4.4 Water Supply, Drainage & Sanitation
Material used for sanitary and plumbing fittings and fixtures shall conform
to and be tested as per the requirements of relevant IS Codes specified
in t echnical specification.
The obstructions in sewer lines shall be checked by inserting a smooth
ball, of diameter 13 mm less than the pipe bore at the high end of the
sewer or drain. If absence of any obstructions, such as yarn or mortar
projecting through the joints, ball shall roll down the invert of the pipe and
emerge at the lower end. The straightness shall be checked by means of a
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mirror at one end of the line and lamp at the other. If the pipeline is
straight, the full circle of the light may be observed. The mirror will also
indicate obstruction in the barrel, if the pipeline is not straight.
The service pipes shall be slowly and carefully charged with water, allowing
all air to escape avoiding all shock or water hammer. The service pipe
shall then be inspected under test / working condition of pressure and flow,
when all draw-off taps are closed. The service pipes shall be checked for
satisfactory support and protection from damage, corrosion and frost.
9.4.5 Architectural & Misc. Works
Material used for sanitary and plumbing fittings and fixtures, floor finishes
and allied work shall conform and tested as per the requirements of
relevant IS Codes specified in Purchaser technical specification.
Fabricated item like metal doors, windows, ventilators, louvers, rolling
shutters and grills etc. shall be checked for correctness of locations and
smoothness of operation and fixtures. All controls and locking devices shall
give fault free performance. Door and window shutters shall operate without
jamming. The clearance at head and jamb for door shutters shall not
exceed 1.5 mm. For double leaf doors, the gap at the meeting stiles shall
not be more than 2.5 mm.
Materials used in glass and glazing shall be procured from source
approved by Purchaser and shall conform to the requirements of the
Technical Specification and IS Codes.
False ceiling panels shall be best quality material in thickness and
properties called for in the specification / schedule of items. Material Test
Certificate to be submitted before bulk supply.
All bought items covered in the scope of contract shall be procured from
sources approved by Purchaser and shall conform to the requirements of
the technical specifications and referred standards /codes.
9.4.6 Pre Cast Concrete Works
i) All the materials used in Pre cast Concrete work shall be tested and
conform to the requirements of IS codes and Purchaser Tech.
Specification.
ii) Concrete mix for Pre cast members shall conform to IS-456-2000.
iii) All relevant QA requirements pertaining to cast in-situ concrete
shall be applicable.
iv) Load test on Pre cast members shall be carried out for the type of
members as decided by Purchaser Engineer as per IS-456-2000.
v) Pre Cast Concrete member shall be checked for dimensions (length,
cross sectional dimensions, straightness, squareness, and flatness)
and tolerances shall be as per Purchaser Technical Specification.
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QUALITY ASSURANCE PLAN

9.1 MECHANICAL SYSTEMS

9.1.1 Flue Gas System

a) Pre-formed fibrous pipe insulation and LRB mattresses/ sections of

b) For resin bonded mineral wool insulation, testing shall be carried

d) Type tests except thermal conductivity shall be regularly carried

e) Type test for thermal conductivity shall be carried out by the

i) All the dampers shall be subjected to operational test/checks.

ii) Gas tight dampers shall be subjected to shop leakage test to

iii) All dampers shall be checked for sealing dimensions to establish

9.1.1.4 Structure, Ducts, Hoppers

ii) Visual inspection of all welds shall be performed in accordance with

iii) NDT requirements of structural steel welds shall be as under:

a) 100% RT/UT on butt-welds of plate thickness ≥ 32mm.

b) For plates of 25mm ≤ thickness<32mm: 10% RT and 100% MPI.

ii) Visual inspection of all welds shall be performed in accordance with

iii) NDT requirements of structural steel welds shall be as under:

a) 100% RT/UT on butt-welds of plate thickness>= 32mm.

b) For plates of 25mm<=thickness<32mm-10% RT and 100% MPI.

c) For plates of thickness <25mm-10% MPI/LPI.

9.1.2.2 Spray Nozzles

9.1.2.4 Other Critical Equipment

Checks/ NDTs shall be done as per relevant Indian Standards or equivalent

9.1.3 Limestone & Gypsum Handling System

i) All plates equal to or above 25mm thickness shall be ultrasonically

iii) Following minimum NDT requirements to be ensured for welds:

a) Butt welds UT/RT and 100% MPI/DPT.

b) Fillet Welds 10% MPI/DPT.

iv) Crusher rotor to be dynamically balanced. Procedure to be submitted for

9.1.3.2 Metal Detectors

i) Functional test including sensitivity, Burn in test, operation of liquid

9.1.3.3 Belt Conveyor System

a) The maximum size of a repair shall be limited to a size equivalent to

b) Small local repair by dough filling of size 25mm x 25mm to a limited

a) Cord dia and breaking strength

c) Dynamic cord pull out test

d) Cord dia, pitch and number of cords

9.1.3.3.3 Belt vulcanizing machine

i) Check for tensile strength shall be carried out on a sample vulcanized

i) In addition to chemical, mechanical, hardness, microstructure as per

9.1.3.3.5 Pull chord & belt sway switches

The following tests shall be carried out:

i) Over all dimension and functional test.

ii) HV & IR test

iii) Degree of protection test report.

The following tests shall be carried out:

i) Burn in test at 50 deg C for 48 hours shall be done for electronic

ii) Over all dimension and functional tests.

iv) Degree of protection test

9.1.3.3.7 Drive Equipment

(b) MPI to be carried out on Gears/Pinions after machining. Case

ii) Flexible Coupling

(a) Ultrasonic testing shall be conducted on forgings for gear sleeve

iii) Fluid Coupling

(d) All couplings to be run tested at shop on no load.

(e) Check for temperature rise, torque-speed, torque-slip characteristics

9.1.3.3.8 Belt Scales

i) Mounting arrangement/Overall dimensional check shall be carried out

iii) All electronic modules shall be subjected to burn in test at 50 Deg C

iv) General check for load cell shall be carried out.

v) Test report for degree of protection on enclosure shall be furnished.

vi) Accuracy/performance check shall be demonstrated at site.