PROJECT QUALITY ASSURANCE

VOLUME- III

PROJECT QUALITY ASSURANCE Volume –III Rev. 02

Sterlite Power Grid Ventures Ltd. Page 1
1.0 General Quality Assurance requirements
1.1 The contractor shall develop a quality assurance plan and program as per
ISO 10005 – 2005 or latest edition and submit it for SPGVL review and
approval. The document will be a binding document for ensuring the
project quality throughout the project execution.
1.2 The following assurance documents shall be submitted for approval before
commencing of any work.
a. Project Organization.
b. Quality assurance organization for Supply inspection, field inspection
& corporate.
c. Project Quality Plan
d. Categorization of material critical to Quality.
e. Construction manual and relevant procedure which shall include.
1. Foundation concrete
2. Structural erection
3. Stringing – Conductor & OPGW
4. Field final checking
5. Pre commissioning & commissioning
f. MQP for all the equipment’s
g. Field Quality Plan
h. Store Management & Store layout plan
i. Inspection checklist for field quality which shall include foundation,
structural erection, stringing, pre commissioning and commissioning.
j. Work instruction for key activities.
k. Final documentation procedure.

1.3 Contractor shall nominate project quality Lead and Quality coordinator
who will be single nodal personnel for all communication and
coordination.

1.4 The Contractor shall ensure the vendors are proposed during the pre-bid
discussion. The credentials of such vendors shall be approved by SPGVL.
It is the contractor’s responsibility to ensure that the vendors are finalized
before signing of the contract.
1.5 In case of any additional vendor approval derived after awarding the
contract, the following minimum requirement shall be met by the vendor.
Also contractor should justify the reasons for additional vendor proposal
with clear documentary evidences and audit report performed by
contractor.

a. Valid ISO 9001 / 14001 certifications

b. BIS or other product certification as applicable

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 c. Minimum 10 years in supply of product proposed.
d. Should have supplied order to major public sector & private
sectors like PGCIL / NTPC / BHEL / Reliance / Adani etc...
e. In house manufacturing & testing facilities.

1.6 Equipment Categorization plan guidelines:

a. Category – I: Critical Items / Equipments are covered under this

category. SPGVL will be involved during Stage / Final inspection.
b. Category – II: Important items / Equipments are covered under this
category. Contractor will witness stage & final inspection.
SPGVL will review the witness report and provide dispatch
clearance.
c. Category – III: Non-Critical items are covered under this category.
SPGVL & contractor will review the manufacturer test reports and
provide clearance for dispatch.

** Any Item not covered in the list shall be discussed and finalized
during Kick Off Meeting.

MQP:
a. For category I & II items, contractor should submit MQP for
SPGVL review and approval.
b. For category III items, contractor will approve the MQP and
submit to SPGVL for information.
c. Final “Factory Acceptance Test” for Category I & II items as per
agreed categorization plan – Witness Point
d. Type test: If valid type test report is not available (or) combination
of the new manufacturer products - Witness Point

FQP:

a. Raw material source approval – Hold Point

b. Slump Test – Witness Point
c. Cube Compression test – Witness Point
d. Foundation Final Inspection & Clearance for Tower Erection –
Hold Point
e. Welder Qualification – Hold Point
f. TFR (Tower Footing Resistance) – Witness Point
g. Tower completeness inspection & Clearance for Stringing – Hold
Point
h. Visual & IR value test of Insulators before hoisting – Witness point
i. Stringing completeness including Jumper and all accessories –
Hold Point

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 j. All critical clearances (Jumper, Ground, Earth wire & Tree) – Hold
Point
k. Line Healthiness (Signature Analysis & Meggar test) – Hold Point
l. Project Quality Documentation – Hold Point

Witness Point – Identified point in the process where the Owner

Engineer or Owner appointed TPIA may witness. The activities
however may proceed.
Hold Point – This is a mandatory verification point beyond which a
work cannot proceed without approval by the Owner Engineer. The
work cannot proceed until the Owner Engineer is able to verify the
quality of the completed work and releases the Hold by means of
written approval.

1.7 The procedure for purchase of materials, parts components and selection
of sub-Contractor’s services including vendor analysis, source inspection,
incoming raw material inspection, verification of material purchases etc.
shall be submitted for Owner approval

1.8 Valid Type test reports for combination of materials as applicable shall be
submitted to Owner for review. If any combination of materials differs,
type test shall be carried out before taking mass production.

1.9 The contractor shall be responsible for all supply materials inspection
irrespective of category and the inspection and certification of supply
materials should be from any of the following inspection agencies.
a. Bureau Veritas
b. Tata Project Limited
c. DNV
d. TUV Nord

1.10 The contractor shall appoint one FQA in-charge with 15 years’ TL
experience at project site, one field quality graduate engineer with
minimum of 10 years of TL experience with 3 technicians of 5 to 8 years’
experience shall be deployed for every 75 KM of stretch to ensure all the
activities performed at site are as per the specification and FQP.

1.11 The cube compression testing machine shall be installed at every 100 KM
for cube testing. The same shall be calibrated and records shall be
maintained for Owner verification.

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2.0 Inspection & Testing at manufacture place

2.1 Inspection by Owner: In respect of the inspection/ testing stages envisaged

as Witness/ Hold point by the Owner, the Contractor shall raise inspection
call to the Owner with advance notice period of 7 working days. In case of
Overseas inspection 30 days advance notice shall be provided.

2.2 The Contractor shall provide to the representatives of Owner, at all

reasonable time, a free access to the manufacturing works and related
premises of the Contractor and vendors.

2.3 The Contractor shall keep the Owner informed in advance about the time
of starting and of the progress of manufacture and fabrication of various
tower parts / equipments at various stages, so that arrangements could be
made for inspection.

2.4 The acceptance of any part of items shall in no way relieve the Contractor
of any part of his responsibility for meeting all the requirements of the
Tender Specification.

2.5 The norms and procedure of sampling for lot testing shall be as per the
ISO 2500. The Level of acceptance shall be discussed with the Owners
and agreed upon.

2.6 The contractor representative shall associate in the inspection with

Owner’s inspector.

2.7 The contractor shall be intimate to owner in writing before 24 hours, in

case of inspection rescheduled. Otherwise the cost of QC inspector visit
shall be recovered from the contractor monthly bill.

2.8 Any repairable defect identified during fabrication / manufacturing which

shall be made rectified only with the consent of the Owner.

2.9 The Contractor shall dispose any non-conformity observed in the products
or services only with due approval from the Owner.

2.10 Material release note will be issued by the representative of the Owner
after satisfactory compliance of inspection and testing requirements. For
further issuing of dispatch instruction will be issued by the SCM or
Project Management. This will be agreed during the KOM with the
contractor.

2.11 In case of any dispute in acceptance criteria, the Tender specification and
Technical specification will be the binding references.

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 2.12 Any material testing shall be carried out at Owner approved NABL
accredited laboratory only.

2.13 The manufacturer shall ensure only calibrated testing equipment’s are
used for conformity test.

2.14 Type Tests shall mean those tests which are to be carried out to prove the
process of manufacture and general conformity of the material to this
Specification. These tests shall be carried out on samples prior to
commencement of commercial production against the order. The Supplier
/ contractor shall indicate his schedule for carrying out these tests.

3 Field Quality Assurance

3.1 All field quality activity shall be carried out in accordance with Owner
approved field quality plan. All field check details shall be recorded /
documented in approved field quality check list at site and duly approved
by SPGVL field quality engineer at site.

3.2 The Contractor shall provide relevant technical inputs and documents to
the Owner for activities related to Field Quality at project site in line with
the recommendations, standards and practices of the original equipment
manufacturers.

3.3 Construction raw material source approval shall be taken before starting
the construction work at site.

3.4 The contractor shall provide the store management system and Store
layout plan for SPGVL approval before starting of the construction.

3.5 The credentials of the subcontractors engaged at site shall be provided to

Owner for approval. The contractor shall ensure all the subcontractors are
evaluates as per evaluation process as defined in ISO 9001.

3.6 The Civil foundation requirements shall be as per IS 456 latest edition.
The minimum and maximum temperature requirement of concrete during
pouring is to be as per code. The procedure shall be submitted for
approval before starting of the concrete.

3.7 The contractor shall be responsible and accountable for the following.

i. Foundation checks and documentation;

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 a. Pit marking, pit excavation, PCC, template alignment,
reinforcement and formwork.
b. Slump check
c. Cube sample
d. Earth strip fixed (if pipe earthing).
e. Curing and back filling.

ii. Tower erection checks and documentation;

a. All structure members are fixed on their positions as per approved
drawing and no fabricated, damaged and rust member is erected.
b. All Bolt & nuts, spring and pack washers are used as per size /
approved drawing and tightened.
c. Tower tightness as per “Torque schedule”
d. Take welding up to Bottom X – Arm.
e. Tower verticality.
f. Tower earthing.
g. Tower footing resistance test before and after earthing connection.
h. Inspection report shall be submitted to owner FQA team once
completed the stretch or 10-15 towers. Owner FQA team shall be
inspected after receipt of inspection call from contractor FAQ team.

iii. Stringing checks and documentation;

a. The contractor shall be started stringing once all foundation and
tower related NCRs are closed of that stretch.
b. Insulator, hardware, earth wire, OPGW and conductor installation
checks should be done before and after as per owner approved FQP.
c. Each insulator visual and IR test at site.
d. Hardware and conductor visual check at site.
e. Scratch, cut, repair sleeve, mid span joint checks.
f. Clamps compressing witness.
g. Sag and tension measurements checks
h. Electrical clearances ground, phase, jumpers, tree etc.
i. Insulator damages and locking pins etc.
j. Fixing of earth-links.
k. OPGW pre installation OTDR checks
l. OPGW OTDR check after installation.
m. OPGW every joint splicing loss checks.
n. OPGW OTDR checks for every 60 km stretch and trace reports.
o. OPGW fiber continuity check of both ends and OTDR check.
p. Photo graphs to be submitted the contractor wherever conductor and
earth wire joints and repair sleeves are installed.

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 iv. Sub Station Equipments installation:
a. Foundations as per drawing and applicable code requirement.
b. Equipment installation checks should be done before and after as
per owner approved FQP.
c. Stage inspections as per approved FQP
d. Pre-commissioning & Trial run checks as per FQP.
e. Commissioning checks as per FQP.

3.8 The cubes for casting shall be drawn as per IS 456 considering the volume
of concrete on day basis as detained in code.

3.9 Curing of concreting shall be as per IS 456 and only OPC shall be used
for concreting.

3.10 All stage of construction is to be certified by the respective Quality

Assurance and control team of the contractor before proceeding to the
next stage. The report shall be submitted to the Owner for review and
approval.

3.11 All construction & supply bills of contractor will be certified by Owner
Field Quality Engineer.

3.12 The Owner or his duly authorized representatives reserves the right to
carry out Quality Audit and quality surveillance of the systems and
procedures of the Contractor's / his vendor's Quality Management and
Control Activities.

3.13 The contractor shall carry out technical audit during construction through
in-house or through external agencies every three months. The report shall
be submitted to Owner for review. The audit shall cover all the aspects of
construction including foundation, tower erection, stringing activities,
contractual obligations, applicable process & procedures, FQP &
procedures implementation, material handling, material storage and
technical competent manpower availability etc…

3.14 Owner will conduct Technical audit of manufacturing facilities and site
function of the contractor. If any non-conformity or observation is noted
the same shall be implemented or resolved within 2 days of notification.
In case of any critical non conformity the work shall not proceed without
taking corrective and preventive action.

3.15 If any NCR observed, the contractor shall propose corrective & preventive
action, analysis the root cause and submit the detailed report.

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 3.16 The contractor shall conduct quality tool box every fortnight at site to
provide awareness to the workforce and supervisors on the importance of
construction quality. The records of such meeting shall be maintained and
owner shall review the same on monthly basis.

3.17 The contractor shall generate monthly quality report detailing all the
activity performed at site & submit the same to SPGVL Quality Head on
or before 5th of every month.

3.18 The contractor shall submit the Project quality assurance documentations
after project completion including Mechanical completion report, as built
drawing, pre commissioning and commissioning reports. The format and
detailed content of the report shall be discussed with the owner during
KOM.

3.19 Implementation of QA Management System shall be monthly reviewed

jointly by the Contractor and the Owner at Corporate and Project site
level. The meeting shall be attended by contractors Project Manager,
Construction Manager and senior management from Quality Assurance
department.

4 Final Documentation
4.0 The contractor shall submit the Project Quality Assurance document
dossier after project completion. The format and detailed content of the
report shall be discussed with owner during KOM. The Project Quality
Assurance document dossier should contain the following documents.

a. As built drawing (Both Manufacturing & field drawings)

a. Material categorization plan
b. Approved vendor list – Item wise
c. Approved MQPs
d. All inspection reports as per MQP – Item wise & Inspection
call wise
e. Material Release Note
f. Approved FQP
g. All Field check list & inspection reports as per FQP
h. Approved source List – Item wise
i. Signature Analysis report
j. Pre-Commissioning & Commissioning check list
k. Copy of MoM

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 5 Standard Formats
Manufacturing Quality Plan:
Title Sheet:

Control checks content sheet:

Manufacturer’s Customer: Project: Item : M.Q.P No & Rev.: Valid from:
Details: Valid up to:

S Components Type of Quantum of Reference Acceptance Type of Manufacturer Supplier Client/ Remarks
N / Operation & check check / document Criteria record TPI
o. Description sampling
of test with basis

Field Quality Plan:

Title Sheet:

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Field checks content sheet:

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