Quality Assurance Tests- Final

7/23/2019 Quality Assurance Tests- Final

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IQA for USAIDs Stabilization Program Activities in FATA and KPQuality Assurance Plan - Annexure G

30 April 2015 (1) Halcrow Pakistan

Annexure G Quality Assurance Tests

Protocols to be followed with Construction Contractor (FWO) Staff

At present the construction contractor has set up material testing laboratories at Hathala on DIK-Tank

road, at Wana on Wana Shakai Makin road and at Miranshah on Bannu Miranshah Ghulam Khan

road. The laboratories are fully equipped to perform tests to ascertain the quality of road construction

materials for all components of road/bridges. HPK is in the process of setting up its material testing

laboratory in D.I. Khan and Bannu with USAID provided equipment to carry out independent

testing. Certain tests have to be performed at approved outsourced laboratories where such testing

facilities are not available at Construction Contractor or HPK laboratories. The following is expected

to be the distribution of testing which will be practiced in the field and laboratories. HPK staff will

collect samples during their field visits/inspections and conduct the tests at established frequency at

Construction Contractor, HPK and approved outsourced laboratories for the systematic monitoring to

ensure that the product is meeting the requirements that have been established for quality checks.

Non-destructive tests will be carried out on site. This will include the Schmidt Hammer and Ultra

pulse velocity tests where required.


2/22



Earthworks- Removal of excess soil and

debris and the preparation of sub gradefor sub base laying.

Co-ordination with construction contracto

on construction program

QA Monitors to check against design data

Checking 5 X-section/KmSoil Classification1 per 5 Km or as / when required.

Compaction/FDT 2/km

CBR 1 per 10 km & Site Photos

BASELINE MEASURE

Procedure for verifying the quality of material and works (Roads)

Granular Sub Base and Agg. Base course

Selected inert well graded material to

form a level.

QA Monitors to undertake & record

Specification Check (i-e) wt/Area 1 per 3 Km

Wearing Course- Mixture of Bitumen, Fine

& coarse aggregate/ Asphalt.

Prime Coat- Mixture of Bitumen &

Kerosene to keep base course intact.

IQA Staff to coordinate with construction

contractor with respect to defined milestones to

facilitate visits by QA Monitors/Supervisor.

QA Monitors to ensureGradation of Aggregate 1 per Km

Thickness 5 per Km

Extraction Test 1 per 5Km

Sam lin for stabilit 2 er Km

QA Monitors to undertake & record

Thickness Check 5/km

Sieve Analysis 1 per 3 km or as

required

Proctor Test 1 per km

FDT/Compaction Test 3/km or asrequired

CBR, Sand Equivalent 1 per 5Km

Key Outputs during Construction:

Field Inspection Form - Three copies

Bi weekly - Generated from South Office - (DI Khan)

Monthly Report - Generated by QA Manager - (Peshawar)


3/22



Foundation upto Plinth

level

Co-ordination with construction

contractor on construction

program

QA Monitors to check against design data:

Width and depth of foundation 4 per building

Bearing capacity 1 for Foundations

Concrete Compressive Strength 1 Set for each grade of concrete

Reinforcement steel Complete Physical tests for each size

of bar from stock.

Bricks/Blocks Strength 5 Bricks/ 10,000 or change of source /as & when re uired.

Procedure for verifying the quality of material and works (Buildings)

Upto Walls bands

beams level

QA Monitors to check against design data:

Bricks/Blocks Strength 5 Bricks/ 10,000

4 Blocks per 10,000

Masonry Mortar Ratio verification Compressive strength as per requirement

Concrete Compressive Strength 1 Set for each grade of concrete for each part

of structure.

Reinforcement steel Complete Physical tests for each size of bar

from stock.

Upto roof slab level

IQA Staff to coordinate with construction contractors with respect to

defined milestones to facilitate visits by QA Monitors/Supervisor.

QA Monitors to ensure:

Thickness of slab, concrete cover to Reinforcement

Concrete Compressive Strength 1 Set for each grade of concrete

Reinforcement steel Complete Physical tests for each size of

bar from stock

QA Monitors to ensure;

Surface Finishing, Painting, Joinery and Electrification works.

Finishing/Completion

Level



Bi weekly - Generated from North Office - (Swat)

Monthly Report - Generated by QA Manager - (Peshawar)


4/22



Proposed IQA Process (Power Sector)

(2)Soil Investigations.(3)Design Basis & Standards.

(4)Detailed Construction Drawings.

(5)Final Bills of Quantities

(6)Final Cost Estimates & PC-1

(7)Final Technical Specifications

(8)Phase 1 Sco e of works

Procurement program.

Information release schedules

Pre-construction Process (Power)

Master Design program.

Master Construction Program IQA Team to review all documentation.

Review shall include checks on Design

standards adopted, Cost estimates,

Construction drawings and Specifications

meet the regulatory requirements. The

IQA process shall be based on the

detailed Construction program with

regard to a key performance indicator

been linked to the percentage completion

of the works. The construction scheduleshall form the baseline measure.

(BASELINE & OPERATIONAL

MEASURE)

KEY OUTPUTS:

A pre-construction as is report (attached) that

shall form a fundamental part of the Baseline

Measure.

QA Monitors/supervisor will be deployed to

ascertain the As is situation prior to

construction. Data collection shall include:

1. Existing distribution lines & conditions

2. Existing Grid stations & Conditions

Testing/Inspection of material in

manufacturing premises C.E design

NTDC/C.E M.I PEPCO and witnessed

by IQA Representatives.


5/22



Earthworks- Removal of excess soil and

debris and the preparation for sub base

laying for foundation.

Co-ordination with Construction contractor

on construction program

QA Monitor/Supervisor to check the work against the

approved drawings and start on site.

( BASELINE MEASURE)

Procedure for verifying the quality of material and works Grid station & Transmission Lines

(Power)

Electrical Material procurement Schedule

QA Monitor/Supervisor to check and witness

Material Type against original order placement.

QA Monitor to check the Inspection Certificate.

Installation on site

Receipt of Material on site.

QA Monitor/Supervisor to check the date of order

placement.

IQA Staff to coordinate with construction contractor/

FATA Secretariat with respect to defined milestones to


QA Monitors/Supervisor to check that the Electrical

Materials been Installed on site as per the approved

drawings & Certifications by (Chief Engineer

Design (NTDC) PEPCO Lahore).

QA Monitor/Supervisor & QA Manager to check

the Material Schedule, prior to order placement.

Material Placement of shipping order

(Approved by Design NTDC/Material

Inspection PEPCO



Bi weekly Progress Report - Generated from South & North Office (DIK and Swat)

Monthly Progress Report - Generated by QA Manager - (Peshawar)

Testing & Commissioning


6/22



Possession of Site. Site survey check. Soil

Testing, Levelling

Co-ordination with Construction contractoron construction program

QA Monitors/Supervisor to check the work against the

approved drawings and undertake independent level and

geometrical checks.

BASELINE MEASURE

Procedure for verifying the quality of material and works (Grid Station)

Excavation of main unit Foundations.

Excavation of Power Transformer FoundationsExcavation of Cable laying foundations.

QA Monitor/Supervisor to check remaining

electrical components against certifications.

Laying of control & Power Cables

La in of 132kV Bus Bar

Installation of remaining proprietary

elements

QA Monitors/Supervisor to check Transformer

types against specifications and drawings.

IQA Staff to coordinate with construction contractor /FATA Secretariat with respect to defined milestones to


QA Monitors/Supervisor to check that the

Electrical Materials been Installed on site as per the

approved drawings & Certifications and carry out

independent verifications & testing.

QA Monitors/Supervisor to check depth of

excavations arrange soil sample for testing at DIKPeshawar University

Installation of Power Transformer

Installation of Current Transformer

Installation of potential Transformer



Bi weekly Progress Report - Generated from South & North Office (DIK and Swat)

Monthly Progress Report - Generated by QA Manager (Peshawar)

Connecting all equipments in the switchyard

Testing and earthing of all equipment


7/22



Procedure for verifying the quality of material and works (Transmission Line)

Coordination with Construction

contractor on construction program.

Possession of site. Site survey check

Soil testing leveling

Excavation of tower foundation and

concreting of stubs

Erection of towers

Laying/sagging of conductor on

towers

Jump ring and installation of

dampers

Testing/commission of transmission

line

IQA Staff to coordinate with construction

contractor/ FATA Secretariat with respect to

defined milestones to facilitate visits by QA

Monitors/Su ervisor.

QA Monitors/Supervisor to check the work

against the approved drawings and

undertake independent level and geometrical

QA Monitors/Supervisor to check the depth

of excavations arrange soil sample for

testing at DIK/Peshawar University

QA Monitors/Supervisor to check electrical

components of transmission line against

s ecifications.


Electrical Material been installed on site as

per the approved drawings & Certifications

and carry out independent verification &

Testing.



Bi weekly Progress Report - Generated from South & North Office - (DIK and Swat)



8/22



Procedure for verifying the quality of material and works (Rehabilitation 11kV/33kV)

Co-ordination with constructioncontractor on Construction Program

Site survey and dismantle/Removal of

damaged items.

Possession of site and

excavation/Concreting of HT/LT pole

foundations.

Installation of transformers and

remaining proprietary elements.

Connecting/Jumpering of transformers

and conductors.

Earthing/Testing and energization of all

equipments.

IQA Staff to coordinate with constructioncontractor (FWO) with respect to defined

milestones to facilitate visits by QA

QA Monitors/Supervisor to check the work

against the approved drawings and

undertake independent level and

QA Monitors/Supervisor to check depth of

excavations arrange soil sample for testing

at DIK/Peshawar University

QA Monitors/Supervisor to check

transformer types against specifications and

drawin s.

QA Monitors/Supervisor to checkremaining electrical components against

certifications.


Electrical Materials been installed on site

as per the approved drawings &

Certifications and carry out independent

verifications & testing



Bi weekly Progress Report - Generated from South & North Office - (DIK and Swat)



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Ongoing construction

Filed Offices

QA Monitors verbally informs and hands over a

copy of Field Inspection form to QA Engineer. QAEngineer reports to QA Manager.

Non Compliance Monitoring Process

Instruction given to site and remedial works

carried out

USAID COR

USAID initiates instruction to FATASecretariat / PaRRSA and informs clients

rectification of defects.

CONSTRUCTION CONTRACTORS

Construction Contractor receives written

instruction from USAID/Clients for

rectification.

PESHAWAR PROJECT OFFICE

COP checks non-compliance report for onwardsubmission to USAID COR.

QA Field Monitor identifies non-compliance either in

Design or Construction. Non-compliance is noted in

Field Inspection form.

(BASELINE MEASURE)

PESHAWAR PROJECT OFFICE

QA Manager reviews report & analyses the non-

compliance and forwards to construction

contractor and COP.

QA Monitors re-checks the rectified work.


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G-1 QA Tests for Roads

Specified Tests Frequency

Earth works

Proctor test to be done in site lab ( I per 5 Km)

Sieve analysis to be done in site lab ( I per 5 Km or as required)

FDT 2 per KM

Soil

Classificationto be done in site lab (1 per 5 Km or as required)

CBR to be done in site lab (1 per 10 Km)

Granular Subbase & Agg. Basecourse

Proctor test to be done in site lab ( I per Km)

Sieve analysis to be done in site lab ( I per 3 Km)

FDT to be done in site lab ( 3 per Km)

CBR, Sand

equivalentto be done in site lab (1 per 10Km or as required)

Los Angeles

abrasion value

to be done in site lab if equipment is available (1

test for 10 Km or as required)

Bitumen / Asphalt

Grade of

bitumenMin 1 test for one road project

Sampling for

stabilityone sample per 5 Km.

Gradation ofaggregates as above

Spray rate For each work day

Temperature During each work day

Soundness test of

aggregates

to be done in site lab if equipment is available (1 ~

2 tests for each road project)

Los Angeles

abrasion value

to be done in site lab if equipment is available (1 ~

2 tests for each source of material)

Coring from

pavement forthickness and

compaction

Four samples per km


11/22




Concrete

Bricks

Blocks

Masonry Mortar

Compressive

Strength

(Cylinder)

Slump Test

Strength,

Absorption, Size

Strength,

Absorption, Size

CompressiveStrength

After 10 , 30 & 50 Cu.m for column, wall and large

pours or minimum one set for each grade ofconcrete as and when required.

Hourly

5 bricks / 10,000

4 blocks / 10,000

From plaster/brick laying, Monthly

Steel Complete

physical test

(Bend,

elongation%,

yield & Ultimate

strength)

For each size of bar from source / shipment.

Structures

X-drainage (Culvert/Cause way)B/walls

R/walls

Side drain

Gabions / Protection works

Foundation

checking(Ht & Width)

Masonry work

measurement

3 per Km2 per Km.

2 per Km

3 per Km

2 per each location

Pavement Marking / studs

Sign boards

Guard Rail

Design

conformity /

specification

02 Location per km

Every 10thsign board

Every 5thGuard Rail

Location of Laboratories for Testing

Component Tests Conducted by Laboratory Field

Earth Work

Proctor test

Halcrow/Constr

uction

Contractor joint

Construction

Contractor

Sieve Analysis

Halcrow/

Construction

Contractor joint

Construction

Contractor

/Halcrow


12/22



FDT

Halcrow/

Construction

Contractor joint

Field

Classification

Halcrow/

Construction

Contractor joint

Field

CBR

Halcrow/

Construction

Contractor joint

Construction

Contractor

/Halcrow

Granular Sub-base &

Aggregate. Base course

Proctor test

Halcrow/

Construction

Contractor joint

Construction

Contractor

Sieve Analysis

Halcrow/

Construction

Contractor joint

Construction

Contractor

/Halcrow

FDT

Halcrow/

Construction

Contractor jointField

CBR, Sand

equivalent

Halcrow/

Construction

Contractor jointFWO/Halcrow

Los Angeles

Abrasion value

Halcrow/

Construction

Contractor joint

Construction

Contractor Lab

Bitumen Asphalt

Grade of

Bitumen

UET

Peshawar/Taxila Out Source Lab

Sampling for

Stability

Halcrow/

Construction

Contractor joint

Construction

Contractor

/Halcrow

Gradation of

Aggregates

Halcrow/

Construction

Contractor joint

Construction

Contractor

/Halcrow

Spray rates

Halcrow/

ConstructionContractor joint

Field

Temperature Halcrow Field

Soundness test

of aggregate

Halcrow/

Construction

Contractor joint

Construction

Contractor Lab

Los Angeles

abrasion value

Halcrow/

Construction

Contractor joint

Construction

Contractor Lab

Coring frompavement for

Halcrow/

ConstructionContractor Joint

Field


13/22



thickness &

compaction

Concrete

Compressive

Strength

(Cylinder

/Cube)

Halcrow/Construction

Contractor joint

ConstructionContractor /Out

Source

Slump test Halcrow Field

Strength,

Absorption

(Bricks)

Halcrow/

Construction

Contractor joint

Construction

Contractor /Out

Source

Size (Bricks)

Halcrow/

Construction

Contractor joint

Field

Strength,

Absorption

(Blocks)

Halcrow/

Construction

Contractor joint

Construction

Contractor /Out

Source

Size (Blocks)

Halcrow/

Construction

Contractor jointField

Compressive

Strength of

masonry mortar

Halcrow/

Construction

Contractor joint

Construction

Contractor /Out

Source

Steel

Complete

Physical test (%

elongation,

bend, yield and

ultimate

strength)

Out Source Lab

In addition the job mix formula for asphalt concrete will be carried out jointly at the Construction

Contractor laboratory. The tests related to the mix design will be supervised jointly and approved by

the material engineer/technician of Construction Contractor and Halcrow.

The concrete mix design if required by the specification will be conducted jointly by the Halcrow andConstruction Contractor staff and approved by the material engineer/technicians.

If in case the material tested at the different laboratories yield results which differ in respect of

meeting the specification then, it is recommended to jointly test the material to arrive at a conclusion

of either accepting or rejecting the material.

It is highly recommended to conduct the field test by Halcrow jointly with Construction Contractor

staff.

It will be difficult at this stage to ascertain the exact percentage of testing to be carried out at

Halcrow or Construction Contractor and outsource laboratories as Halcrow will mostly be spot

checking the test in the field and at the laboratory. It is envisaged that about 25% of the testingshould be carried out independently at the Halcrow laboratories.


14/22



G-2 QA Tests for Buildings and Other Works

The works being executed in the North region (Malakand) shall be controlled from Swat office

and a central laboratory established at Swat.

Material Test Test Method Frequency

Soil

Soil and graded materials

Classification

MDD

Field Density

Moisture content

Gradation

Plasticity Index

Bearing Capacity

AASHTO M-145

AASHTO T-180

AASHTO T-191

ASTM C-566

ASTM C-136

AASHTO T-90

ASTM D1194

As per

requirement

As per

requirement

As per

requirement

As per

requirement

As perrequirement

As per

requirement

Once for

foundations

Coarse Aggregate Gradation

Water Absorption & Sp.Gr.

L. A. Abrasion

Soundness (Na2So4)

Flat & Elongated particlesClay lumps & Friable part.

Unit Weight

Material finer # 200 sieve

ASTM C-136

ASTM C-127

ASTM C-131

ASTM C-88

ASTM D-4791ASTM C-142

ASTM C-29

ASTM C-117

From built

stock as per

requirement

Monthly

As perrequirement

After 3-

months

Monthly

As per

requirement

As per

requirement

As perrequirement

Fine Aggregate Gradation with F.M.

Water Absorption & Sp.Gr.

Organic Impurities

Unit Weight

Material finer # 200 sieve

ASTM C-131

ASTM C-128

ASTM C-40

ASTM C-29

ASTM C-117

From built

stock as per

requirement

Monthly

As per

requirement

As per

requirement

As per

requirement


15/22



Material Test Test Method Frequency

Concrete

Clay Bricks

Blocks

Masonry Mortar

Compressive Strength

(Cylinder)

Slump Test

Strength, Absorption, Size

Strength, Absorption, Size

Compressive Strength

ASTM C-39

ASTM C-143

ASTM C-67

ASTM C-140

ASTM C-109

After 5, 10 ,

30 & 50 Cu.m

for column,wall and

large pours or

minimum one

set for each

grade of

concrete or as

required.

During

concreting (as

required)

5 bricks /10,000

4 blocks /

10,000

From plaster

or brick

laying,

Monthly

Water Chlorides, Sulphates,

pH.,TDS

AASHTO T-26 once for

source

Cement Physical tests ASTM C-150 (Mill Test

certificate)

Reinforcement steel Complete physical tests

(bend, % elongation, yield

and ultimate strengths)

ASTM A-615 For each size

of bar from

source.

Piping works Pressure test

Leakage test

ASTM C-828

ASTM C-828

As per

requirement

As per

requirement

Electric cables

Specify testing and

commissioning

For each

source / as

per

requirement


16/22



G-3 QA Tests for Power

11kV / 33kV Distribution Systems

Material Specified Routine Lab Tests Frequency

HT and LT Structure

a) Complete structuresOnce before pre

shipment from

Manufacture Premises

Verification of dimensions, weights and

Transverse load test.

-do-

b) On members-do-

Tensile strength Test , Elongation Test , Bend Test

, Embrittlement Test , Hardness Test and Yield

Strength Test.

-do-

c) Galvanizing-do-

Weight , uniformity and Adherence of zinc

coating

-do-

Rabbit ConductorACSR , Al-Aluminum

Conductor ACC and

GSL Wire

a) Aluminum

Verification of Diameter, Weight, Breaking load of

single strand, Tensile strength, Resistivity test,

Wrapping and DCR of single wire and complete

strand.

-do-

b) Steel (For ACSR Only)-do-

Verification of Diameter, Tensile strength,

Elongation, Wrapping, Lay Ratio Test Adherence,

Uniformity and Adherence of Zn coating.

-do-

c) Complete conductor-do-

Breaking load and unit weight -do-

Transformers 11 and 33

/ 0.415kV

25, 50 , 100 and 200

KVA

d) Transformer oil tests

Checking Specific gravity, Viscosity, Flash Point,

Acidity value, Dielectric Strength and Pour Point.

-do-

e) Routine tests

Polarity and Phase relationship, Load and No

Load test, Losses test, Induced voltage test and

over voltage withstand test, Tank pressure test,

Bird test and Paint thickness test, Turn Ratio and

Transformer resistance test.

-do-

Steel cross arm ,Pin

steel , Tension Clamp , Verification of dimension and weight, Tensile Testand Yield Strength, Elongation and Embrittlement-do-


17/22



G-4 132kV Transmission Line

Eye Nut , D-Shackle ,

Earthling Unit , Stay

Rod , PG Connector ,

Misc Material.

test. Mechanical Test: (Lead should not loose or

separate at 1000Kg load.)

a) Galvanizing -do-

Weight of Zn, uniformity, Adherence and bend

test.

-do-

Concrete

Compressive Strength (Cylinder) 1 test per 5 HT and LT

foundations.

Gradation of Course and Fine Aggregate As per requirement


Verification of weights ,UTS ,Elongation ,Bend

test , chemical analysis test ,Embrittlement ,

Yield Strength and Thermal Shock Test.

Once before pre shipment

from Manufacture

Premises.

Galvanizing

Thickness , weight and uniformity of zinc

coating and Impact Test.

ACSR Lynx Conductor

and 9mm Earthwire

Dimension , weight , TST , Lay ratio , DCR of

single and complete ,breaking load test,wrapping test, Elongation ,Weight , adherence

and uniformity of Zn coating.

-do-

Disc InsulatorsDimensional test, Temperature cycle,

Mechanical breaking, Porosity, Galvanizing, Oil

puncture voltage and operation test.

-do-

Hardware

(ST-L , SF-9, MS-9 , SB

vibration Dampers , PG

Clamp and Misc)

Breaking Load, Elongation, unit weight,

verification of dimensions, TST, Galvanizing test

and Zn coating thickness.

-do-

Tower FootingResistance Measuring tower footing Resistance TFR

Checking earth resistance

of each Tower.

Concrete

Compressive Strength (Cylinder /cube) 1 test per 5 Tower

Gradation of Coarse and Fine Aggregate As per requirement

Slump test As per requirement


18/22



G-5 132kV Grid Station


Power Transformer with

Auxiliary control panel

a) On Power Transformer

Once before pre

shipment from

Manufacture

Premises.

Measurement of insulation resistance of

windings , Voltage ratio and phase

displacement , winding resistance (HV &

LV) , Capacitance and Dissipation factor of

insulation of T/F and bushings ,No load loss

& current , short circuit impedance & load

loss (ONAN&ONAF) , separate source

voltage withstand test, induced over-voltage

withstand test & measurement of partial

discharge , OLTC functional tests AND

lightning impulse voltage withstand test.

a) Oil Tests

Viscosity, Pour point, acidity value, Moisture

content, Dielectric Dissipation factor,

Interfacial tension and dielectric strength.

b) Auxiliary Control Panel Functional Tests

11KV Switchgear Panels

(Incoming, Outgoing, Bus

Coupler & Capacitor Bank Panel)

Visual Inspection & Dimensions,

Electrical operation tests, (Ampere,

voltage, Pf, Energy meter), Indication

Lights, Push buttons, continuity of earth.

Trip Circuit Supervision, O/C, S/C, E/F,

Back up E/F, Capacitor Un-balanced

protection, under & over voltage Relays.

Load break switches Mechanical

performance, Mechanical Interlocking.

Power frequency withstand Voltage test

(Auxiliary circuit) 2KV for one minute to

Auxiliary circuit.

Power frequency withstand Voltage test

(Main circuit) 36KV for one minute to

Main Circuit

Insulation test of VCB Vacuum Tube and

resistance of Main circuit and

Verification of Interchangeability of

Components & Mechanical operation

test.

-do-

AC/DC Auxiliary Panel

Line Control Panel CP-30

Transformer Control Panel CP-50

Applied 2KV across Auxiliary Circuit for 1

minute, General and functional Tests on AC

and DC portion

-do-

Line Relay Panel RP-3Transformer Relay Panel RP-4

Applied 2KV across Auxiliary Circuit for 1

minute, General Tests, Functional Tests on

Panel, Functional Tests on Tripping &

-do-


19/22



Supervision, Distance Relay, O/C & E/F

Relays.

95 mm Copper Conductor,

Al-Aluminum Conductor 600

mmEarth wire 7/3 (9mm Dia)

Measuring Diameter , Breaking Load ,

Elongation , Lay ratio , Resistance and Unitweight , TST , Zinc coating ,Uniformity , and

adherence.

-do-

I. 2.5mm 4 core control cables

II. 2.5mm 8 core control cables

III. 2.5mm 16 core control

cables

IV. 6mm2 4 core control cables

Thickness of insulation, sheath, Diameter of

single wire, elongation of conductor, TST and

elongation of PVC sheath and insulation

before and after ageing.

Hot deformation of PVC insulation and

sheath.

Heat Shock, cold bend test, Color fastness

test, Resistance to burning test, Waterabsorption and loss of mass for a PVC

insulation/sheath.

Insulation resistance, copper tape resistance

and DC resistance of copper conductor.

-do-

120mm 3 core power cables

500mm Single core Power cables

Verification of dimensions, power frequency

voltage test Conductor resistance test , Heat

Shock test , Behavior of low temperature test,

Flame test, Heat deformation of PVC sheath ,

DC resistance of copper conductor ,

Resistivity of semi conducting screens

-do-

Battery charger Visual inspection , Dielectric strength test ,

Properties of smoothing circuit , Checking of

protective devices , Properties of current

limiter , Noise level test and Checking of

alarms

-do-

12 m Beam

13.1 m Column

13.1 m Earth Mast

11kV Structure 4m Long and

substation connectors.

Yield load, Breaking load , Yield stress

Ultimate stress , Elongation, Bend test

-do-

I. 132kV Circuit Breaker

II. 132kV Line / Bus

Disconnector

Average speed of opening and closing,

Opening and closing synchronism between

plates, closing & Opening time.

-do-

Mechanical Operation Test

Switching Operation opening and closing

voltage. Motor charging time and normalworking voltage.


20/22



Dielectric test of main circuit, Aux & control

circuit.

Alarm and Lock pressure of SF6 gas.

132kV Surge Arrestor Residual voltage test at nominal discharge

current , Power frequency reference voltage

test ,Partial discharge test and Verification of

Terminal Markings

-do-

132kV Transformer

Current Transformer and 132kV

Line Current Transformer.

Measurement of Capacitance and dielectric

dissipation factor ,Test of short-time power

frequency withstand voltage,

Partial discharge measurement(B)

-do-

Error Test

a) Error of Metering /Protection

Winding

Ratio Error

Phase Displacement Error

132kV Voltage Transformer Verification of Terminal Markings ,

Measurement of DC resistance ,

Measurement of capacitance and dielectric

dissipation factor , Induced withstand

voltage test , Measurement of Excitation and

Partial discharge measurement

To be performed in

the Manufacture

Lab

Concrete Compressive Strength (Cylinder) After 5, 10, 30 & 50Cu.m for column,

wall and large

pours or minimum

one set for each

grade or as

required.

Gradation of Course and Fine Aggregate As per requirement

Slump Test During concreting

(As per

requirement)

Masonry Mortar Compressive Strength Plaster or Brick

laying (As per

requirement)

Cement Physical Test Mill Test certificate

Bricks / Blocks Water Absorption , size , Compressive

strength

5 bricks / 10,000

4 blocks / 10,000

Reinforcement steel Complete physical tests (bend, % elongation,

yield and ultimate strengths)

For each size of bar

from source.


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G6 Water (Irrigation/Dams)


Earth works

(Excavation of foundations and abutments)

X-Sect 3 No.

Soil

Classification3 Nos.

Concrete

Tests3 Nos.

Foundation

treatment & grouting

Concrete

Test3 Nos.

Embankment completion in layers from

bottom to crest

Compaction 3Nos per Meter of compacted fill

Thickness 3Nos per Meter of compacted fill

Gradation 3Nos per Meter of compacted fill

Spillway & intake Structure

Soil

Classification

3 Nos per structure

Concrete After 5, 10, 30 & 50 Cu.m for column, wall

and large pours or minimum one set for

each grade or as required.

Masonry 03 Nos. per 5m

Irrigation Channels X Section 03 Nos. per km

Concrete After 5, 10, 30 & 50 Cu.m for column, walland large pours or minimum one set for

each grade or as required.


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Date post:	13-Feb-2018
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Quality Assurance Tests- Final

Documents