Quality Assurance Guidelines for Naval Equipment

Q: How is the applicability of Quality Assurance Plans (QAPs) determined for induction orders?

The applicability of QAPs for induction orders is determined based on conditions such as whether a Standard Quality Assurance Plan (SQAP) has been issued, whether the equipment has been supplied earlier, and if there are changes with respect to the last supply. These conditions determine whether the relevant SQAP or an amended QAP should be used .

Q: In what scenarios is it not required to submit drawings for naval spares, and what governs the inspection process?

It is not required to submit drawings for naval spares ordered against OEM Technical Specifications. In such scenarios, the inspection process is governed by details provided in the approved Part Illustration List (PIL) or DBOM .

Q: What procedural steps are critical for a successful shock test according to the document?

Critical procedural steps for a successful shock test include visual inspection, endurance run, shock testing to specified levels, post-shock visual inspection for defects, disassembling and inspecting critical components, reassembling, and conducting a proving run .

Q: Why is shock testing necessary for certain naval equipment, and under what conditions should it be conducted?

Shock testing is necessary to ensure the equipment can withstand operational conditions in hostile environments. It is required under conditions such as the absence of a prototype, considerable differences from a prototype, or significant modifications affecting shock resistance. Equipment must be shock tested to confirm durability and functional integrity under shock loads .

Q: How does the document outline the differentiation of shock grade classification for naval equipment?

The document differentiates shock grade classification based on the vessel's role and equipment criticality. It establishes categories like I.N. Shock Grade ‘A’ for equipment aboard Class I ships and Naval Shock Standards -2 for applicable equipment aboard Class I and II ships .

Q: What considerations are taken into account for shock calculation reports for naval equipment?

Shock calculation reports must consider factors such as equipment mass, foundation strength and stiffness, response of sub-components, shock loading duration, and physical properties. Advanced modeling techniques like Finite Element Analysis may be utilized .

Q: What are the prerequisites for undertaking Quality Assurance (QA) inspections according to the provided guidelines?

The prerequisites for undertaking QA inspections include having a valid Purchase Order (PO), a complete set of drawings approved by designated agencies, an approved Quality Assurance Plan (QAP) by the Inspecting Authority, and an Acceptance Test Plan (ATP).

Q: What role does the Inspecting Authority play in the approval of Quality Assurance Plans (QAPs)?

The Inspecting Authority is responsible for issuing or approving QAPs for each Purchase Order. They can specify the use of existing approved QAPs, issue new ones, and decide on modifications as needed based on the equipment and order provisions .

Q: How does the document recommend handling changes to drawings for future orders?

If changes are valid for future orders, amendments to approved drawings should be endorsed in all records to ensure consistency in future procurements. In the absence of changes, firms are to adhere to guidelines for submission of existing approved drawings .

Q: Under what circumstances is a revised Quality Assurance Plan necessary, even if a Standard Quality Assurance Plan exists?

A revised QAP is necessary when an SQAP exists but the supply involves components or processes not covered by it. Amendments must be made to incorporate these new aspects into the QAP for the order .

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Quality Assurance Guidelines for Naval Equipment

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QAD-01

CONDITIONS OF RELEASE
1. This Document has been prepared and issued to enable all stakeholders to
have the same understanding and appreciation of various facets of Quality Assurance
cover provided by the Naval Directorates of DGQA. The provisions of this document are
for guidance of and compliance by all concerned.
2. This Document is DGQA copyright and the information therein may be subjected
to DGQA and Indian Navy rights.
3. It is pertinent to mention that meeting the QAP requirement does not guarantee
the desired output from the equipment which is associated with the designing of the
equipment. However, meeting the QAP does guarantee conformance to approved
drawings.
4. This document refers to only Quality Assurance Plan to be adopted during
manufacturing processes and in no way absolve either the supplier or the user from
statutory obligations relating to health and safety at any stage of manufacture or use.
5. Unless otherwise specified, a reference in this document means the issue and all
the amendments to that document current on the date of reference.
6. As the provisions of this document is for compliance,any ambiguity or differences
in perceptions between two agencies are to be referred to Headquarters, DQAfor
clarification.
7. This document is not to be released, reproduced or published without written
permission of directorate of quality assurance (DQA).
8. DQA Reserves the right to amend or modify the contents of this publication
without consulting or informing any holder.
5
FOREWORD
1. The Directorate of Quality Assurance (Warship Project) [DQA(WP)] and
Directorate of Quality Assurance (Naval) [DQA(N)] are two of the 13 Directorates
functioning under the Director General of Quality Assurance (DGQA) in the Department
of Defence Production, Ministry of Defence, Government, of India. The Quality
Assurance responsibility of „Mission Critical Equipment‟ of Indian Naval Warships such
as Main Propulsion, Power Generation & Distribution, Shafting Line, Steering Gear &
Stabilizer, Controls & Instrumentation, Water Generation, Compressors, Pumps, HV Air
Conditioning & Refrigeration, STPs, Aviation equipment, Winch, Underwater Valves,
Weapons/sensors, Electronic/Electrical Defence stores, Navigational Aids etc has been
vested with DQA by the Indian Navy. This onerous task is carried out by DQA through
their 27 field establishments across the country, which provide Quality Assurance cover
for all types of Marine Engineering & Hull Machinery (including associated
electrical/electronic equipment/ control systems), Weapons/sensors,
Electronic/Electrical Defence stores, Navigational Aids and spares being procured
against Purchase Orders placed by Defence Shipyards, Naval Procurement Agencies,
Coast Guard and DRDO, both for warships under construction and in commission.
2. This document, christened as Quality Assurance Document (QAD), will be
applicable to all procurements, for the above stake holders, for which the QA cover is
provided by DQA. The process has been evolved based on internationally followed
norms, experience gained by the Indian Navy over six decades of operation and the
infrastructure available within the country. It is a comprehensive document,
summarising all the policies in vogue, and whilst few aspects have been amplified to
bring in clarity, this document has no changes with respect to existing norms. It is
envisaged that adherence to the QAD will enable the Industry to manufacture
equipment that conform to the requirements of warship applications which are inherently
more exacting than those found in commercial or land based applications.
3. With the technological advancements making inroads rapidly, it would be the
endeavour of HQ DQA to keep abreast of future developments in Quality Assurance
methodology and practices which may bring about changes to the concepts and
procedures envisaged and revise these guidelines from time to time.
New Delhi (AK Dutta)
Rear Admiral
03 Apr 17 Addl Director General
Quality Assurance(Warship Project)
6
Contents
Introduction .................................................................................................................. 12
Pre-Requisites .............................................................................................................. 14
Drawings ...................................................................................................................... 16
Quality Assurance Plans .............................................................................................. 20
Outsourced Components/Items .................................................................................... 24
Inspections, Tests and Trials ........................................................................................ 28
Documentation ............................................................................................................. 34
Preservation & Packaging ............................................................................................ 36
Inspection Note ............................................................................................................ 38
Jurisdiction ................................................................................................................... 40
Conflict Resolution ....................................................................................................... 42
7
List of Appendices
Appendix
No.
Description Page No.
A
Procedure for drawing approval for QA Cover of
first time induction Systems and Equipment
41
B Applicability of Approved drawings 45
C
Submission of Drawings for Replenishment Orders
of Equipment / Spares
47
D Applicability of Approved QAPs 49
E Details of Acceptable Import Documents 51
F Sample ESS Plan 55
G Environmental Test Specifications 61
H Factory Acceptance Trials 65
J
Division of Responsibility between DQA(N) and
DQA(WP)
67
K Geographical Jurisdiction of Field Establishments 73
List of Annexure
Annexure
No.
Description Page No.
I Sample of GA drawing with DBOM 75
II Guidelines for preparation of GA drawings 81
III Thermal Cycle Stress Screening Plan 85
IV Random Vibration Stress Screening Plan 87
V ESS Stress severity Plan 89
VI INShock policy 91
8
ABBREVIATIONS USED
AIS Action Information system
APMS Automatic Power Management System
ASNT American Society for Non-destructive Testing
ASW Anti Submarine Warfare
ATP Acceptance Test Procedure
AVR Automatic Voltage Regulator
BOM Bill of Material
CDA Controller of Defence Accounts
CHP Customer Hold Point
CNC Contract Negotiation Committee
CoC Certificate of Conformance
COMINT Communications Intelligence
COO Country of Origin
COTS Commercially Off the Shelf
CPRO Controller of Procurement
CQAE Chief Quality Assurance Establishment
CQAO Chief Quality Assurance Officer
DBOM Detailed Bill of Material
DGS&D Director General of Supply and Disposals
DMDE Defence Machinery Design Establishment
DP Delivery Period
DPM Defence Procurement Manual
DPT Dye Penetrant Testing
DPRO Directorate of Procurement
DQA Directorates of Quality Assurance (includes both DQA(WP) and DQA(N))
DQA(N) Directorate of Quality Assurance (Naval)
DQA(WP) Directorate of Quality Assurance (Warship Project)
ECDIS Electronic Chart Display and Information system
EMI / EMC Electromagnetic Interference / Electromagnetic Compatibility
ET Environmental testing
ESS Environmental Stress Screening
EW Electronic Warfare
FAC Fast Attack Craft
FATs Factory Acceptance Trials
FCL First Contact Letter
FCS Fire Control System
FD Forced Draught
FFF Form, Fit and Function
GA General Arrangement
GMDSS Global Maritime Distress and Safety System
HP High Pressure
IFF Identification of Friend or Foe
IHQ,MoD(N) Integrated Headquarters of Ministry of Defence (Navy)
IN Indian Navy
INCO International Commercial
I – Note Inspection Note
ISNT Indian Society for Non-destructive Testing
9
JSG Joint Services Guide
LCU Landing Craft Utility
LP Low Pressure
LST Landing Ship Tanks
MCMV Mine Counter Measure Vessel
MO Material Organisation
MPT Magnetic Particle Testing
MQAP Master Quality Assurance Plan
NABL National Accreditation Board for Testing and Calibration Laboratories
NAI Naval Armament Inspection
NAVAIDS Navigational Aids
NBC Nuclear Biological Chemical
NEC Naval EMI/EMC Center
NDT Non-Destructive Testing
NSQR Naval Staff Qualitative Requirement
NSS Naval Shock Specifications
NTG Naval Technical Group
OEM Original Equipment Manufacturer
OGT Ocean Going Tugs
OPA Order Placing Authority
OPV Offshore Patrol Vessel
PAC Proprietary Article Certificate
PCB Printed Circuit Board
PIL Parts Identification List
PO Purchase Order (including NSQR/SOTR/TNC Minutes as applicable)
POTS Purchase Order Technical Specification
PTS Purchase Technical Specification
PSPP Part Supply Part Payment
QA Quality Assurance
QAE Quality Assurance Establishment
QAO Quality Assurance Officer
QAP Quality Assurance Plan
QAD Quality Assurance Document
QC Quality Control
RFP Request for Proposal
RT Radiographic Testing
RVSS Random Vibration Stress Screening
SCQA Standard Conditions for Quality Assurance
SDB Seaward Defence Boat
SO Supply Order
SOTR Statement of Technical Requirement
SQAP Standard Quality Assurance Plan
STC Supplier‟s Test Certificate
TCSS Thermal Cycling Stress Screening
TE Tender Enquiry
TNC Technical Negotiation Committee
TSP Technical Specifications
UT Ultrasonic Testing
UWT Underwater Telephone
10
VCI Vapour Corrosion Inhibitor
VPCI Vapour Phase Corrosion Inhibitor
WESEE Weapons & Electronics System Engineering Establishment
11
RECORD OF AMENDMENTS
Sl.
No.
Date of
Amendment
Amendments Authority Remarks
12
Chapter 1
Introduction
0101. Engineering and Hull equipment and machinery, including their associated
electrical equipment like motors, starters, control panels, control systems,
Weapons/sensors, Electronic/Electrical Defence stores, Central Naval Stores and their
spares being supplied for installation/use onboard Indian Naval ships and submarines
are required to pass through Quality Assurance norms/inspections in accordance with
the provisions contained in this document.
0102. An order can be for a system, equipment or spares. For clarity and uniform
understanding by all stake holders, these are defined as under:-
(a) System. System refers to any combination of equipment inter
connected through pipes, cables, wires, belt, hanger, couplings etc and designed
to perform as a composite unit to meet an intended and pre-defined performance;
like Air Conditioning System, Propulsion System, Power Generation System,
Navigation System etc.
(b) Equipment. Equipment refers to a combination of assemblies,
sub-assemblies and components which are inter connected and linked together
to independently perform a specific and defined function within any system; like
pump, diesel engine, air compressor, motor, generator, valve, heat exchanger,
radar, antenna etc.
(c) Spares. Following will be constituted as spares:-
(i) Assemblies. These are parts of equipment and are combination of
components that would constitute standalone functional equipment by
itself; like turbo chargers, engine driven pumps, relief valves etc.
(ii) Sub-assemblies. These are also combination of components
but would not constitute any standalone functional equipment by itself; like
rotor assembly, tube stack assembly, impeller assembly etc.
(iii) Independent and individual components
0103. The vendor, at any point from receipt of RFP/TE, may seek clarifications on QA
related aspects from the concerned Inspection Agency, [the local Quality Assurance
Establishment (QAE)] or the Inspecting Authority [Directorate of Quality Assurance
(Warship Project) (DQA (WP)/Directorate of Quality Assurance (Naval) (DQA (N)], if
required. Contact details of various QA agencies are available at the DGQA website
([Link]
13
0104. In case of equipment covered under dual inspections by Class and
DQA(WP)/DQA(N), QA coverage according to approved QAP by DQA(WP)/DQA(N) is
mandatory. Inspection note from QAO will be mandatory for equipment and will be
issued post completion of all inspection stages as per DQA(WP)/DQA(N) approved
QAP. The vendor may associate the Class whilst QAO is undertaking inspection for
economy of efforts.
0105. The vendor is to contact the inspecting agency within five working days of the
receipt of purchase order to initiate Quality Assurance Cover. The First Contact Letter
(FCL) from respective CQAE/QAE to vendor will be issued on receipt of purchase order;
either from OPA (by email or post) or from Vendor. A meeting is to be held between the
vendor and QAO at the earliest opportunity, but not later than seven working days of
first contact with the QAO. A copy of minutes of this meeting is to be forwarded to the
Order Placing Agency and Inspecting Authority clearly mentioning the timelines for
submission of various documents by the vendor and plan of action to execute the order
within the delivery period. Failure to adhere these provisions and the schedule drawn up
will result in downgrading of the vendor rating.
0106. Manufacturing is to commence only on availability of approved QAP issued by
the Inspecting Authority.
14
Chapter 2
Pre-Requisites
0201. Quality Assurance cover is provided by the Inspecting Authority, through the local
Inspecting Agency only when the Purchase Order mandates and authorises the
Inspecting Authority and the specific Inspection Agency to provide the QA cover. The
pre-requisites for undertaking QA inspections are as follows:-
(a) A valid Purchase Order (PO).
(b) Complete set of drawings, approved by designated agencies as provided
at Chapter 3.
(c) QAP approved by the Inspecting Authority and valid for the instant PO.
(d) Acceptance Test Plan (ATP)
0202. Each of the equipment/item mentioned in the PO should be unique and traceable
by unique part no and/or unique drawing/s.
0203. Conformity of the details provided in the PO and those submitted by the firm viz.
Part IIIustration List (PIL), approved OEM documents etc. Quality Assurance (QA)
cover will be provided with respect to the specifications in the Purchase Order and any
mismatch of details will obviate further progressing of QA cover.
0204. Necessity for type testing and qualification testing (like shock testing, specific
environmental tests, EMI/ EMC tests, endurance trials etc) are to be clearly indicated in
the PO. All electrical equipment (Weapons/sensors, cable, electronic systems, motors,
starters & control panelsetc)and mechanical equipment/systems (Pumps, engines,
valves, compressors etc) are mandatorily required to be type tested, if not done earlier.
The nature and type of tests will vary depending on the equipment and system and will
be specified in PO.
0205. Requirements of FATs should be specified in the PO.
0206. Irrespective of the quantum, any change in material, design, duty point,
manufacturing process, sourcing, governing standards/specifications (view
obsolescence/ revision etc), with respect to supplies made earlier will be construed as
„Change‟, requiring revision of drawings and/or QAP including qualification/type testing.
15
16
Chapter 3
Drawings
0301. The drawings are to have all details as necessitated to ensure compliance to the
requirements of the PO and are to be in compliance with BIS-SP 46-2003.
0302. The drawings for induction/shipyard orders are to be approved in accordance
with the procedure placed at Appendix ‘A’, by authorities as under:-
(a) By Professional directorate for compliance to NSQR/ SOTR.
(b) By Production directorate wrt to installation
(c) By Inspection Authority wrt to Quality Assurance
0303. The process flowchart for approval of drawings is depicted in figure 1.
Fig. 1: Process flowchart for approval of Drawings.
17
0304. Applicability of drawings, including for repeat or replenishment orders placed by
shipyards and/or Navy (IHQ,MoD(N)/MOs) will be governed by the provisions provided
at Appendix ‘B’. Details and methodology for submission and reference of drawings for
replenishment orders are placed at Appendix ‘C’. Repeat/Replenishment orders for
system/equipment those have been inducted into the Navy through third party/class QA
cover in the past will be treated as first time inductions for the purpose of QA cover
through DGQA.
0305. All previously approved drawings and QAPs being used is to be the latest
approved version available, irrespective of the fact that the present equipment/item in
use has been accepted against a previous version. Similarly, all governing standards
and specifications will be of the latest revision/edition irrespective of the fact that the
present equipment/item in use has been accepted against a previous version.
0306. Irrespective of the quantum, any change in material, design, duty point,
manufacturing process, sourcing, governing standards/specifications (view
obsolescence/ revision etc), will be construed as „Change‟, requiring revision of
drawings and/or QAP including qualification/type testing.
0307. In cases where detailed drawings are to be submitted in accordance with the
provisions at Appendix „B‟, the drawings should be submitted as a complete set with GA
drawing and Manufacturing drawings (sub assembly/component drawings, Component
Layout Drawing, Wiring Chart, Cable Schedule, Connector Details etc), with both
mutually identified and duly linked with one another.
0308. The detailed/component drawings, irrespective of being submitted for approval or
presented at site for inspection, should include (may not be limited to) the following:-
(a) Dimensions and units
(b) Tolerances
(c) Main Assembly/ Sub Assembly details
(d) Bill of Materials/Part Identification List (PIL) along with Material
Specifications including grade, condition and specification number, “Make” &
“Model” in case of COTs items.
(e) For Sub Component Drawings, correlation details with the PIL & Main
Assembly Drawing
(f) Packaging & Preservation details
(g) Weight with tolerance
18
(h) Working/Test Pressures and working medium/testing medium
(j) Applicable Specification Number (along with the No of Version and Year of
Publication)
(k) Product specific testing requirements and acceptance norms thereof
(l) NDT zones and Quality level of NDTand acceptance norms thereof
(m) ET/ESS and Type test requirements
(n) Weld details and acceptance norms thereof
(p) Manufacturing process/process flow chart for major components
(q) Painting Procedure with specifications
0309. In addition to above, for electrical system drawing, following are considered
mandatory:-
(a) Schematic diagram indicating inter-panel connectivity.
(b) The GA drawings that will establish the physical disposition of panels wrt
each other.
(c) The GA drawings of sub units along with DBOM and relevant reference for
wiring chart/cable schedule and component layout drawings.
(d) The DBOM is to form the basis of PIL up to component level and both
BOM and PIL should map one to one as in case of mechanical items.
0310. Drawings should also clearly indicate items/components/sub-assemblies that are
imported, bought out and COTS along with full details thereon. This should include the
source of procurement/import, the model and the make of the bought out/COTS items.
In case of electronic modules fabricated/assembled indigenously with imported/bought
out components, requisite information to ensure quality and traceability is to be
provided.
0311. The size of drawings presented are to be such that all indicated parts are clearly
and unambiguously identifiable with a minimum letter fond size of Arial 10, subject to
minimum A4 size.
19
20
Chapter 4
Quality Assurance Plans
0401. The QA cover will be provided in accordance with the approved QAP issued by
the Inspecting Authority. For each Purchase Order (PO), either the approved QAPs will
be specified in the PO or a new QAP will be drawn and approved afresh.
0402. Standard Quality Assurance Plans (SQAPs) have been formulated with
participation of all stake holders and promulgated for some systems/equipment. In some
other cases, an existing approved QAP may be applicable with or without changes. In
all other cases, QAP is to be drafted by the manufacturer, taking reference of following
documents (uploaded at [Link] (The documents under
reference are to be taken for guidance only and the various tests and other
requirements of quality assurance will be governed by the QAP as approved by the
Inspecting Authority based on PO/Purchase Technical Specification/TNC Minutes.):-
(a) Guidelines for Quality Assurance for Engineering and Hull equipment for
Indian Naval Warships
(b) Generic QA guidelines for Electrical/Electronic equipment
(c) Various Master Quality Assurance Plans (MQAPs)
(d) QAPs issued previously
0403. The approved QAP could be an SQAP or a previously approved QAP or a new
QAP. The applicability of the QAP will be as per the provisions placed at Appendix „D‟.
0404. The QAP is to cover all components, sub-assemblies and full assemblies
including motors, control panels, consoles etc.
0405. The formulation and approval of QAPs for various types of order/procurements
will be governed by the provisions enumerated in succeeding paragraphs.
0406. For a system/equipment for which SQAP has been issued, only the relevant
SQAP is acceptable. Formal approval to use the QAP will be accorded as under:-
(a) Where SQAP for the instant system/equipment has been issued, uploaded
and available with RFP/on the DGQA website on the day of submission of offer
by the firm, the relevant SQAP will be the approved QAP for the instant order.
(b) In case the instant supply has components and/or process not covered in
the SQAP, the firm is to seek clarification and confirmation with respect to
inspection aspect and norms of new introductions. The relevant SQAP with these
amendments/introductions will then be the approved QAP for the instant order.
21
SQAP will subsequently be amended to incorporate these aspects for future
orders.
0407. No other form or variant of QAP will be acceptable for equipment/system for
which SQAP has been issued and available.
0408. In cases where SQAP has not been issued and where an existing QAP is to be
used, the firm has to make a formal request through the Inspecting Agency.
Concurrence for use of the existing QAP with/without changes will be issued by
inspecting authority on receipt of request from the firm. Where concurrence has been
accorded prior/during CNC/TNC, the PO be issued with the relevant QAP (as amended,
if required) as the approved QAP for the instant order.
0409. Where there are changes with respect to last supply, the drawings and/or DBOM
needs to be amended and approved as per extant rules. Subsequently, the firm submit
its proposed QAP, incorporating changes where required with respect to existing QAP,
through the Inspecting Agency to seek approval. It will be imperative that validity of the
functional and type tests as per earlier design is ratified by the competent authority
without which all functional/type tests as applicable will need to be undertaken for
current production. Approval for use of the amended QAP with/without changes will be
issued by inspecting authority on receipt of request from the firm. Where approval has
been accorded prior/during CNC/TNC, the PO be issued with the relevant QAP as
amended as the approved QAP for the instant order.
0410. In case of fresh QAP being drafted by the firm, it should conform to provisions of
MQAP and/or latest version of approved QAPs issued earlier where applicable. Whilst
existing QAP for same/similar equipment/item supplied earlier can be taken for
guidance, any changes required in terms of addition/deletion of tests or modifications
that has been necessitated view lessons learned and/or technological advancements
needs to be verified and confirmed from the inspecting authority prior undertaking any
manufacturing activity.
0411. All queries with regards to using an existing QAP, with or without changes or
submission of a draft QAP for fresh approvals are to be through the local QAO for final
approval by the Inspecting Authority. Since the QAP flows from the PO and drawings
therein, all queries and draft QAP shall be forwarded/submitted along with PO and
references/approved drawings, as per the provisions placed at Appendix „B‟.
0412. DQA and their field units will provide required clarifications and confirmation on
applicability and/or validity of relevant SQAP/previously approved QAP for a
system/equipment/item as and when the relevant details like previous purchase order,
INote
reference, equipment/item specifications like drawing no and approved QAP etc
are provided, even during the indenting or tendering stage. In addition, an intending
supplier can also seek these clarifications on receipt of tender enquiry and before
submitting the offer, if it so desires. All such clarifications are to be sought through the
concerned local QAO under intimation to OPA and Inspecting Authority. The inspecting
22
Authority will accord concurrence or otherwise within seven working days of receipt of
request from the firm.
0413. Notwithstanding the availability of SQA/Ps, previously approved QAPs and
MQAPs, the approval of the Inspecting Authority to use the relevant QAP is to be
obtained for each purchase order, except in cases where the firm is accepting the
available SQAP. Where SQAP exists or concurrence has been accorded by the
Inspecting Authority for use of previously approved QAPs with or without amendments,
the same can be incorporated in the purchase order as approved QAP for the instant
order. Where the details of approved QAP are not provided in the Purchase Order, the
approval is to be sought from the Inspecting Authority as per the applicable clauses
placed at Appendix „D‟. The process for QAP approval is as follows:-
23
24
Chapter 5
Outsourced Components/Items
0501. Whilst it is the prerogative and mandate of the vendor to manufacture or source
manufactured components as deemed necessary, it is imperative that the information is
provided in the approved drawings to facilitate smooth QA cover. The mode of sourcing
is to be indicated in the approved drawing/DBOM explicitly. QA cover for the
components which are manufactured in-house will commence with raw material
inspection, go through in process inspections, testing & trials as necessary and
culminates with inspection of preservation & packing and final dispatch clearance. QA
cover for components which are sourced from other manufacturers/vendors (outsourced
components/items) will be provided in accordance with the provisions provided in
succeeding paragraphs.
0502. The following will be construed as outsourced components:-
(a) Imported Items
(b) Commercially Off The Shelf (COTS) items
(c) Bought out items
(d) Sub contracted items
0503. Input materials which go for further processing and manufacture like metal
plates, billets, stocks, sections, tubes, wires, cables, metallic & non-metallic sheets etc
will not be treated as outsourced components. POLs, chemicals, critical components of
safety and lifesaving systems etc, though available commercially, will not be considered
as outsourced/COTS for the purpose of QA [Link], these will be tested for
all requirements as necessitated by the governing standards. For some input materials,
where the quantities are meager and all tests as per governing standards not
feasible/viable, the same may be accepted against STC. However, such instances
should be indicated up front, recorded in TNC/CNC minutes or in PO.
0504. Imported items. Imported items are those which are manufactured in a
foreign country and imported to India. Imported items will be accepted against import
documents as per directives in vogue. Presently the documents to be submitted are as
follows:-
(a) Bill of Lading
(b) Country of Origin
(c) Shipping Bill
(d) Bill for entry to warehousing
(e) OEM‟s Test Certificate/Quality Assurance Guarantee Certificate
25
(f) OEM‟s Confirmation Certificate
(g) Firm‟s Guarantee Certificate as per SOs.
0505. Functional tests of imported items may be undertaken in addition, as per
guidelines enumerated at Para 0603(c) / Appendix „H‟ respectively.
0506. To cater for different types of documents issued by different agencies and
different formats and formalities across various countries, documents as indicated
against each at Appendix „E‟ will be acceptable as valid documents for providing QA
cover for imported items.
0507. COTS items. COTS items cover those items/equipment which are
available in the open market, are under the regular production of the firm and can be
procured off the shelf without having to give a specific manufacturing order.
0508. COTS/Catalogue items will be accepted on the basis of Suppliers Test Certificate
(STC) and/or Certificate of Conformity (CoC) with following conditions:-
(a) Suppliers Test Certificate (STC) is issued by the original manufacturer of
the COTS [Link] of Conformity (CoC) is issued by the equipment
manufacturer or integrator who has sourced the COTS item for use in the
equipment. CoC/STC must indicate governing specifications and values to which
the item has been tested. The certificate must include copies of test reports.
(b) In case of manufacturers certified under relevant quality standards (like
ISO, OSHAS etc), the pre published data sheet or company quality policy
bringing out the details of test carried out on specific items may be accepted.
(c) Indian Navy reserves the right to test a sample out of that supplied, for
conformity to desired specification. Failure of the test sample will make the
supplier liable for rejection/return of the entire lot. The test may be undertaken by
IN anytime during the guarantee period at an accredited lab.
0509. Bought out items. Bought out items are those which are in the general product
range of the manufacturing firm, but manufactured on placement of specific order by
main firm and production is covered by main firms‟ quality control program. Bought out
items manufactured indigenously will be subjected through QA inspection unless
otherwise specified in the PO. Where bought out items are not subjected to inspections,
relevant test certificates/reports and compliance certificate is to be submitted by
manufacturer indicating governing specifications and values to which the item has been
tested.
26
0510. Sub Contracted items. These are such items/components manufactured by a
sub-contractor of the main firm against specific purchase order from the main firm and
with reference and relevance to the PO/TSPs of the main order.
0511. In case parts/components being outsourced, the main firm is required to submit
ink/digitally signed copy of sub-order and ensure that the outsourced out items meet the
specifications/standard. Subcontract must include the main PO reference and governing
specifications clearly as mentioned in main PO. Inspection where required, will be
carried out at sub-contractor's premises as per approved drawings/QAP/ATP.
0512. Jurisdiction of QAO for Sub-contracted/bought out items. Where the
manufacturer of the sub-contracted/bought out item is not co-located within the
jurisdiction of the primary QAO, the QA cover will be provided by the local QAO under
whose jurisdiction the manufacturing firm is located, against a sub nomination approved
by the inspecting authority. Similarly, for cases of bought out items those have to
undergo detailed inspections per approved QAP, sub-nomination is to be adopted in
cases where the jurisdiction of main QAO is different.
0513. In cases of sub-nomination, the main vendor will be responsible through the main
QAO for providing approved drawings and QAP to the nominated QAO. Once approved
drawings and QAPs are received by the nominated QAO, then for all subsequent
actions/requirements, including clarifications from the nominated vendor, if any, this
nominated case is to be treated at par with a main vendor and main QAO procedure, till
issue of I-Note.
0514. All Certificates like STC, CoC, import documents, other test certificates etc
should be submitted in original. Traceability of digitally signed documents or
e-documents, where applicable and submitted, is to be ensured and shown by the firm
for verification.
27
28
Chapter 6
Inspections, Tests and Trials
0601. Inspections relate to those activities undertaken to assure compliance of the
process and product to the specifications and standards as provided in the PO and
approved drawings/DBOM.
0602. Inspection could include following:-
(a) Raw material inspections which may include witnessing of pouring, forging
etc.
(b) Destructive tests of samples/test pieces for chemical
composition/mechanical properties.
(c) Component level (including weldments) Non Destructive Tests (NDT) like
RT, UT, DPT, MPT etc to detect surface/sub surface defects and grain boundary
discontinuities.
(d) All Castings will be subjected through RT to qualify the same in
accordance with the approved Class of Castings, unless otherwise specified in
PO or governing standards.
(e) Micro/Macro examinations.
(f) Dimensional checks before assembly.
(g) Sub equipment/component level pressure testing in addition to NDT for
integrity/strength conformity.
(h) Witnessing procedures to ensure compliance to manufacturing plan and
traceability of the component.
(j) Inspection/verification of calibration status of measuring instruments/
machinery/other instruments including furnaces/lathes/boring centers etc for Heat
treatment/melting/machining etc.
(k) Measurement of Structure Borne Noise and/or Air Borne Noise.
(l) Recording of Vibration levels.
(m) Clearance of Customer Hold Points (CHPs) by the nominated
Inspection Agency prior proceeding further with manufacturing, (both for
“Witness” and “Review” as per applicability) to obviate rejection at later stage.
29
(n) All tubes/pipes will undergo eddy current test unless exempted per PO.
(p) All forgings will undergo UT for soundness and integrity checks.
(q) All electronic components will undergo endurance and burn in test, if not
waived off in the PO.
0603. Tests relate to those activities undertaken on completed component, assembly,
equipment or system for design validation of specific parameters and performance
evaluation. Following tests and trials are undertaken:-
(a) Production tests. These are those tests, as given at para 0602 above,
undertaken during the manufacture of each piece/batch as per the approved
[Link] will also include Environmental Stress Screening (ESS). Details of ESS
are placed at Appendix „F‟.
(b) Qualification/Type tests. These are those tests undertaken to validate
the design and are generally undertaken only on the prototype or first piece/set
unless specifically mandated by PO. These include Environmental Testing (ET),
EMI/EMC tests and shock testing. Samples of ET specifications are placed at
Appendix „G‟.The EMI/EMC tests will be carried out as per IHQ MoD (N)
approved Naval EMI/EMC acceptance Plan (EMI-AP) duly vetted by NEC (MB).
(c) Functional Tests. These are those tests under taken on a component,
an assembly or equipment to evaluate the functional capability and capacity,
including SBN, ABN and vibration signature of the item under testing. These
functional tests are to be carried out in accordance with the Acceptance Test
Plan approved by IHQMoD(N) or their authorised [Link] subjecting an
item for functional test may require other components not in present order or
supporting infrastructure not catered/envisaged for while placing the order, or not
available with the instant vendor/firm on whom the order is placed, there is a
requirement to clearly define the applicability of such tests. The following
guidelines will be applicable across all types of orders with respect to undertaking
of functional tests:-
(i) All equipment/system which are part of first time or induction
ordering will undergo functional tests to establish its ability to confirm to
specifications and requirements as provided in PO.
(ii) All equipment/assemblies like pumps, engines, compressors etc.
which are part of even replenishment orders should undergo functional
tests unless waived off in the purchase order. It will be the responsibility of
the vendor/firm to provide such facility to undertake the functional tests.
30
(iii) All subassemblies and components will need to undergo functional
tests if such tests are mandated in the original approved drawings/DBOM.
Any wavier for such tests should be mentioned in the PO.
(iv) For all other spares where functional tests are not indicated in
approved drawings/DBOM, no functional tests will be undertaken, unless
dictated specifically in the PO.
(v) Where functional tests are destructive in nature like filter elements,
electrodes etc, relevant sampling criteria should be specified in
PO/Approved drawing.
(vi) Where functional tests are not feasible for lack of infrastructure or
support facilities, the vendor/firm is to appraise the OPA before
submission of offer and seek appropriate directions/orders as applicable.
(vii) In general, the functional tests will be operating the equipment to
rated load/performance under normal operating conditions. Any other
specific regime or requirement like only no load run, partial loading etc
should be clearly defined in drawings, tendering/tender response and
recorded in the PO.
0604. Trials relate to monitoring the operation and performance of the completed
subassembly/
assembly/equipment/system. Trials validate overall functional performance
parameters as per [Link] would include following:-
(a) Production/Routine trials – These are trials that each piece/system has to
undergo to ensure designed performance.
(b) Endurance trials – These are trials during which the equipment/system is
operated continuously at pre-determined duty cycles for a pre-defined, extended
duration to ensure sustainability of the equipment/system for prolonged
operation. The applicability of endurance run to each piece/system or only the
pilot case will be governed by the provisions of PO and approved QAP.
(c) Factory Acceptance Trials (FATs) – The requirement for conduct of FATs
would be specifically indicated as part of the PO. FATS is the final operational
run of the equipment at the manufacturers test bed, in a configuration as close to
the actual layout on board, before the equipment is cleared for dispatch for
onboard use/installation. Where the deliverables constitute a system, an
Integrated FATs is required to be [Link] and modalities of conduct of
FATsis placed at Appendix „H‟.
0605. Environmental Stress Screening (ESS). The ESS, though part of the
manufacturing process, plays a vital role in establishing the process and product
capability. Guidelines for conducting ESS are placed at Appendix „F‟.
31
0606. Inspection process for Replenishment/Repeat Orders. Replenishment/
repeat orders can be for complete system, equipment or spares. The inspection process
for replenishment orders will be governed as follows:-
(a) Systems and equipments will be inspected in accordance with relevant
QAP and associated approved drawings as undertaken for induction orders.
Type tests, qualification tests, endurance trials etc will be governed by the
provisions of purchase order. Where these are not explicitly mentioned in the PO,
type tests, qualification tests and endurance trials will be undertaken only if
relevant type test, qualification test and endurance trial have not been
undertaken earlier or there are changes with respect to the system/equipment
that had undergone these trials earlier.
(b) Spares sourced from non-PAC firms will be subjected to complete
QA/inspection process as warranted by the approved QAP/drawings up to the
component level.
(c) In respect of spares where inspection clause per PO is “As per OEM Tech
Spec”, inspection/QA cover will be governed as follows:-
(i) The inspection will be undertaken in accordance with
specification/details provided in the DBOM/Approved PIL.
(ii) If specifications/sufficient details are not indicated in PIL, the details
provided in the drawings as indicated in DBOM/submitted by firm will be
taken as reference.
(iii) Inspection will cover conformance to material specifications,
manufacturing process and dimensions. Material specifications will be
against STC and others will be verification of certificate of conformity
issued by the firm. Physical verifications of dimensions will be undertaken
for binding/critical dimensions.
(iv) Type testing/qualification tests where necessary, will be undertaken
if not undertaken earlier or if relevant test certificate is not available with
the firm or if the item has any changes.
(v) All routine/functional tests that are part of ATP as per
Specifications/original induction QAP will be undertaken unless specifically
waived off by the OPA.
0607. Further, all tests/trials are to be undertaken at NABL accredited laboratory, under
intimation to the concerned QAO. In cases where testing is accepted to be undertaken
at facilities which are not accredited by NABL, witness of testing by QA agency is
32
mandatory. Sentencing/interpretation of all NDT tests like RT, UT, MPT, DPT etc should
be provided by a technician qualified in ISNT/ASNT level II in the relevant discipline.
0608. The QAO will attend to various stages of inspections on receipt of inspection call
from the vendor. Whilst a broad production schedule indicating likely period of
inspection calls is to be prepared and handed over by the firm to local QAO on receipt
of FCL, a formal request for specific inspection is to be made at least three working
days for inspection in station and seven working days for inspection out of station.
Urgent cases may be mutually worked out between the firm and QAO. Details of
internal QC inspections and reports of the firm are to be provided along with the
inspection call letter.
0609. In some cases, considerable time lapse is observed between the inspection of a
particular sub-assembly and its integration with the main equipment. In such cases, the
validity of QA inspection of the sub-assembly becomes suspect due to considerable
lapse of time from its inspection. There fore, the shelf life of every component or
assembly cleared is to be indicated after completion of inspection. Only components/
assemblies within the valid shelf life are to be taken up for assembly/integration in/with
the main equipment/system. The vendor will provide details of any life-limited item,
included as part of the equipment/ assembly/ sub-assembly, as part of the Inspection
Process.
0610. Inspections will be undertaken only within the currency of delivery period. In
exceptional cases, where delivery period has expired, the Inspection Agency may
consider extending the QA cover and continue with inspections on request from the
vendor/firm subject to the firm having taken up the case for delivery date extension with
the OPA. However, since Inspection note/Form IV can be issued only within the
currency of delivery period, in such cases, the I-note/form IV will be issued only after the
delivery period is extended by the OPA. The Inspection Agency proceeding with the QA
cover despite the expiry of the delivery period will not entitle the firm to any claims or
guaranteed acceptance of the item/equipment by the OPA nor will it bind the OPA to
provide delivery extension. Such inspections will be at the sole risk and responsibility of
the vendor/firm. The validity of such inspection is only 30/60 days without/with
revalidation. Therefore, DP extension is to be made available before the expiry of this
period, failing which the validity of inspections undertaken will expire precluding issue of
I-note.
0611. In accordance with the provision of article 7.9.1 of DPM 2009, “In certain cases
where the contractor offers stores for inspection during the last few days of contract DP
or on the last day of contract DP, the inspector can inspect the store and sentence it as
per standard franking clause”. In such cases, units will undertake inspection of
equipment and stores only where the inspection call has been made and I-note will be
issued mentioning that the inspection has been completed in accordance with clause
7.9.1 of the DPM 2009.
33
0612. After the I-note is issued, the item has to be dispatched in accordance with the
INCO Terms specified in the PO. In case of non-dispatch within 30 days period, another
30 days of grace period is provided. However, for dispatch during the grace period, the
I-note needs to be revalidated. After 60 days, the items have to be re-offered for
inspection.
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Chapter 7
Documentation
0701. In some cases, particularly induction/shipyard orders, the deliverables also
include documents like technical description, operating manuals, PIL, maintenance
manuals etc.
0702. For POs which include documentation as deliverables, I-note/Form IV will be
issued only on completion of the contractual obligations per PO.
0703. Notwithstanding any provisions for submission of final documentation de-linked
from issue of I-note/form IV, and for cases where documentation is to be approved by
IHQMoD(N) or another third party, and the final document can be produced only after
the FATs, the draft documents needs to be submitted as a pre-requisite for final
dispatch clearance.
0704. For equipments/systems that are to be subjected to FATS, the draft operations
manual is to be made available prior raising request for conduct of FATS.
0705. For Electrical/Electronic and weapons/sensors, clearance certificates from NTG
will form the basis for acceptance of documents as part of deliverable.
35
36
Chapter 8
Preservation & Packaging
0801. Preservation and packing is the last process before the equipment is cleared for
dispatch from the factory to the consignee. Since the equipment or the spare is put to
use much later, is imperative that adequate preservation is provided and that the items
are suitably packed and delivered safely to the consignee. The measures to be
complied with are as follows:-
(a) The medium and mode of preservation is to be unambiguously spelt out in
the binding/ GA drawing with any additional specific requirement at the
component level in the DBOM. The protection and preservation could include
painting, electroplating, vacuum packaging, encapsulating with VCI/VPCI,
shrouding etc.
(b) Specific procedures are to be provided in the drawing along with the
specifications and standards as applicable and mentioning generic conditions like
„standard commercial packing‟ etc are not acceptable.
(c) The preservation process is to commence immediately on completion of
the last inspection procedure. Particular emphasis is to be paid to sealing/closing
of open ends immediately on completion of relevant tests; including during in
process inspection to obviate ingress of any sort of contaminants. Suitable
preservation of all electrical and electronic contacts, consoles and items are also
to be undertaken immediately after the inspection process.
(d) The packing list providing details of items are to be enclosed with the
package.
(e) Suitable tally providing the consignment and consignee details should be
placed prominently on the package.
(f) The following additional details are also to displayed prominently on the
packing:-
(i) The life of preservation(Re-preservation due on -------------)
(ii) Any periodic inspection or maintenance required.
(iii) Any special or specific handling and transportation requirement.
(iv) Storage requirement in warehouse.
(v) Use before ------------- in case of items with shelf life
37
38
Chapter 9
Inspection Note
0901. The programme of Quality Assurance culminates in issuing a document,
generally termed as Inspection Note (I-Note) that clears the item or equipment for
acceptance and dispatch.
0902. Two formats have been promulgated for Inspection Note as mentioned below:-
(a) DGS&D(S) – 84 Form – These are Inspection Note issued for orders
placed by any agency or organisation except shipyards and sub–orders. This
form is entirely filled by the Inspecting Agency. The payment cases under this
form of I-note are processed through CDA for orders placed by Indian Navy.
(b) Form 4 – These are issued when an item is inspected for which the order
was placed by a shipyard or in case the item is a part of a sub–order. In this
case, the firm fills up the form and submits the same to Inspecting Agency for
approval and issue. The payment cases under this form of I-note are not
processed through CDA.
0903. The issue of Inspection Note (Form 4 / DGS&D(S) – 84 Form) by Inspection
Agency primarily certifies that:-
(a) The component or equipment has been inspected in accordance with
approved QAP and drawings.
(b) The requirements stated in the Purchase Order have been met; with
approved concessions or deviations if any.
0904. The Inspection Note reflects the acceptability of the ordered goods at the point of
despatch. In case the equipment or part is damaged during transit, the applicable
clauses of insurance, guarantee and warranty will be invoked.
0905. The Inspection Note is a document having financial implications. Hence all
regulations and orders in force should be strictly adhered to. The salient features are:-
(a) The Inspection Note will be issued only after all inspections have been
completed, including that of documentation, preservation and packing.
(b) The number of Inspection Notes in each order will not exceed the total
number of Part Supply Part Payment (PSPP) clause mentioned in the Purchase
Order.
39
(c) During issue of I-Note for part quantities, the rules for painting,
preservation, packing and shipment will be applicable at par with the complete
equipment and there shall be no concessions.
(d) The Inspection Note will be issued only if the delivery period is valid.
(e) The Inspection Note can be signed by authorised officers only.
(f) The inspection note will be issued within 07 working days of meeting all
requirements.
0906. No Certified True Copy or duplicates of the Inspection note will be issued as a
routine. If specifically sought by the firm or Order Placement Authority, a certificate from
Purchasing Agency stating “No payment has been made against the lost Inspection
Note and no payment will be made against the original document if retrieved”, has to be
submitted along with the request for issue of a duplicate Inspection Note. The extant
rules will be rigidly adhered to.
0907. A Vendor rating of the firm will be an integral part of all I-notes. Vendor rating is
an indexed grading of the performance of the firm with respect to instant order and will
cover attributes such as quality of process, quality of product and adherence to
timelines. Lower vendor rating could result in de-registration or capacity de-valuation of
the firm in accordance with provisions of JSG - 07.
0908. For equipment covered under Dual Inspection, Inspection note from QAO will be
mandatory and will be issued post completion of all inspection stages as per
DQA(WP)/DQA(N) approved QAP. Similarly, in case of inspection of weapon items
where few components will be inspected by Naval Armament Inspection (NAI), DQA(N)
will remain the primary QA authority while NAI will issue Inspection Clearance
Certificate to vendors for components falling under their purview. I-Note will be issued
by DQA(N) on completion of all QA activities as per QAP and receipt of clearance
certificate from NAI as well as NTG for documentation.
0909. Despatch Clearance. Under special circumstances, where part quantity not
covered in the PO or in very rare occasions where the complete system is required at
the consignee urgently and before the I-note/form IV can be issued, the OPA may seek
approval for despatch clearance of the inescapable quantities to meet the immediate
requirement. The approval for despatch clearance will be accorded by the Inspecting
Authority on a case to case basis, provided all QA activities are completed. However,
Inote/
form IV will be issued only after all requisites are met and available. This facility is
to be used only as an exception. Such despatch clearance does not entitle the firm to
seek issue of I-note/form IV till all pre-requisites are otherwise met. Such clearances will
be at the sole risk and responsibility of the vendor/firm to fulfill all the mandatory
obligations for issue of I-note/form IV.
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Chapter 10
Jurisdiction
1001. The DQA organization provides quality cover for a wide range of equipment and
systems through the various field units located across the span of the country. In order
to have absolute clarity with respect to the inspecting authority and inspection agency,
clear demarcation of responsibilities with respect to functional jurisdiction and
geographical jurisdiction have been made and is enumerated in succeeding
paragraphs.
1002. The inspecting authority for an equipment/system will be in accordance with the
demarcation of the responsibilities between DQA(WP) and DQA(N) as placed at
Appendix „J‟
1003. Inspection agency will be based on the functional jurisdiction with respect to
Inspecting Authority and the geographical jurisdiction of the Inspection Agency. The
geographical jurisdiction of various inspecting agencies is placed at appendix „K‟.
1004. The inspecting authorities also reserve the right to nominate a different
inspection authority or inspection agency, considering core competence and work load.
Such cases will be taken up with the OPA as required.
1005. The purchase orders are to indicate the inspecting authority and the inspection
agency in the purchase order. Any requirement for change or amendment to the same
will be taken up by the nominated inspection agency through its inspecting authority.
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42
Chapter 11
Conflict Resolution
1101. The Quality Assurance process is an intense and iterative process involving
many stakeholders, viz. the OPA, production and professional directorates/Command
Headquarters, the Inspection Authority/Agency and the vendor/manufacturer. Therefore,
there is bound to be differences in perceptions and these are to be resolved as provided
in succeeding paragraphs.
1102. Authority to approve and/or amend QAP is the Inspecting Authority. For
systems/equipment for which SQAPs have been issued with the participation of the
various stakeholders, deviation from SQAP will be accepted only in exceptional cases
like change in process, sourcing etc. Any request/case with respect to the QAP in so far
as the specifics of QAP are concerned is therefore to be referred to the Inspecting
Authority through the nominated Inspection Agency.
1103. Authority to specify/amend the governing parameters including specific
standards, grades, qualification/type test requirements, limiting parameters, indication of
list of COTS equipment/ module/ sub-assembly etc will be the OPA. The Inspection
Agency will accept the product/process only when they are within the prescribed limits
as per the specifications provided in the PO. Any request/case with respect to
changes/amendments to the governing standards/specifications or parameters is
therefore to be referred to the OPA under intimation to the Inspecting Authority and the
nominated Inspection Agency.
1104. Concessions and Deviations will be governed as per the provisions in
Chapter 13 of Guidelines for Quality Assurance for Engineering and Hull equipment for
Indian Naval Warships.
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44
Appendix ‘A’
(Refers to Para 0302)
PROCEDURE FOR DRAWING APPROVAL FOR QA COVER
OF FIRST TIME INDUCTION SYSTEMS AND EQUIPMENT
1. Submission of Drawing. The firm to submit the GA drawings with respect to
the system and/or the equipment under procurement containing the layout, boundary/
installation parameters/dimensions and a detailed bill of material (DBOM).
2. If the main or subsequent GA drawings have assemblies and subassemblies in
their BOM, GA drawings of these assemblies and subassemblies along with their
DBOM will also need to be submitted. Thus, all assemblies, subassemblies and parts
constituting the system and equipment should get reflected in the GA drawings and
DBOM submitted, duly linked in a parent child relation that will ensure forward and
backward traceability.
3. Manufacturing Drawing. The manufacturing or detailed drawings will remain
with the firm, to be produced to the QA team during the visit for inspection.
4. Detailed Bill of Material. Each GA drawing is to have its associated DBOM.
Specifications and parameters which ensures that the product will meet the
requirements of PO and which are required to draw up QAP are to be provided in the
DBOM. While providing the details in the DBOM, following are to be included:-
(a) Drawing no of each assembly, sub assembly and component indicated in
the drawing
(b) Material specifications including grade/condition
(c) Manufacturing process (including heat treatment and stress relieving
diagram where applicable) in case of major, critical, loaded and stressed
components.
(d) Components where specific testing and examination like RT, UT, MPI, DP
etc are required with the corresponding drawings depicting shooting sketch and
inspection norms and acceptance criteria for the specific BOM (can be schematic
without dimensional, or manufacturing details).
(e) Requirement of type testing, functional testing etc in respect of assemblies
and subassemblies
(f) Areas of Critical dimensions, weights and tolerances (Values and limits
need to be indicated in the manufacturing drawing only)
45
(g) Interfacing requirements of mating components
(h) In case of COTS, Imported and bought out items, the details like make
and model, country of origin etc.
5. This DBOM is to form the basis of PIL and both DBOM and PIL should be
mapped one to one. Sample of GA drawing with DBOM and guidelines for preparation
of GA drawings are placed at Annexure I &II respectively.
6. Formulation of Requirement in GA Drawings. Lack of adequate
information provided at the approval stage can lead to incomplete or inadequate QA
cover. Therefore, various stake holders are to arrive at acceptable level of depth in
drawings and information to be submitted by the manufacturer prior issue of Purchase
Order. With experience gained over time, this will be frozen and issued as equipment
and system specific drawing requirements, as in the case of Standardised QAPs being
issued presently.
7. Approval of Drawings. The drawings for induction/shipyard orders are to be
approved by authorities as under:-
(a) By Professional directorate for compliance to NSQR/ SOTR.
(b) By Production directorate with respect to installation.
(c) By Inspection Authority with respect to Quality Assurance.
8. Manufacturing Drawing Verifications. The first step of Quality assurance will
be verification of the availability and completeness of manufacturing drawings. The
drawings will be verified with respect to the drawing no and details provided in the
approved GA drawing and DBOM as well as with respect to complete representation of
data and information in the drawing to undertake the production and process
inspections. Inspection will be undertaken only when these are confirmed and any
incomplete or missing information or data will be intimated to the firm to be made good
before commencing the inspection.
9. Amendment to Drawings during Production. Any amendments required
in the drawings due changes necessitated during production can be incorporated by the
manufacturer in the drawing duly authenticating the changes, if such changes are not
affecting the details provided in the approved GA drawing and DBOM. If binding data
and parameters of GA drawing and DBOM requires change, the drawings will need to
be reapproved as at para 7 above.
10. Stamping of Manufacturing Drawings. After the inspection is
undertaken, along with stamping of the product, the copy of the drawing held by the firm
will be stamped by the inspector as being the reference of inspection undertaken
providing details of the Purchase Order no, the QAP no and the date of inspection. The
46
same drawing will be stamped every time an inspection is undertaken; for the next
stage of same piece, a subsequent piece or order.
11. As Built Drawing for Future Reference. After the manufacture of the first
piece is completed, an as built drawing incorporating all changes is to be made and
stamped by the inspection agency. The as built drawing of first piece will become the
reference for manufacture of subsequent pieces. In respect of subsequent production,
no changes in dimensions or parameters from the as built drawing will be accepted by
the QA team without the approval of the competent authority.
12. Post Production Verification. In case of a requirement of verification at a
later date, the firm will be required to provide the inspection details and the relevant
stamped drawings as required by the Navy. A certificate from the firm that these details
will be provided as and when needed is to be obtained from the firm with every
purchase order.
13 Overhaul and Maintenance requirements. All overhaul processes,
acceptable tolerances, limits etc is to be included in the maintenance manuals
submitted by the firm.
14. Notwithstanding the above, the responsibility of design and performance will be
that of the firm. Therefore the following will apply to all orders:-
(a) Full responsibility of design and performance will be of firm.
(b) Approval of drawings is to ensure and bind firm with limiting boundaries
and specific requirements.
(c) QA cover is to ensure that the production has been undertaken in
accordance with the defined process and specifications.
(d) Stamping of manufacturing drawing is to ensure continued reference to
same drawing and repeatability of the product and is not an authentication of the
design or any change.
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48
Appendix ‘B’
(Refers to Para 0304)
APPLICABILITY OF APPROVED DRAWINGS
(A) FOR INDUCTION ORDERS
CONDITION DRAWING
Has
supplied
earlier.
Approved drawings
are GA drawings
with Detailed Bill of
Material (DBOM).
Has no changes in
present supply
Latest version of approved, as fitted
drawing.
Has changes in
present supply
Revised drawings and/or DBOM
approved afresh.
Approved drawings are up to component
level as per practice in vogue prior Apr
2016. Present supply with or without
changes
New GA drawings and DBOM need to be
approved per current directives in vogue.
Has not supplied earlier
New GA drawings and DBOM need to be
approved afresh per current directives in
vogue.
(B) FOR SYSTEM/EQUIPMENT/ASSEMBLY/SUB ASSEMBLY – DPRO/MO ORDERS
CONDITION Induction OEM Others
Has
supplied
earlier.
Approved drawings
are GA drawings
with Detailed Bill of
Material (DBOM).
Has no change in
present supply
Latest version of approved as fitted
drawing.
Has changes in
present supply
Revised drawings and/or DBOM
approved afresh.
Approved drawings
are up to component
level as per practice
in vogue prior Apr
2016.
Present supply
without changes
Latest version of approved as fitted
drawing.
Present supply with
changes
Revised drawings approved afresh
Has not supplied earlier NA
New drawings up
to component
level approved
afresh.
49
(C) FOR SPARES – DPRO / MO ORDERS
CONDITION
Inspection
against OEM
Tech Specs
Others
Has
supplied
earlier.
Approved drawings are
GA drawings with
Detailed Bill of Material
(DBOM).
Has no change in
present supply
Drawings per DBOM
Has changes in
present supply
Revised drawings and/or DBOM
approved afresh.
Approved drawings are
up to component level
as per practice in
vogue prior Apr 2016.
Has no change in
present supply
Details per
Approved PIL
Latest version of
approved as fitted
drawing.
Has changes in
present supply
Revised drawings
up to component
level, approved
afresh.
Has not supplied earlier NA
New drawings up
to component
level, approved
afresh.
50
Appendix ‘C’
(Refers to Para 0304)
SUBMISSION OF DRAWINGS FOR REPLENISHMENT
ORDERS OF EQUIPMENT/SPARES
1. In cases of replenishment orders placed by any OPA, which also includes orders
for On Board Spares and Base & Depot Spares for first time inductions, the necessity to
have any drawing approved should not arise under normal circumstances, since these
have already been inducted into the IN against approved drawings and QAP.
2. Fresh approval of drawings will be required only under following conditions:-
(a) Any change, irrespective of the quantum, in design which includes
material, dimensions including tolerances, operating/duty point, binding
dimensions etc since these could have effect on stress distributions,
compatibility, installation requirements, functional parameters (including
endurance and environmental qualification parameters) etc.
(b) Any change in manufacturing process or sourcing since these may call for
changes in QAP.
(c) Any change in governing specifications including reference standards
since these may change testing and acceptance norms.
(d) In specific cases, where complete equipment system installed in one
platform/ship is being retrofitted on another platform/ship which may necessitate
changes in the binding data.
3. In cases where there are changes as brought out above, the corresponding
drawings needs to be re-approved/re-validated as follows:-
(a) The firm submits the revised drawings along with the original (latest
version of drawings approved earlier) to the OPA indicating the changes
incorporated/necessitated under intimation to the respective inspecting agency.
(b) Where there are no changes in the equipment, but the platform/ship where
it would be installed is different from initial fit, the firm to submit the binding data
to the respective OPA for ratification, under intimation to the inspecting agency.
(c) The OPA obtains approval or otherwise of the competent authority for the
changes incorporated/necessitated or the concurrence to use the existing
equipment as it is with respect to existing approved drawings on new platform
and forwards to inspecting agency for ratification or otherwise of existing QAP.
51
(d) The approval accorded for changes should clearly indicate if its validity is
only for the instant order or valid for all future orders as well. Where the changes
are valid for all future orders irrespective of command or platform applicability,
the necessary amendments to approved drawings is to be endorsed in all
records for future procurements. In such cases, this revision of the drawings will
become the latest version of approved drawings.
4. In cases where there are no changes and the existing approved drawings are
valid, their submission will be governed as follows: -
(a) Where the latest versions of approved drawings are GA drawings along
with DBOM, only mention of the relevant item no drawing with traceability to
details in PO is sufficient and no physical submission of any drawing is required.
The firms will be required to present the original stamped drawing held in its
custody to the QA team during the first visit for inspection.
(b) Where the latest version of the approved drawings are detailed drawings
up to component level, original drawings of the latest version of approved
drawings will need to be presented to the QAO for verification. Whilst submission
of authenticated copies is sufficient for processing the QAP and other initial
formalities, inspection will commence only after verification of the originals.
Nonavailability
of original drawing will require the vendor to obtain fresh approval of
the competent authority.
(c) In case of spares ordered against OEM Tech Specs, there is no
requirement to submit any drawings and inspection will be carried out in
accordance with details provided in approved PIL/DBOM.
5. Whenever a change is envisaged or necessitated, the process for revision and/or
clarifications can be taken up any time by an OEM with the concerned professional
directorate for amendment to their approved drawings and DBOM, even when there is
no tender or order pending on the firm.
6. It will be incumbent on all firms responding to a tender, to indicate and intimate
any changes that have been incorporated or necessitated in any of the items or
components with respect to last approved drawings and supply, during their offer, so
that necessary clarifications and approvals can be accorded prior issue of PO, if not
done earlier.
7. Any delay or difficulty in execution of order due to changes noticed with respect
to last supply that has not been intimated during the offer and before issue of PO will be
fully attributable to the firm.
52
Appendix ‘D’
(Refers to Para 0403)
APPLICABILITY OF APPROVED QAPs
(A) FOR INDUCTIONORDERS
CONDITION QAP
SQAP
issued
Has
supplied
earlier
Has no change in
present supply
Relevant SQAP as approved for previous order.
Have changes wrt
last supply.
Relevant SQAP, with amendments if required
Has not supplied earlier Relevant SQAP, with amendments as required
SQAP
not
issued
Has
supplied
earlier.
Has no change in
present supply
Latest version of approved QAP. In case a later QAP
for similar equipment of a different supplier is
available, necessary changes to the existing QAP will
be incorporated and issued as „Approved as
Amended‟
Have changes wrt
last supply.
Revised QAP if necessary. For faster approval,
changes wrt previous supply be submitted along with
proposed QAP. Type tests/ Qualification tests will be
required unless waived off by OPA
Has not supplied earlier
New QAP to be drafted by firm and approved by
Inspecting Authority
(B) FOR SYSTEM/EQUIPMENT/ASSEMBLY/SUB ASSEMBLY – DPRO/MO ORDERS
CONDITION Induction OEM Others
SQAP
issued
Has
supplied
earlier.
Has no change in
present supply
Relevant SQAP as approved for previous order
Have changes wrt last
supply.
Relevant SQAP, with amendments if required
Has not supplied earlier Relevant SQAP, with amendments as required
SQAP
not
issued
Has
supplied
earlier.
Has no change in
present supply
Latest version of approved QAP
Have changes with
respect tolast supply.
May Require Revised QAP. For faster approval,
changes with respect toprevious supply be
submitted along with proposed QAP. Type tests/
Qualification tests will be required unless waived
off by OPA
Has not supplied earlier
NA
New QAP to be drafted by
firm and approved by
Inspecting Authority
53
(C) FOR SPARES – DPRO/MO ORDERS
CONDITION QA per OEM Tech Specs Others
SQAP Issued
Details provided in
approved DBOM OR PIL
Relevant articles of
SQAP
SQAP
not
issued
Has
supplied
earlier.
Has no changes with
respect tolast supply
Details provided in
approved DBOM OR PIL
Latest version of
approved QAP
Have changes in
present supply
Details in revised and
approved DBOM OR PIL
May require
amended QAP
Has not supplied earlier NA
QAP drafted and
approved afresh.
54
Appendix ‘E’
(Refers to Para 0506)
DETAILS OF ACCEPTABLE IMPORT DOCUMENTS
Sl
No
Document Interpretation Acceptable Documents Remarks
1
Bill of
Lading
Bill of lading is a
document issued by the
carrier which details a
shipment of
merchandise and gives
title of that shipment to
a specified party
OR
Bill of Lading is a
document issued by the
actual transporter (Ship,
Airway or agent) of the
equipment which clearly
indicate the description,
quantity,port of
collection and port of
discharge
(a) Bill or receipt issued
by the Shipping
Company/Shipping agent/
Ships‟ Captain
(b) Shipping Bill
(c) Airway bill
(d) Couriers‟ Bill
In case main firm intends procuring
the imported component/item
though other Indian sources
through suborder, the same should
be ratified by OPA, preferably
before placement of PO. In such
cases, the original importers‟
document can be accepted if
traceability can be established with
respect to the items being supplied
as having been currently and
correctly imported.
If Indian vendor receive items
through Courier services and are
unable to submit the original Bill of
Lading, items can be cleared
based on packing slip on the
consignment and verifying Courier
service's Bar Code on packing.
2
Shipping
Bill
Shipping Bill is a form
used by Customs &
Excise before goods
can be exported from
the country or removed
from a bonded
warehouse and
indicates details of PO,
goods, consignee etc.
(a) Invoice issued by
foreign firm giving details
of PO, goods, consignee
etc and submitted to
freight agent/customs
towards transportation by
sea/air
(b) Complete packing
list of all items along with
complete details of
ship/flight through which
the item have been
supplied, issued by logistic
firm tasked by foreign
supplier/ manufacturer to
supply the item
It is an imp document required by
Customs authorities for allowing
shipment. It is prepared by exporter
& it contains following :-
1. Name of Vessel
2. Name of the port of discharge
3. Country of final destination
4. Exporter's name and address
5. Details about packages.
6. Quantity and details of each
case
7. FOB price
[Link] no. of packages with
weight & value
9. Name and address of the
importer
55
3
Bill of Entry
to Ware
Housing
A form issued by Indian
Customs and Excise to
list goods prior to entry
to warehouse for home
consumption on import
Certificate by Indian
Customs giving
confirmation of the entry of
items into the Indian port
containing the details of
supplier, port of loading ,
country of origin, no of
packages and weight etc.
4
Country of
Origin
A document which
certifies that the
products exported are
wholly
obtained/produced or
manufactured in that
particular Country. This
certificate is issued by
the Chambers of
Commerce/ Such
Authorised Signatory of
the country in which
imported item
/equipment is
manufactured.
(a) Country of Origin
certificate issued by
Chamber of Commerce or
Government of respective
country.
(b) If country of origin
is indicated in Shipping Bill
or Bill for entry to
warehousing and is
matching with BOM, the
same may be accepted.
(c) In case firm cannot
produce country of origin
certificate issued by
Chamber of Commerce or
Government of respective
country, the same should
be told upfront to OPA and
if OPA ratifies in Purchase
Order or subsequent
document, one of the
following documents can
be accepted
(i) Certificate issued
by Foreign
Supplier/OEM
(ii) Declaration
Certificate for country
of origin issued by the
OEM in case of PAC
firms
Country of Origin (COO) is the
country of manufacture, production
or growth where an article or
product comes from. The origin of
the product does not refer to the
country where the goods were
shipped from but to the country
where they were made. In the
event of the product being
manufactured in two or more
countries, origin is obtained in the
country where the last substantial
economically justified working or
processing is carried out. As a
thumb rule if more than 50% of the
cost of producing the goods
originates from one country, then
that country is acceptable as the
country of origin.
In case of trading bloc, certificate of
origin may be allowed to state the
trading bloc (for e.g. European
Union as origin) rather than specific
country
5
OEM'S
Certificate
of
Conforman
ce
Certificate of
Conformance (CoC)
issued by OEM stating
that spares are tested
for FORM,FUNCTION&
FITMENT
OR
CoC issued by the OEM
from whom the
item/equipment is
sourced.
CoC is to be verified against
specific serial no or batch no, to be
available on the CoC and same
details of the instant piece/pieces
being supplied.
56
A document certified by
a competent authority
committing or promising
that the supplied good
or service it covers
meets the agreed upon
or required
specifications.
6
OEM'S
Test
Certificate/
Quality
Assurance/
Guarantee
Certificate
Test certificate issued
by OEM (the original
manufacturer)
indicating conformance
with relevant
criteria/standard/norm.
(a) OEM‟s Test
certificate
(b) If foreign source is
Indian vendor/firm‟s
principal, then certificate
issued by the Indian firm
indicating conformance
with relevant standards/
equipment function
supported by the authority
letter issued by foreign
manufacturer that they are
the principals of the Indian
firm.
In case order is placed on
Vendor/Agent other than the PAC
firm, the document furnished is to
be issued by the PAC firm/OEM of
the main equipment.
The test certificate should also
indicate the relevant standards or
specifications to which the tests
have been undertaken.
7
Indian Firm
Guarantee
Certificate
Warranty/Guarantee
Certificate issued by
Indian vendor on whom
order is placed.
Warranty/Guarantee
Certificate issued by
Indian vendor on whom
order is placed.
Note: Any mismatch in item code/description/part number between import
document and purchase order should be ratified by the OPA; either by amending the
PO or by approving the FFF certificate submitted by the firm.
57
58
Appendix ‘F’
(Refers to Para 0603(a))
GUIDELINES FOR CONDUCT OF ESS
Aim
1. The aim of this letter is to lay down guidelines for formulation of effective ESS
programme and methodology for conduct of ESS on Electronic Components/Units/
PCBs/Modules. The guidelines also provide directions to manufacturing agencies to
incorporate tests at the design and manufacturing stage to weed out such deficiencies,
which can manifest at a later stage causing avoidable down time of the equipment and
expensive corrective action thereupon.
Applicability of ESS
2. Indigenous Manufacturing. The ESS is to be applied to 100% electronic
components/units/assemblies as part of manufacturing process for indigenously
manufactured electronics. Hardware incorporating purely mechanical system/elements
including wire wrapped backplanes and fragile electronic items viz. LCD panels, Hard
Disk
Drives etc may be exempted from ESS.
3. The present guidelines will be applicable for the new POs placed after
promulgation of this policy. For all previous POs, ESS plan as per approved QAP may
be followed. For new orders pertaining to spares of Systems/Equipment supplied
earlier, ESS scheme as per guidelines in vogue/as conducted at the time of delivery of
the system would be applicable.
4. Applicability for Imported/COTS Items. In case of imported and COTS
items, following guidelines will apply:-
(a) During the course of production, a variety of imported/COTS items
(components/PCBs/modules) may be used by the manufacturer of main system.
ESS on such items is to be carried out at the next higher indenture level. The
severities are to be decided based on designed parameter of weakest component as
per data sheets of components in order to ensure that there is no damage to the
used part whilst conduct of ESS.
(b) However, in case the Imported items are being supplied by the manufacturer
in „As It Is‟ condition with no addition/alternations, such items are to be accepted
based on CoCs clearly endorsing the standards to which the items comply and
physical values of test conditions the items have been subjected to ESS.
(c) Use of fully finished COTS items needs to be specifically approved by
IHQ MoD(N)/(Professional Dates)/OPA and are to be accepted against CoCs as in
case of „As It Is‟ imported items.
59
ESS Programme
5. It is necessary to conduct ESS at the earliest possible stages where it is possible to
reveal latent defects and initiate necessary corrective actions. Following needs
consideration while devising effective ESS programme:-
(a) A viable ESS program must be dynamic wherein the screen parameters
must be actively managed and tailored to the particular characteristics of the
equipment being screened.
(b) Effective ESS program generally involve more than one type of screen.
(c) Thermal cycling and random vibration are considered the first and second
most effective screens respectively in identifying latent defects.
(d) While severity of the applied stress screen must be strong enough to
effectively reveal the latent defects, care must also be taken not to over-stress the
item which could either cause damage or reduction in residual life. At the same time,
non-precipitation of latent defects is indication of weak stress level. The stress must
conform to stringent level within designed parameters of the weakest component.
Design parameters are generally much higher than the operating parameters.
(e) ESS is applied to 100% of the units manufactured including spares and
repaired units.
ESS Process Sequence
6. The electronic hardware is recommended to be screened as per the following
sequence:-
Stage-1 : Perform thermal cycling screening at PCB level
Stage-2 : Perform random vibration at PCB level or higher indenture
Stage-3 : Repeat thermal cycling screening at an indenture higher than
PCB level
7. The conduct of thermal cycling prior to random vibration pre-stresses potential
defects which can then be surfaced more effectively by random vibration. Random
vibration also conditions some defects to the point of failure which are detected by a
subsequent thermal cycling with performance monitoring. All ESS requirements must be
accomplished at the lowest feasible level of assembly. The following three indenture
60
levels have been identified for conduct of ESS: -
(a) PCB level
(b) Module/ sub-unit level
(c) Unit/Cabinet level
ESS Flow Diagram
Stage 1 Stage 2 Stage 3
Stage -1 Stage -2 Stage -3
8. Screens for Conduct of ESS. A tailored screen requires that specific
parameters of equipment being screened, be reviewed such that defects are detected
and removed without incurring undue damage to the equipment. The screening
levels should not exceed design limits, but they must be of sufficient strength to
precipitate failures due to weak parts and manufacturing defects at the earliest time
such
that corrections are most cost effective. Two screens each for Thermal Cycling Stress
Screening (TCSS) and Random Vibration Stress Screening (RVSS) have been defined
at Annexure III&IV respectively. In case a screen with severity below the above two
screens is proposed for any item, approval of Professional Directorate is to
be sought for use of such items with suitable justification. The screen for such
cases would then be worked out based on the limitations imposed by the
specifications of the items approved to be used. Accordingly, the applicable screen
severities can be categorized as follows: -
(a) Screen-A (Severe). This would be the default screen with most
stringent severity based on design parameters of weakest component for effective
precipitation of latent defect.
(b) Screen-B (Moderate). To be selected based on parameters of the
items necessitating use of screen severity below the above Screen „A‟ category.
Prior approval for use of such items has to be obtained by the firm from
Professional Directorate. The tailored screen would accordingly be specified in
the QAP with suitable justifications. Reason for application of this screen for the
item instead of Screen „A‟ is to be justified in the QAP and list to be attached with
QAP.
9. Based on the above process sequence and categorisation of screens, it is
proposed to denote the stress severity of products as per the notat ion
“Product (XXX)”, where the first “X” represents thermal screen severity for Stage-1,
PCB - Thermal
Cycling Stress
Screening
PCB or Higher
Indenture Level -
Random Vibration
Stress Screening
Higher Indenture Level
otherthan PCB - Thermal
Cycling Stress Screening
61
the second “X” represents screen severity for random vibration at Stage-2 and third
“X” represents thermal screen severity for Stage-3. For example “Item (ABB)”
would indicate that the item is to be subjected to thermal stress as per screen „A‟ in
Stage-
1, random vibration as per screen B in Stage-2 and thermal stress as per screen B in
Stage-3. A proposed format for ESS plan is placed at Annexure V.
10. Thermal Cycling Stress Screening (TCSS). The following aspects are
to be considered whilst conducting TCSS:-
(a) The temperature range for thermal cycling should be established by
considering the component characteristics and the equipment specifications for
maximum and minimum designed values under operating and storage
conditions. The temperature range should be as large as component
characteristics will permit regardless of the products intended operational limits.
(b) The rate of change of temperature between the extremes must be as
rapid as possible to create the optimum level of thermal stress. The minimum
acceptable rate of change is 5° C per minute.
(c) The number of cycles is more closely related to the temperature range
and rate of change than to the equipment complexity or number of parts.
Tailoring of this parameter is generally done based on the analysis of failures
observed with the incremental number of cycles.
(d) Dwell time at maximum and minimum operating and storage temperatures
should be only enough to achieve thermal stability.
11. Random Vibration Stress Screening (RVSS). The following aspects are
to be considered whilst conducting RVSS:-
(a) Random Vibration Stress Screening may be performed
preferably at lower indenture level.
(b) The attitude or orientation of item for RVSS shall be decided based on
the plane which provides maximum shear force to the soldered joints and
components during random vibration. The RVSS is to be conducted preferably
in allthree axes.
(c) For a module level testing, the fixture shall be structurally rigid without
causing resonance and further amplification to the Unit Under Test (UUT).
(d) EUT shall be subjected to sinusoidal sweep between 20-2000 Hz to
identify the existence resonance prior to conduct of RVSS. If the equipment
resonance frequencies fall within the input frequency range, excessive energy
could be seen by the equipment and damage could occur. One of the
following two measures may be taken in such cases: -
62
(i) Modify the equipment design to achieve a more rugged item to
obtain a resonance falling outside the input frequency range.
(ii) Make a notch on the input profile eliminating frequency band of
5 Hz before and after the resonating frequency.
12. Approval of ESS Programme. The manufacturer is solely responsible for
drawing up the ESS programme as the design parameters of the components are
known to them. Once the ESS screen is finalized, the same is to be submitted to
DQA(N) through respective field units for approval. Such ESS plan will be annexed to
the QAP.
63
64
Appendix ‘G’
(Refers Para 0603(b))
ENVIRONMENTAL TEST SPECIFICATIONS
1. Indigenously Manufactured Equipment. Electrical/Electronic equipment should
comply with following environmental test specifications to be conducted in accordance
with the current version of JSS 55555 in for ceunless specifically indicated in the PO.
Confirmation of compliance to Environmental specifications would involve conduct of
physical tests on the first production system.
Sl.
No.
Test Test No. Specifications Remarks
(a) High
Temperature
17 Procedure 6. Test Condition K:
(a) Operation at +55°C
(b) Storage at +70°C
(b) Low
Temperature
20 Procedure 4. Test Condition H: at
-10°C
(c) Vibration 28 Equipment Installed in Major
Warships
(i) Mast head region
The equipment
should be in
switched ON
condition during the
test. The equipment
would be mounted
on the vibration table
by its normal means
of attachment on
ship.
Frequency
range
Amplitude
5 to 14 Hz ±1.25 mm constant
displacement
14 to 23 Hz ±0.45 mm constant
displacement
23 to 33 Hz ±0.125 mm
constant
displacement
(ii) After region
5 to 23 Hz
±0.45 mm constant
displacement
23 to 33 Hz ±0.125 mm
constant
displacement
65
(iii) Main region
5 to 33 Hz
±0.125 mm
constant
displacement
(d) Mould Growth
21 Temperature 30°C, RH greater
than 90%
Separate equipment
can be used for this
test. To be
conducted on
representative
samples.
(e) Corrosion Salt 9 Temp 350 C and RH 90 to 95 %
For Exposed items - Procedure 1
For Protected items-Procedure 2
Separate equipment
can be used for this
test. To be
conducted on
representative
samples.
(f) Driving Rain 12 Test Condition C For exposed items
(g) Damp Heat 10 The temperature and relative
humidity 40°C at 95% RH
(h) Tropical
Exposure
27 Test condition A – 7 cycles
(Protected)
Test condition C – 28 cycles
(Exposed)
(j) Drip Proof 11 - For protected items
(k) Solar Radiation 25 Irradiance of 1.2 + 0.10 kW/m2
Procedure 1
For exposed items
(l) Shock or
Impact
24 (a) NSS Grade I (for equipment
fitted below waterline) – 120g,
8ms (vertical) and 70g, 8ms
(lateral).
(b) NSS Grade II (for
equipment fitted above waterline)
– 50g, 11ms (vertical) and 22g,
8ms (lateral).
The equipment
should be in
switched OFF
condition during the
test.
66
Mechanical
equipment/
systems
(a) NSS Grade „A‟ in accordance
with IN Shock Standards and
Shock Testing Procedures for
Surface ships (for equipment –
fitted below waterline – 120 8ms
(vertical) and 70 g, 8ms (lateral)
Refer Annexure „VI„
(b) NSS Grade II (for equipment
fitted above waterline -50g, 11ms
(vertical) and 22g 8ms (lateral).
In accordance with
BR 3021
(m) Bump 5 Peak acceleration 100 m/s2, pulse
duration 16ms, No. of Bumps
4000±10, general ruggedness
test.
67
68
Appendix ‘H’
(Refers Para 0604(c))
FACTORY ACCEPTANCE TRIALS
1. FATs, if indicated as part of the PO, are the ultimate test to validate the design
and performance of the equipment before it leaves the supplier‟s premises for
installation on board. It is therefore mandatory that all pre-requisites towards conduct of
FATs are completed and available to the satisfaction of the FATs team.
2. The pre-requisites and procedures for conduct of FATs are enumerated in
succeeding paragraphs.
3. Pre-requisites. Availability of the following are essential pre-requisites for
conduct of FATs:-
(a) FATs protocol approved by the professional directorate. The approval
should also include interface protocols signed between WESEE and the firm.
(b) Approved system layout, including technological components if any. The
requirement or otherwise to provide simulators to cater for interfacing
system/equipment require to prove FATs protocol but not available with the firm
should be clearly mentioned in the approved layout.
(c) Operating and limiting parameters to be monitored, including essential
and/or permissible physical phenomenon like leakages, hunting, deflections etc.
(d) Report of FATs undertaken in-house.
(e) Draft operating manual of the system/equipment.
(f) Any other equipment/system specific requirement as provided in the PO.
(g) FATs team as constituted by IHQ/ Professional Directorates/ OPA.
(h) Completion of all QA activities preceding FATs.
4. Conduct. On the availability or assured availability of the pre-requisites at sub
paras 3(a) to 3(h) above, the firm is to make a formal request to IHQ MoD(N)/OPA,
under intimation to the Inspecting Authority and Inspection Agency for scheduling FATs.
On receipt of the request, the competent authority for FATs will co-ordinate and
schedule the conduct of FATs per extant procedures in force.
69
70
Appendix ‘J’
(Refers to Para 1002)
FUNCTIONAL JURISDICTION OF DQA(WP) &DQA(N)
Demarcation of Responsibilities
1. The demarcation of QA responsibilities between DQA(N) and DQA(WP) for QA
inspection will hereinafter be as follows:-
(a) Demarcation of responsibility will be based on division of main equipment
as followed for new construction ships. Quality Assurance responsibility with
regard to “Electronics / Electrical / Weapons Equipment” will fall under the
purview of DQA(N) whereas integrated electrical machinery such as Diesel
Alternators / Turbo Alternators / Pumps / Integrated Control Systems with motors
and associated control panel will fall under the purview of DQA(WP) (in addition
to existing Engineering and Hull Equipment).
(b) Responsibility of QA will be all inclusive wherein the QA authority
providing coverage for main equipment will also be responsible for QA coverage
for associated equipment parts, spares, test, equipment / tools, irrespective of
the fact whether such items are supplied along with main equipment or are an
isolated procurement by Material Organisations (MOs) or other Order Placing
Authorities (OPAs). The responsibility of QA coverage based on Pattern
Number is ceased.
(c) In case of common spares for multiple main equipment falling under the
purview of both DQA(N) and DQA(WP), the QA will be undertaken by the QA
agency as per Purchase Order, if main equipment is not indicated. In case of
indication of any of the main equipment, the QA will be undertaken as per the
indicated main equipment, under the provision of Para 1(a) above.
2. Systems of Integrated Nature. The new integrated system complex is
combination of many legacy systems which were earlier dealt individually either by
DQA(N) or DQA(WP). The same is no more feasible as one supplier is likely to supply
the entire integrated system. The IPMS, for example, will be under the QA authority of
DQA(WP) including all sub-systems therein, except for Automatic Power Management
System (APMS). The QA coverage for APMS will remain with DQA(N), however, those
of Battle Damage Control System (BDCS) and other systems will be with DQA(WP).
Changes in such QA responsibility will thus be applied to legacy systems, too. For
example, Flood Alarm / Fire Detection and Fighting Systems will fall under purview of
DQA(WP) as part of IPMS as well as individual equipment.
3. General Stores. DQA(N) will continue to provide the QA coverage for Stores
of general nature viz. broom, mopping cloth, naphthalene balls, soaps, ropes, general
hardware items, paints, chemicals etc.
71
4. QAP Approving Authority. The approving authority for QAP will be
DQA(N)/DQA(WP) as per the provision of Para 1(a). Approved QAPs for a specific
equipment / sub-assemblies / system (regardless of approving authority viz DQA(N) or
DQA(WP)) will be applicable if no changes have been incorporated and validity of the
same concurred by Inspecting Authority.
5. An indicated list of equipment depicting responsibility of DQA(N) and DQA(WP)
is as follows:-
Indicative List of Equipment Under DQA(N)
1. Electrical Stores
Sl.
No.
Item Description
(a) Submarine Batteries
(b) Battery Charger
(c) Cables
(d) Light Fittings
(e) Navigational Light Control Panel
(f) Switchboards and Energy Distribution Centers (EDCs)
(g) Hand / Auto Change Over Switches
(h) Fuse & Distribution Panels
(j) Automated Power Management System (APMS)
(a) (k) Automatic Emergency Lanterns (AELs)
(b) (l) Transformers
(c) (m) Rectifiers
(d) (n) Converters (Static & Rotary)
(e) (p) Impressed Current Cathodic Protection (ICCP) System
(q) Helicopter Starting System
(r) Galley Ranges and Deep Fat Fryer
(s) Glide Path Indicators, GSHB, SGSI
(t) Sound Power Telephone
(u) General Purpose Electrical / Electronic Test Equipment
(v) Signaling Projectors
(w) Emergency Supply System
(x) Electric Hooter
(y) MF Beacon, CCTV
72
2. Electronic Stores
Sl.
No.
Item Description
(a) Radars
(b) Internal and External Communication system
(c) Combat Management System
(d) Ship‟s Data Network
(e) NAVAIDS (Gyro, Log, Echo sounder, AIS etc.)
(f) Integrated Bridge System (IBS)
(g) EW & COMINT Equipment
(h) Meteorological Equipment / Survey Equipment
(j) NBC System fitted on IN Ships (SIRS / SICADS)
(k) Data Link
(l) IFF, UASS, GMDSS, ECDIS
3. Weapons & Sensors
Sl.
No.
Item Description
(a) Missiles / Rocket / Torpedo Launchers
(b) Gun Mounting (Except Barrels)
(c) Fire Control Radar
(d) Fire Control System of all Weapons
(e) Night Vision Binoculars
(f) Sonar, XBT, UWT, ASW FCS, TOTED and Winch Handling System
(g) Periscope
(h) Wind Speed and Direction System
(j) Degaussing System
(k) SWISS, MISU, Chaff System
4. General Naval Stores
Sl.
No.
Item Description
(a) Oils & Lubricants
73
(b)
Refractory and Insulating Material, Fire Retardant Compounds and
Materials
(c) Life Saving Equipment - Life Rafts, Life Jackets, Bullet Proof Jackets etc.
(d) Rubber Products – Sheets, Tubes, Hose, Gaskets, Oil Seals, „‟O‟‟ rings
etc.
(e) Diving Equipment, Breathing Apparatus
(f) Floor Covering, Linoleum including FR Linoleum
(g) Textiles and Furnishing Fabrics
(h) Asbestos Sheets, Ropes, Packing Material etc.
(j) Paints &Chemicals
(k) Portable Fire Extinguishers
(l) Rigging Material, Chain Cables, Anchors etc.
(m) Pulley Blocks
(n) Wood
(p) Electrodes/Weld Consumables
(q) Ferrous and Non Ferrous Plates/Sections
(r) General Hardware Tools and Fasteners
(s) Rubber Fenders
(t) Inflatable Boats
(u) Gas cylinders
Indicative List of Equipment Under DQA(WP)
1. Main Propulsion & PGD Group & Associated System Equipment
Sl.
No.
Item Description
(a) Main Propulsion System and associated equipment including Control
Systems, Shafting, OBMs
(b) All types of Alternators, Emergency Generators, Compressors
(c) Pressure Gauges / Differential Pressure Gauges & Temperature Gauges,
Tank Content Gauges & Magnetic Level Switches, Gas Analysers
(d) Distilling Plants / Fresh Water Generators / Reverse Osmosis Plants
(e) LP, HP, Servo, Salvage & Diving Air Compressors & FD Blowers
74
(f) Valves for Steam Systems Fuel / Lub Oil System, Compressed Air System,
Avcat System, Fire Main, Sea Water, Fresh Water and Chilled Water
System including underwater valves, Rod Gearing for Valves
(g) IPMS
2. Auxiliary Equipment
Sl.
No.
Item Description
(a) All types of pumps (Motor Driven as well as Diesel Driven) with associated
motors and Control / Starter Panels
(b) A/C, Refrigeration and Ventilation system (other than trunking) including
associated equipment and control panels
(c) System Pipes. All types of Steam Systems, Fuel / Lube Oil and
Lubrication System, Compressed Air System, Tele motor System, Hydraulic
System, Avcat System, Fresh Water / Chilled Water System, Sea Water / Brine
System, Ref Gas system, Exhaust System of all types of equipment including
compensators, Boiler Tubes
(d) Steering Gear and associated equipment including Control Panel
(e) Ship‟s Stabilizer and associated equipment including control panel and auto
pilot
(f) Bilge Separators & Bilge Eductors / Ejectors, Steam Sirens, Air Whistle
(g) Shock Mounts
3. Hull, Miscellaneous & Fire Fighting Equipment
Sl.
No.
Item Description
(a) Fire and Flood Alarm System including associated valves, Sensors and
Control Panels, Fixed Fire Fighting systems
(b) All types of Doors & Hatches, Man Holes, Bow Door & Ramps, Scuttles /
Windows, Deck Head Tubes / Glands, Ladders,
(c) Helo Traversing & Handling system, Helo Landing Grid, Helo Hangar &
general purpose Rolling shutters, Helo Fuelling / De-fuelling System.
(d) LP / HP Air Bottles
(e) Davits, Derricks, Booms, Fairleads, Bollards, Capstan, Winches for
Helicopter Handling / Towing / Minesweeping Boat Davit / Ammunition
Loading & General Purpose.
75
(f) Bellows, Load Hangers
(g) Miscellaneous Equipment. Laundry Equipment, Sewage Treatment Plant,
Pollution Control Eqpt, Incinerator, Blowers, Vacuum Cleaners, Oily Water
separator, Miscellaneous Domestic Eqpt. etc.
(h) Workshop Equipment. Lathes, Drilling Machines, Grinding Machines,
Milling Machines, Welding Equipment and accessories, Wood Cutting Eqpt,
Lifts, Chemical Cleaning Equipment., Shot Blasting Equipment,
Electroplating Equipment, Coating, Surface & Heat Treatment Equipment,
Hydraulic Presses
4. Electrical & Controls
Sl.
No.
Item Description
(a) Motors for all general applications, Ventilation Motors, NC Fan motor, Motor
for Motor – Generators
(b) Starters & Control Panels for electrical motors & all equipment.
(c) Automatic Voltage Regulator (AVRs), Window Wipers
(d) Heating Elements pertaining to equipment
76
Appendix ‘K’
(Refers to Para 1003)
Geographical Jurisdiction of Field Units of DQA(WP)
S.
No.
Establishment Geographical Jurisdiction
(a) CQAE (WE), Mumbai Maharashtra (except Pune), Parts of Telangana
& Goa for Induction Orders of Shipyards
(b) CQAE (WP), Mumbai Maharashtra (except Pune), Parts of Telangana&
Goa for Induction Orders of DMDE
(c) CQAE (EFS), Mumbai Maharashtra (except Pune), Parts of Telangana&
Goa for Eastern Origin Equipments& Stores
(d) CQAE(MS), Mumbai Maharashtra (except Pune), Parts of Andhra
Pradesh & Goa for replenishment orders of
CPRO/MOs
(e) QAE (WE), Pune Pune region
(f) QAE (WE), Vadodara Gujarat area, UT of Daman & Diu, UT of Dadra &
Nagar Haveli
(g) CQAE (EFS),
Visakhapatnam
Andhra Pradesh
(h) QAE (FPC), Bangalore Karnataka, Kerala for steam related equipment
(j) QAE (WE), Bangalore Karnataka, Kerala for all other equipments
(k) QAE (EFS), Chennai Tamil Nadu for Eastern Origin Equipment &
Stores
(l) QAE (WE), Chennai Tamil Nadu for all other equipment
(m) QAE (WE/EFS), Kolkata West Bengal, Bihar, Orissa, North Eastern States
for Eastern Origin Equipment & Stores
(n) QAE (WE), Kolkata West Bengal, Bihar, Orissa, North Eastern States
for Induction Orders of Shipyards and for
replenishment orders of CPRO/MOs other than
Eastern origin stores
77
(p) QAE (WP), Kolkata West Bengal, Bihar, Orissa, North Eastern States
Induction Orders of DMDE
(q) QAE(WE), New Delhi Delhi, Uttar Pradesh, Uttrakhand, Haryana &
Rajasthan
(r) QAE (WE), Bhopal Madhya Pradesh, Chhattisgarh
(s) QAE (WE), Jalandhar Punjab & Northern India
Geographical Jurisdiction of Field Units of DQA(N)
Sl.
No.
Establishment Geographical Jurisdiction
(a) CQAE (WE), Bangalore
Karnataka and areas in and around industrial
township of Hosur
(b)
CQAE (NS), Mumbai
{along with QAE(N),
Mumbai}
State of Goa, Union Territories of Daman, Diu,
Southern parts of Madhya Pradesh (Below Tropic
of Cancer), Maharashtra and Gujarat State
(c) CQAE (WS), Mumbai
State of Goa, Union Territories of Daman, Diu,
Southern parts of Madhya Pradesh (Below Tropic
of Cancer), Maharashtra and Gujarat State
(d) CQAE (N),
Secunderabad
Andhra Pradesh and Telangana
(e) QAE (N), Chennai
Tamil Nadu (except areas in and around Industrial
Township of Hosur and western cities close to
Kochi)
(f) QAE (N), Kochi Kerala and Western parts of Tamil Nadu
(g) QAE (N), Kolkata
Orissa, West Bengal, Bihar, Jharkhand, Assam
and North Eastern States
(h) QAE (N), Faridabad
Delhi, Haryana, Rajasthan, U.P., Uttrakhand,
Punjab, J&K, Himachal Pradesh and Northern
parts of M.P. (above Tropic Cancer)
(j) QAE (UB), Mumbai
State of Goa, Union Territories of Daman, Diu,
Southern parts of M.P (Below Tropic of Cancer),
Maharashtra and Gujarat State
(k) DQA (N) Inspection Cell,
Hardwar
Hardwar (Uttrakhand)
78
Annexure I
(Refers to Para 5 of Appendix „A‟)
Sample of Drawing with DBOM
79
80
81
82
83
84
Annexure II
(Refers to Para 5 of Appendix „A‟)
Guidelines for Preparation of GA Drawings
1. The drawings are to conform to basic design of engineering drawing as per BISSP
46-2003.
2. Besides meeting the basic requirements as per BIS-SP 46-2003, the following
specific details are to be provided with the drawings:-
(a) The title Block of drawing should have additional details as follows:-
(i) Description of Equipment/component with Model
(ii) Part No. of the component
(iii) Drawing revision no
(b) Technical Details Block to be provided with design data /Operating
parameters.
(c) Requirements to meet Purchase order and specifications, especially
requiring approval from designer; is to be included under heading "Notes". The
following details, where applicable, to be included under "Notes" heading:-
(i) Shock requirements
(ii) Welding requirements
(iii) NDT requirements
(iv) Heat treatment requirements
(v) Specific test viz functional check, Pressure/leak test etc.
(vi) Painting requirements
(vii) Preservation requirements
(viii) Surface Treatment
(ix) Electrical Protection
(x) EMI/EMC requirements
(xi) Type testing requirements
(xii) Weight & CG details
(xiii) Tolerances & Surface finish details
(d) The drawings should have one broad "Bill of Material" on the drawing
indicating all major assemblies/sub-assemblies/components as per BIS-SP 46 -
2003.
85
(e) In addition, an additional sheet called "Detailed Bill of Material (DBOM)"
having details of the assemblies, sub-assemblies and components in the
drawings. The details to be provided is as per para 4 of the procedure and in
conformity with the sample case presented.
(f) Drawings of all assemblies, sub-assemblies and components of the
system should have forward and backward traceability. The methodology of
traceability adopted should therefore be appended to the set of GA drawings
submitted, to ensure that all users can exploit the details provided in the
drawings. A suggested numbering system is given below:-
AB -000-000- 000-000
Two alphabets of Firm's name
Numerical Indication of System
Numerical indication of Equipment/
Assembly
Numerical indication sub- assembly
Numerical indication of Component
For example: Order is placed on M/s ABC Ltd. to supply AC Plant
The first two alphabets may be AB
First three numeric will be 001-006 for 20 – 140 (7 models
available) TR AC plant assembly
Second three numeric will be 001-006 for sub-assemblies viz.
Compressor, Condenser, Evaporator,
receiver, Oil tank Separator and Base
frame etc.
Third three numeric will be 001-999 for components of sub –
sub assemblies like tube bundle with
tube sheet, oil pump in compressor,
pressure relief valve etc
Fourth three numeric will be 001-999 for components like
crank shaft, tubes, tube plate, valve
body, valve spring, pump body, pump
screw etc
The Main GA drawing no. will be AB-007-000-000-000 (plant is say
140 TR)
86
The Assembly drawing no for compressor will be AB-001-000-000
The sub assembly drawing for oil pump will be AB-001-001-000
The component level drawing no. for crank shaft will be AB-001-
001-001-001
In case component do not pertains to any assembly like base
frame, its drawing no. will be AB-001-000-000-001
87
88
Annexure III
(Refers to Para 8of Appendix „F‟)
THERMAL CYCLING STRESS SCREENING (TCSS)
Sl.
No.
Level Screen Test Details Remarks
1 PCB Level A -40 °C to +70 °C,
10 Cycles (Ramp 10° C/min)
or
20 Cycles (Ramp 5° C/min)
Dwell: 10 min
Power OFF condition
B -20 °C to +55 °C,
10 Cycles (Ramp 10° C/min)
or
20 Cycles (Ramp 5° C/min)
Dwell: 10 min
2 Sub Unit /
Equipment
A -30 °C to +55 °C,
6 Cycles (Ramp 10° C/min)
or
12 Cycles (Ramp 5° C/min)
Dwell: 10 min
Power ON condition
B -10 °C to +50 °C,
6 Cycles (Ramp 10° C/min)
or
12 Cycles (Ramp 5° C/min)
Dwell: 10 min
89
90
Annexure IV
(Refers to Para 8of Appendix „F‟)
RANDOM VIBRATION STRESS SCREENING (RVSS)
Sl.
No.
Level Screen Test Details Remarks
1 PCB Level /
Sub Unit /
Equipment
A 20-80 Hz, +3db Octave
80-350 Hz, PSD 0.04 g²/Hz
350-2000 Hz, -3db Octave
10 min per axis,
G rms = 6.06 (Profile given
below)
1. On all three
axes.
2. Power ON
condition
B 20-80 Hz, +3db Octave
80-350 Hz, PSD 0.02 g²/Hz
350-2000 Hz, -3db Octave
10 min per axis,
G rms = 4.284 (Profile given
below)
Random Vibration Profile
91
92
Annexure V
(Refers to Para 9 of Appendix „F‟)
ESS: STRESS SEVERITY PLAN
Sl.
No.
PCB Level/Sub Unit/ Equipment Screen
Parameters
Remarks
1
(A)
(B)
SUB UNIT-1
Nomenclature
Part No.
PCB LEVEL
PCB Assy – A (MIL)
Part No.
PCB Assy B(NON MIL)
Part No.
XAA
AXX
BXX
2
(A)
(B)
SUB UNIT -2
Nomenclature
Part No.
PCB LEVEL
PCB Assy – A (MIL)
Part No.
PCB Assy – B ( NON MIL)
Part No.
XBB
AXX
BXX
3
(A)
(B)
CABINET/EQUIVALENT LEVEL
Nomenclature – (MIL)
Part No.
Nomenclature – (NON MIL)
Part No.
AAA
BBB
93
94
Annexure VI
(Refers to Para 1(l) of Appendix „G‟)
THE IN SHOCK POLICY
1. This policy specifies the general guidelines related to the shock resistance and
shock tests required for various equipment fitted onboard IN ships. However, with
advent of new technology and substantial up gradation of shock testing facilities within
the Navy, it has been felt that this policy is not comprehensive and merits reformulation.
2. In order to unambiguously define various issues concerning shock classification
of Marine Engineering equipment designated for usage on board ships, it is imperative
that the guidelines contained in succeeding paragraphs are meticulously followed in
conjunction with BR 3021 (I). The issues that require to be addressed while assessing
the shock grading requirements for new equipment being inducted for onboard usage
are highlighted below:-
(a) Criteria to undertake actual shock testing of the equipment with the
availability of modern theoretical analysis techniques and modeling and
simulation tools.
(b) Criteria for accepting shock calculation in view of availability of modern
theoretical analysis and modeling and simulation tools.
(c) Requirement of shock testing one in a series of equipment or each model
in a series of equipment.
(d) Utilisation of improved infrastructure and capability of indigenous labs for
shock testing of shipboard equipment.
(e) Criteria for the equipment to be shock tested with Shock mounts or for the
equipment to be inherently shock resistant to the specified levels.
(f) Methods to be adopted for acceptance of shock calculations, i.e. Static „g‟
method or dynamic analysis.
(g) Requirement of individual equipment or complete system (in the case of
mechanically coupled systems) being designed for shock resistance.
3. In order to clarify the above issues and in the light of advancements in modeling
and computing techniques, it is considered essential to introspect and revise the IN
95
shock policy. Therefore, to make the existing policy more explicit, necessary guidelines
for a comprehensive shock policy are promulgated below.
SHIP CLASSIFICATION
4. Based on the role of a ship, the classification to be followed for the purpose of
shock grading is listed below. The list is indicative, however, the “Staff Requirements
should clearly specify the Class based on the specific role of the vessel.
CLASS I CLASS II
Aircraft Carries/ADS Survey Ships/Crafts
Cruisers SDBs
Destroyers FACs
Frigates Submarine Rescue Vessel
Corvettes CG Ships
MCMVs OPVs
Tankers Training Ships
LSTs/LCUs OGTs
Missile Boats Auxiliary Crafts
EQUIPMENT CLASSIFICATION
5. Each equipment on a vessel should be assigned to one of the under mentioned
three categories, based on its critically and function with respect to the role assigned to
the vessel. Each of these categories has different shock resistance requirements, which
are enumerated below in decreasing order of severity.
(a) CATEGORY A. Equipment necessary for the vessel to return to base
under its own power. Such equipment must be capable of surviving the “Mission
Critical” shock loadings, i.e. the vessel must survive a single underwater shock
load as specified for this category, which does not incapacitate the hull, essential
equipment and systems necessary for the ship to return to base under its own
power.
(b) CATEGORY B. Equipment necessary for the vessel to fulfill its assigned
operational role. Such equipment must be capable of surviving the “Mission
Critical” shock loadings, i.e. the vessel must survive a single underwater shock
load as specified for this category, which does not incapacitate the hull, essential
equipment and systems necessary for the ship to undertake its operational role
(combat efficiency).
96
(c ) CATEGORY C. Equipment not falling in the above two categories and
covers all equipment which do not necessarily mandate shock grading. Such
equipment is to be supported and fastened in a manner so that they do not cause
any danger to life and equipment in close vicinity, owing to shock loads.
6. A representative list of equipment in the above mentioned three categories is
appended below:-
CATEGORY A CATEGORY B CATEGORY C
Propulsion machinery and
associated auxiliaries and
controls.
Stabiliser System Laundry Equipment
Essential/Emergency Alternate Power Galley equipment
Power Generation
machinery and associated
auxiliaries
Generation machinery and
associated auxiliaries and
controls
Steering Gear Air Conditioning Machinery
and System
Domestic Refrigeration
Units
Fuel Transfer System Refrigeration Machinery and
System
Workshop Machinery
All major Damage Control
and fire Fighting equipment,
system and controls thereof
Distilling Plants Domestic equipment
other than fresh water
pumps and system.
HP Air Compressor Lubricating oil Pumps and
Systems
Fresh water pumps and
system.
7. Whilst defining Category A and B equipment, the normal operating configuration
shall be taken as being the most probable configuration of the equipment when the
vessel is under hostile environment. When there is a range of likely operating
conditions, the most severe will govern the requirement for shock qualification.
SHOCK GRADE CLASSIFICATION
8. Based on the role of a vessel and criticality of equipment designated for fitment
thereof, as outlined above, the under mentioned shock classification norms are to be
followed:
(a) I.N . Shock Grade ‘A’. I.N. Shock Grade „A‟ is applicable to Category „A‟
equipment onboard Class I ships.
97
(b) Naval Shock Standards -2 (NSS-2). NSS-2 is applicable to Category „B‟
equipment onboard Class I ships, besides Category „A‟ and „B‟ equipment on
Class II ships.
9. The I.N. Shock Grade „A‟ curves and NSS II curves are placed at Enclosure 1
and 2 respectively for ready reference.
WEIGHT CLASSIFICATION FOR SHOCK TEST/CALCULATION
10. Shock tests/calculations are to be undertaken based on the weight of the
equipment and facilities available for undertaking shock tests. The equipment are
classified into three weight categories as listed below:-
(a) Up to 600 kg - Light
(b) Between 600-2500 kg - Medium
(c ) Greater than 2500 - Heavy
POLICY FOR TESTING
11. Light and medium category prototype equipment are to be shock tested as a part
development programme. Heavy category prototype equipment are normally not to be
shock tested, however, if there are any features which reflect doubt on the shock
resistance, then shock test is be undertaken.
12. All “Fight of its kind” equipment is to be shock tested under the following
conditions:
(a) If there has been no prototype for the same, or
(b) If the equipment differs considerably from the prototype, or
(c) If any major modification have been undertaken on the equipment, which
would have significant effect on the shock resistance of the equipment.
13. Equipment of a particular model, with any variance to a previously tested model
is to be necessarily shock tested, as the dynamics of such equipment are different from
the originally tested equipment. Further, the OEM will provide test certificate/proof of
shock test calculations for all follow on equipment (for the same type and mounting
98
arrangement). Equipment which have been subjected to shock test are to be “Yellow
Banded” and is to be used for training or in shore based applications.
SHOCK TESTING PROCEDURE
14. The details of procedure to be followed for shock testing of shipboard equipment
are placed at Enclosure 4 for ready reference. MIL-S-901 (D) (Navy) may also be
referred as a guideline document.
STANDARDISATION OF FORMAT FOR SHOCK CALCULATION
15. In case of equipment where shock qualification is to be done on the basis of
shock calculation, the essential criterion to be followed while formulating the shock
calculation report are highlighted at Enclosure 5 for ready reference. As a first step the
Static „g‟ method is to be used for evaluation of the equipment. However, if the
equipment fails to qualify the Static „g‟ calculations, the Dynamic Design Analysis
Method (DDAM) or Transient Shock Analysis Method (TSAM) is to be used for
evaluating the equipment.
SHOCK TESTING WITH OR WITHOUT MOUNTS
16. The equipment/assembly to be shock tested is to be mounted on shock and
vibration mounts which will eventually be used for mounting the equipment during actual
shipboard usage. Thus equipment designed for being rigidly mounted in the ship shall
be subjected to shock test in the same state, whilst equipment designed for installation
on flexible mounts shall be subjected to the shock test with the intended mounts in
place. Further the shock attention across the mounts is also to be recorded to
corroborate the efficacy of the mount selection.
SHOCK TESTING OF MECHANICALLY COUPLED SYSTEMS
17. The equipment/assembly to be shock tested is to be essentially fitted with all
associated pipe work, cabling and controls and sensors, besides any other attachments
necessary for normal operation of the entire assembly. Thus, the piping, cabling,
controls and auxiliaries associated with any equipment are to be tested to the first
supporting bracket fixed to some structure other than the equipment, if not integrally
mounted on the equipment itself.
99
TEST FACILITIES
18. Shock testing of various equipments is to be undertaken at NSTL
(Visakhapatnam), unless prior approval for conduct of the same at an alternate location
has been obtained from the Integrated Headquarters of Ministry of Defence
(Navy)/Directorate of Marine Engineering. The details of test facilities available at M/s
NSTL and DMDE are placed at Enclosure 6 for ready reference.
19. Flowchart for Design/Verification checks for shock is placed at Enclosure 7.
100
Enclosure 1
101
Enclosure 2
102
Enclosure 3
103
Enclosure 4
Scope of Testing
1. The equipment which is shock tested would be complete with all accessories viz.
interconnecting pipes. Sensors, transmitters, indicators, gauges etc. In the case of
electrical/electronic equipments, which are mounted separately, the same would be
subjected to shock loads as stipulated in JSS 55555.
Sequence of Testing
2. The equipment which is earmarked for shock test shall undergo the following
tests (in that sequence):-
(a) Visual inspection to identify apparent defects
(b) Proving run or endurance run as per the duration and modes specified in
procurement specification.
(c) Shock test of the equipment to levels specified in procurement
specification.
(d) Visual inspection for apparent defects/looseness, which would have
occurred due to shock loads.
(d) Disassembly of the equipment into components and visual inspection.
(f) NDT (DPT) of critical components.
(g) Assembly and proving run of the equipment.
3. The equipment is considered to have passed the shock test if the following
conditions are satisfied:-
(a) There are no mechanical damages/failures.
(b) There is no deterioration of performance of the equipment when compared
to pre-shock test status.
104
(c ) There are no cracks, leakages of working medium/control medium or any
other defects that may lead to degradation of characteristics of the article.
(d) There is no change in status of switches (on/off) or malfunctioning of
equipment/skid-mounted sensors, transducers gauges etc.
105
Enclosure 5
GUIDELINES FOR SHOCK QUALIFICATION BY SHOCK CALCULATION
1. The following shall be considered explicitly in the calculations, which shall be
made for each of the principle axes separately:-
(a) The mass of the equipment.
(b) The strength and stiffness of the foundation.
(c) The response of the sub components of the equipment.
(d) The duration of the shock loading
2. The calculation/method employed for evaluation of the centre of gravity of the
complete equipment and individual components are to be clearly indicated.
3. The complete material and physical properties of the components of the
equipment are to be indicated.
4. The natural frequency of the equipment as mounted on the ship is to be either
calculated or determined by tests. On evaluation of the natural frequency, the
equipment/components are classified as either rigid/flexible as per guidelines in BR
3021(I).
5. A Non-Linear Lumped Mass Modeling is to be adopted for evaluation of the
characteristic of the equipment. The Boundary conditions and constraints applicable to
the equipment are to be clearly specified in the model. Advanced techniques such as
Finite Element Analysis and tools such as ANSYS/PAFEC code may be used for the
analysis clearly specifying the number of nodes and elements used for discretizing the
equipment.
6. The “frequency ration” of the natural frequency of the equipment to the Shock
input frequency is to be evaluated as per guidelines in BR 3021(I).
7. The “Shock amplification Factor” and load multiplier required to applied for the
calculations is to be evaluated as per guidelines in BR 3021(I).
106
8. The acceleration, Velocity, Time period values as applicable for the calculations
are to be obtained as per guidelines in BR – 3021(I).
9. The permissible shock design stresses are to be obtained as per guidelines in
BR – 3021(I).
10. The Bending Moment, Shear force, Bending Stresses and displacement as
obtained in the calculations are to be clearly specified for the equipment and each
individual component of the equipment. The effect on various clearances of the
equipment/components is to be clearly stated in the calculations,
11. A flow chart indicating the steps to be undertaken for design/verification checks
for shock is highlighted in the next page.
107
Enclosure 6
DETAILS OF TEST FACILITIES
1. Test facilities Available at NSTL Visakhapatnam. The following infrastructure /
facilities are available for undertaking actual shock testing of equipment:-
[Link] TEST FACILITY PAYLOAD PAYLOAD
SIZE
REMARKS
(a) Test machine
(Drop test/free fall
machine)
up to 600 kg 1m x1m 600kg-90 g
(b) Test machine
(Drop test/free fall
machine)
up to 1000 kg 1.5x1.5m Max acceleration - 600g
Min. weight - 200kg
(c ) Floating Shock
Platform (FSP-I
small)
Up to 2000kg 2.5 X 1.5 X
1.5m
The platform is floated in
NSTL shock tank of size
15mx12mx10m and
explosives are used in the
rank to create the required
shock levels.
(d) Floating Shock
Platform (FSP-II
Large)
Up to 15000
kg
8x3x2m The platform is floated in
NSTL Shock tank of size
15mx12mx10m or in open
water and explosives are
used in the tank to create
the required shock levels
(e) Shock tubes Shock tubes are fabricated to accommodate any size of
equipment. Very high levels of shock pulses are
channelized in the shock tubes and applied on the test
equipment.
2. Test Facilities at DMDE, Secunderabad. DMDE has an impact-testing
machine (K-200M) for subjecting equipment weighing up to 200 kgs to impact
loads.
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Enclosure 7
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Common questions