TECHNICAL SPECIFICATION OF ON LINE CONDITION

MONITORING SYSTEM

1.0 SCOPE

1.1 This specification covers the Design, Manufacture, Supply

Erection, Testing & Commissioning of latest state of art on line
condition monitoring system comprising of AGMS for
generator, vibration monitoring system and complete integrated
analyzing and diagnostic system, software and hardware for
turbine generator units of 6 X 250 MW Nathpa Jhakri Hydro
Power Station.
1.2 The scope of work shall include supply, erection & commissioning
of all the accessories such as sensors,
processors/controllers/transducers, input/output modules,
diagnostic station, peripherals, software, protection units, data
acquisition units, workstation (common), special cables and
junction boxes etc. Any other equipment required for
completeness of the system, and satisfactory performance shall
also be considered as in the scope of supply
1.3 The scope of work shall also include training of at least one
week’s duration at owner site for at least 3 (three) Engineers of
the corporation regarding operation and maintenance of the
system including analysis/interpretation of reports.
1.4 The scope of work shall also include technical support for
analysis/interpretation of data during warranty period of 2 (two)
years for which cost shall be deemed to be included in the prices
given in the bid.
1.5 The system complete in all respect shall be designed by the
supplier, approved by SJVNL and subsequently supplied,
installed and commissioned by the supplier. Methods of
installation of different components and material/hardware used
shall also be mentioned clearly and shall not in any way
compromise the integrity and safety of the machine.

2.0 EXPERIENCE

The bidder shall have at least of 10 (ten) years of experience

regarding supply, erection, testing, commissioning of on line
Condition Monitoring of hydro turbine generator sets of size and
capacity of 100 MW and above and supplied/installed 10 (ten)
power houses any where in world including at least 2 (two) No.
of similar system in a hydro power plant any where in India &
working satisfactorily for at least one year as on date of

1/14
 submission of bid. Bidders shall have to furnish performance
certificate from the purchaser. Other contractual/financial criteria
should be as per CVC guidelines. The bidder shall give a brief
detail of at least 2 (two) on line condition monitoring system of
hydro generators installed by them and working satisfactorily for
period of one year and above.

3.0 BASIC INFORMATION TO BIDDER

3.1 PROJECT LOCATION : Jhakri, Tehsil Rampur Bushahar, Distt.

Shimla, H.P

3.2 TURBINE DATA

1. Manufacturer : M/s GE Hydro, Norway

2. Number of units :6
3. Type of Turbine : Vertical Francis
4. Rated Design Head : 428 M
5. Rated Output : 255 MW
6. Synchronous speed : 300 rpm
7. Run away speed : 545
8. Weight of Turbine rotating parts: 45 Tons
9. Bearing : Shell type

3.3 GENERATOR DATA

1. Type : Vertical shaft, water

wheel driven, alternating
current synchronous
generator
2. Rated out put : 278 MVA
3. Power factor : 0.9 lagging
4. Frequency : 50 Hz
5. Direction of rotation : Clockwise when viewed
from top
6. Stator winding connection : Star
7. Generator earthing : Star point earthed through
a distribution T/F
8. Inertia constant (H) : 4 MW-Sec/MVA
9. Stator and Rotor winding insulation: F
10. Bearing type : a) 2 (Two) Guide Bearing
pivoted pad located above
and below rotor

2/14
 b) 1 (One) Thrust
Bearing below rotor, Spring
plate type
11. Air Gap at center of pole : 30 mm
12. Rotor Diameter : 5940 mm
13. Shaft Diameter : 1010 mm
14. Active height of stator :3M

4.0 TECHNICAL REQUIREMENTS

ALREADY EXISTING SYSTEM

Three sets of vibration detectors (Displacement type) are already

installed at each of upper, lower and turbine bearing bracket, at
right angel to each other and wired up to the main processor of
distributed control system vibration cubical. The values are taken
as Smax and are used for trending purpose and alarm and trip of
the unit in abnormal conditions.

To further enhance the condition monitoring of the unit,

following systems are required:-

A. Measurement of Air gap.

B. On line vibration monitoring/analysis system.
C. Complete hardware and software for analysis and diagnosis.

The following detailed specification shall be considered for

designing on line condition monitoring system.

4.1 MEASUREMENT OF AIR GAP :

4.1.1 INTRODUCTION

The supplier shall be responsible for design, manufacture,

test, supervision of site installation and commissioning of an
air gap monitoring, diagnostic and analysis system for on line
monitoring of generator air gaps. Inspection of material
before dispatch shall be done by SJVNL. The system shall
provide dynamic air gap measurements as required without

3/14
 requiring a service outage and permit static measurements
also and randomly monitor the condition of the generator air
gap. Magnetic field, dust, oil and carbon particles found in the
air gap should not alter the system measurement. System
installation shall be done for all units during maintenance of
the generator at site during the month of Dec’09 to March 10.
The installation of the system sensors and cabling must be
possible when rotor is in place. The system provided shall not
compromise the reliability and safety of the Generator. The
supplier must have extensive experience in the supply of air
gap sensor in the field and sensors installed in the past ten
years should still meet original specification and design
requirements. The system must provide software for
complete diagnostic and analysis.

4.1.2. SCOPE OF WORK

The supplier shall design, manufacture, test, supply, install at

site 6 (six) sets plus one spare set of air gap monitoring
system (AGM). Air Gap Monitoring system comprising of all
kind of sensors, controller/processors, cables (including
special cables), conduits, diagnostic unit, protection unit,
display unit including standard furniture and fixture etc. for
online monitoring of the condition of dynamic air gap without
an interruption in the operation of the machine. The AGM
system furnished and installed shall not in any way
compromise the integrity and safety of the machine. The
system shall be complete in all respect covering all major
items. Any other item which is not specifically stated, but
essentially required for installation and trouble free operation
of the system shall also deemed to have been included in the
supplier’s scope without any additional cost to purchaser.

4.1.3 AIR GAP SENSORS AND CABLE LEADS

The air gap sensors must be preferably of capacitive type with

one plate of the capacitor being the air gap sensor and the
other plate being the rotor poles. The capacitive air gap
sensor shall be permanently installed in the air gap on the
stator iron packets of the stator inside wall. The number of
sensors shall correspond to be at 2 (two) planes, one near top
and one at bottom of stator core and shall be minimum 4

4/14
 (four) sensors at each plane. The sensor frequency response
shall range from 0 to 1000 Hz of static and dynamic air gap
measurement and shall have a linearity better than or +/-
1%. Maximum operating temperature of the sensor shall be
125 degree centigrade. The material used for fabrication of
the sensor shall be compatible with class ‘F’ epoxy insulation
or higher grade , totally immune to the generator magnetic
field. Calibration charges for each sensor shall be included in
the offered price by the supplier. A synchronization probe
used for rotor pole reference purpose shall be installed & the
same shall also be used for the keyphasor reference required
for vibration analysis purpose. The synchronization probe
shall be a proximity type that shall detect a small metallic
target fixed to the rotor shaft. The leads for the sensor shall
be of suitable type and size which will be brought out and be
terminated in a wall mounted enclosure. Only one cable per
sensor shall be used. The leads for the synchronization probe
shall be of suitable type and size. The leads from the
synchronization probe to the wall mounted enclosure shall
also be routed in a protective conduit. The placement of all
conduits shall not interfere with normal operation and
maintenance of the generator. The conduit shall be fastened
securely to the stator frame/civil structure to prevent
movement due to vibration.

4.1.4 WALL MOUNTED ENCLOSURE (IF ANY)

The wall mounted enclosure shall meet the oil and dust tight
requirement of EEMAC/NEMA standard. Its dimensions shall
be sized to accommodate on line air gap monitoring system
with all cable leads. Protective conduits for sensor leads,
synchronization leads and the AC power line shall be rigidly
fixed to the metallic housing. The sensor cable lead shall be
labeled to show the associated sensor. A 14 gauge copper
wire shall be connected between the ground lug on the air
gap monitoring system and the generator ground bus. The
location of the wall mounted enclosure shall not interfere with
normal operation and maintenance of the generator.

4.1.5 AIR GAP MONITORING SYSTEM HARDWARE/SOFTWARE

The supplier shall furnish an air gap monitoring (AGMS) which

is specifically designed for use with the permanently installed
sensors. The system furnished shall operate with an IBM (or

5/14
 equivalent) type computer and an Hewlett Packard (or
equivalent) type printer. The AGMS shall measure the static
and dynamic air gaps and shall be controlled by a user
friendly software package to display results in a polar,
rectangular and tabular form. The AGMS shall provide
software and/or hardware alarm when the air gap reaches
preset alarm levels and shall store automatically, at least 20
rotations before and after an alarm event occurred in short
term storage. The system shall be capable of storing the
trends in the form of polar plot on continuous and permanent
basis in long term storage. The supplier shall specify the
sampling time, raw data format, hard disk capacity and the
necessary hardware required. The system must be capable of
accepting externally triggered events to be able to take
measurements during machine trips, start and stops of the
unit.

Communications from AGM system to the computer shall

depend on a highly reliable opto-isolated differential EIA 485
or equivalent communication link. The supplier shall provide a
complete installation, testing and operation guide with the
AGMS for operating personnel.

4.1.6 FIELD INSTALLATION

The supplier shall provide sensor, cable leads and

synchronization probes, wall mounted enclosures, opto
isolated RS 485 or equivalent communication links for air gap
monitoring system. Provision for the engineering design and
supervision for the placement and installation of the AGMS on
the generator shall be provided by the supplier with a
complete installation report. Semiskilled and unskilled
manpower will be provided by SJVNL. Supplier shall indicate
the no. of persons required in the offer. Highly
skilled/specialist required for field installation will be provided
by the supplier.

Installation criteria:-

• The AGMS applied to all generators for 6X250MW,

15.75 KV, 300 rpm.

6/14
 • Locate the sensor at 300 mm from top and/or bottom of
the stator laminations – as designed.
• Total number of sensors – Min. four sensors at each
plane.
• The sensor dynamics is proportional to the air gap.
• Installation to be made during the period of annual shut
down of machines tentatively between Dec’09 to
March’10.

4.1.7 COMMISSIONING

The supplier’s field engineer shall provide all necessary test

equipment to verify the proper operation of the installed
AGMS. The supplier shall provide a complete diagnostic
procedure guide for the operating personnel.

4.1.8 INTERPRETATION OF AIR GAP & VIBRATION READINGS

The supplier shall provide on site analysis/interpretation and

technical support of initial on line condition monitoring test
readings for all six machines and two subsequent test
readings per machine taken during warranty period of two
years and any other data needed to be analyzed/interpreted
during this period of two years.

4.1.9 WORKING ENVIRONMENT FOR AGMS

AGMS covered in this specification shall be capable of

operating trouble free at an ambient temperature range of 0
degree to 50 degree centigrade (max.), 90% relative
humidity and present noise level normally of the order of 90
db and available vibration level of normally 100 to 200
microns and the present disturbances beyond the above limits
in power house. Temperature in the vicinity of sensors will
approx. 125 degree centigrade (max absolute).

7/14
4.2 ON LINE VIBRATION MONITORING SYSTEM

4.2.1 INTRODUCTION

The machine has three horizontal guide bearings i.e Upper

Guide Bearing (UGB), Lower Guide Bearing (LGB) and Turbine
Guide Bearing (TGB) and one vertical load sharing bearing i.e
Lower Thrust Bearing.

Existing system for vibration monitoring is of VIBRO-METER

make having two proximity probes of 4 mV/micron sensitivity
at each Upper, Lower and Thrust Guide Bearing. UVV 697,
Version 02 and PLD 772, Version 21 cards are used.

PLD772 Level detector and display module is used to

measure, monitor and display the analog voltages output by
other modules in a system.

The UVV 697 is a dual channel (X and Y) relative vibration

processor matching two non contacting proximity
transducers/conditioners.

Present vibration monitoring system is used to display relative

shaft vibration at three location in terms of Smax value and
the same are used for trending the overall vibration levels at
each bearing position and also for alarm and trip purpose.
Buffered output is available through BNC adaptors
corresponding to each vibration sensor.

To enhance the capability of present vibration monitoring

system, on line vibration analysis system is proposed to be
installed for the following information to be monitored and
stored in data base for diagnostic purpose :

Historic Plots Transient Plots Real time plots

• Waveform • Trend • Bar graph
• Spectrum • Cascade • Trend
• Orbit • Shaft • Waveform
Centerline
• Shaft • Bode • Spectrum
centerline
• Polar • Polar • Orbit
• Trend • Multi Polar • Polar
• Waterfall • Long waveform

8/14
 Installing this system will assist us to decide when machinery
should be shut down and repaired before costly damage or
mechanical malfunction occurs. Also with accurate diagnostic
information we can isolate potential machinery problem,
reducing maintenance time, reduce forced outages by
trending vibration and process the information to planned
outages.

4.2.2 SCOPE OF WORK

On line vibration monitoring system comprising of relative

and absolute shaft vibration (radial) using proximity
transducers as required, transducers for velocity/acceleration
monitoring sensors, axial shift proximity sensors for axial
vibration measurement, different types of cables,
monitoring/analysis system, software etc. for all 6(six) units
shall be in the scope of supply.

The target/focus components for vibration measurement

(radial and axial) shall necessarily include the following:

• All three guide bearing i.e UGB,LGB cum thurst

bearing and TGB.
• Turbine cover i.e Upper turbine cover and spiral
casing.
• Axial vibration at Rotor. The proposed location for
the sensor are:-
ƒ Near coupling of DE and rotor shaft.
ƒ Inside thrust bearing facing mirror
surface of DE shaft.
The supplier shall indentify the place of mounting
and the required surface on the rotor/thrust bearing,
design and do the needful.

Any other item which is not specifically stated, but essentially

required for installation and trouble free operation of the
system shall also deemed to have been included in the
supplier’s scope without any additional cost to the purchaser.
The proximity probes which are already installed shall only be
used form the buffered output. However, every utilized
buffered output should be provided with alternative output for
such signal.

9/14
 The details of scope shall be as follows:

Basic transducer system:

• For relative shaft vibration the existing system shall

only be used. However, every utilized buffered output
should be provided with alternative output for such
signal.
• For axial shift, 2(two) no. proximity transducer,
installed 90 degree apart comprising standard mount
probe, proximity sensor and extension cable etc.
• 2(Two) nos. accelerometers for each location i.e UGB,
LGB cam Thrust Bearing and TGB shall be provided in X
and Y radial direction.
• 1 (One) no. accelerometer for each location i.e Spiral
Casing and Turbine Cover preferably in Z direction.
• Keyphasor used for air gap monitoring should also be
used for vibration monitoring system.

For monitoring/analysis system:

Monitoring/analysis system shall comprise input

module/cards, proximity monitor, output modules/cards,
hardware parts and accessories, cables and junction boxes
etc.

Software:

Software packages for configuring data acquisition and

monitoring, for achieving/accessing the data and for
analyzing and interpreting the data shall be provided under
the package or as part of complete package.

4.2.3 WORKING ENVIRONMENT FOR VIBRATION

MONITORING SYSTEM

Vibration monitoring/analysis system covered in this

specification shall be capable of operating trouble free at an
ambient temperature range of 0 degree to 50 degree
centigrade (max.), 90% relative humidity and present noise

10/14
 level normally of the order of 90 db and available vibration
level of normally 100 to 200 microns and the present
disturbances in power house. Temperature in the vicinity of
sensors will approx. 90 degree centigrade (max absolute).

5.0 MONITORING OF AGMS, VIBRATION

a) Monitoring hardware: Monitoring hardware shall

comprise of online multi channel data acquisition units
which simultaneously monitor and synchronize high
and low speed parameters for processing monitoring
software. The hardware shall be capable of operation in an
ambient temperature up to 50 degree centigrade. The
monitoring hardware shall:
• Accept input from air gap, vibration, and other sensors.
• Provides synchronize measurements of air gap and all
connected parameters under condition from stand still to
run away.
• A system shall be suitable for mains operation (240V+/-
10%) 50 Hz AC., 48/220 VDC available with owner.
• Also shall have UPS with 30 (thirty) minutes back up.
• Permit continuous alarm monitoring capability with user
defined dual level threshold input.
• Accepts analogue signal sources as required.

b) Monitoring software: the online Monitoring software shall

be capable of the following:
• Co-relation of all required electromechanical parameters
for reliable and quick machine diagnostic.
• Should be user friendly and capable of trending analysis,
alarm monitoring etc. and should be Window based.
• Monitoring in entire transit zone from machine stand still
to over speed.
• Position for networking facility.
• Automatic data storage to provide tracking of pre and post
alarm measurements for at least one year in long term
storage, possibility of interfacing with existing IMS/Control
system of NJHPS having facility of long term storage shall
also be mentioned by the bidder.

11/14
 • The software shall be capable of providing following
minimum out puts for diagnostic:-

i) Polar view of the rotor and stator providing

information about roundness and eccentricity of both
stator and rotor.
ii) A signature display of the minimum air gap of each
rotor pole over one revolution.
iii) An average air gap function providing a programmable
and automatic air gap trending measurement.
iv) Simultaneous display of multiple parameters for
data/event co-relation.
v) Password protection to prevent unauthorized access.
vi) Any other measurement necessary for complete
diagnostic of generating unit.
vii) Waveform display.
viii) Frequency spectrum of vibration data.
ix) Bode plot and polar plot during run up, run down and
over speed.
x) Orbit of vibration.

6.0 DOCUMENTS TO BE SUBMITTED ALONG WITH QUOTATION

Following documents shall be submitted along with quotation in

triplicate:

• Clause by clause confirmation regarding compliance of this

specification and deviation, if any, shall be stated clearly
w.r.t specification.
• Latest detail list and technical literature/specification for all
the component of the total system.
• Single line block diagram for the total specification for all
the complete monitoring system.
• Location of sensors duly marked on the generator/turbine
section.

6.1 Integration With Present Operator Station

(OS)/Information Management System (IMS)

12/14
 ADVANT Control system AC 410 ABB make OS and AC 450
ALSTOM make IMS are operational in the power house. The
bidder shall also include in his offer a proposal along with
additional cost involved if any for integration of AGMS and
vibration monitoring system with the existing OS/IMS . Overview
of IMS system is given in drawing section.

7.0 INSTRUCTION MANUALS

The contractor shall furnish 6 (six) copy of instruction manuals

along with hard copy for the testing, installation, operation and
maintenance of the entire system before the dispatch of the
equipment. All instruction data etc. shall pertain only to the
equipment supplied. The bidder shall furnish catalog/leaflets of
all the equipment software offered along with the bid. The bidder
shall also provide the soft copy of the manuals.

8.0 SPARES

a) All types of sensors, conditioners, cables- 16.66%

i.e 1/6th of total supplied quantity for all six units.
b) All types of cards, power suplly units, racks-
16.66% i.e 1/6th of total supplied quantity for all
six units.

9.0 WARRANTY

Two years after successful commissioning during which the

supplier will rectify any hardware/software related fault with in a
period of one month at site from the date of notification of such
fault. However if the period taken for rectification is more than
one month, the total period of warranty for that particular unit
shall be extended by total period of faulty condition.

10.0 TRAINING

Supplier to impart training of at least one week’s duration at

owner site for customer operating and maintenance engineers
on the fundamental of the system (as installed) and the use of
the monitoring instrumentation package and software with
suitable recommendation, test procedures, data/result

13/14
 interpretation, test file management etc. for implementation by
end user. Therefore, training charge, if any, shall be considered
as included in the main offer.

11.0 Drawings

1. Generator Cross Section

2. Overview IMS

14/14
 Workstation (WS_A1) Workstation (WS_A2)
with Viewer functionality with Viewer functionality

Inkjet Color A
(not included in offer!)

Database Server (DBS_A)

with Long Term Storage

Data Server (DSV _A) I m_- I

with Short Term
Laser Printer A Storage
(not included in offer')

Inkjet Color B Data Server (DSV_B) [=J --GCOM

(not inclueded in offer!) with Short Term =-
Storage

-1:] Database Server (DBS_B)

with Long Term Storage

Laser Printer B
(not included in offer)

Workstation (WS_B1)
with Viewer functionality
D D Workstation (WS_B2)
with Viewer functionality
r
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278 ,""VA

305 '""VA

15.75 kV

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SJVN Manufacturcr Name & Address ' Monufaclu lin!'! Quality Pian ~ Project: NJHPS
Shimla Item:AGMS QP No. QAIlAGMSIOI Ref. No.
Rev. No.OO Supplier:
Dotoo:25.08.09 i
...... Page NO.OJ of04
I Form.i
~~~~~~

81. No. Component & Cltaracteristic CI.", Type of Quantum Reference Acceptance Agency ___ Remarks
0pE'ration Cheek ofCheok Document NornlS or M C S
Record
--­ 6
I 2 3 4 5 7 8 9 10 11
l. IncoI11ing MateriallBought Out Items
1.1 Probes (Proximity Identification of the product Major Visual 100% TC P P V
Probe, Visuallnspection Major Visual 100% TC P P V
Synchronization Dimensions Checks Major Measure 100% TC P P V
Probcs and Rotor 1-:;;;
Axial Vibration Functional Check Major Test 100% TC P P V
proxiJnity Transducer • Frequency Response
etc.) • Aecuracy
• Linearity
• Sensitivity
• Repeatability
• Degree ofProtection (IF
Class)
• Maximum Operating TS! TS!
temperature etc. Manufacturer Manufacturer
Check for lnsulation Major Test 100%
data sheet! data sheetl 'Yc--­ p P V
Relevant Relevant p
1.2 Conditioners Identification oftbe prodUct Major Visual ]00% Standardl Standardl TC P V
Visuallnspection Major Visual ]00% DRG DRG TC P P V
Dimension Check Major Measure 100% TC P P iV
--;;;
Functional Checks Major Test 100% TC P P V
• Amplification
• range matching .
• AID convertors
• Opticullsolation
• lnput fault detection etc.
Check for Insulation Major Test 100% TC P P V
1.3 Cables (including Dimensions Major Measure 100% TC P P V
coaxial cables) Functional Checks Major Test 100% TC P P V
1.4 Junction Visual Check Major Visual 100% 1 lAC! TSiEE.MACi TC P P V
BoxeslMarshalling Dimensions .lvIajor Measure lOO"Io NEMAI NEMAI TC P P V
BoxeslWaU Mounted 1P Class Major Test iooO;;- Monufseturer Manufaeturcr
TC p P V
I Enclosures data sheet data sheet

(~~~
~

 Manufacturing Quality Assurance Plan for On Line Air Gap Monitoring System
SJVN Manufacturer Name & Address Manulltctu rint! Quality Plan I Project: NJHPS
ShlmJa
ltem:AGMS QP No. QAJlAGMS/OI ! Ref. No.
Rev. No.OO ' Supplier:
Dated:25.08.09
Page No.02 of04..
. ~~
SI Component & Characteristic Class Type of Quantum Reference Acceptanc Ponnat '. .Agencv Remarks
No. Operation Check ofCheck Document eNorms Of M C S
-----­
Record
I 2 3 4 5 6 7 8 9 10 11
1.5 Power Supply Visual Inspection Major Visual 100% TC P P V
Modules Dimensional check Major Measure 100% TC P P V
Functional Checks as applicable Maior Test 100% TC P P V
1.6 Communication Visual Inspection Maior Visual 100% TC P P V
Links Dimensional check Maior Measure 100% TC P P V
Functional Checks as'l'l'licable. Maior Test 100% TC P P V
1.7 Processorsl Verification o[Clocks, Scan Time, Major Test 100% TC P P V
Controllers Refresh rate, L2 cache, FSB Clock
etc.
Functional Check Major
! TSI TSI P
Tcst 100% IC P V
--------­ Mwtufllctur Manufaetur
1.8 Cooling Fans Dimensional Check Major Measure 100% er data er data TC P P V
Functional Check Major Test 100% sheet! sheet! TC P P V
1.9 Signal Processing Visual Inspection Maior Visual 100% Relevant Relevant TC P P V
Modules Functional check Major Test 100% Standard! Standard! TC p P V
(Network Int.rmce, DRO DRO Te p p V
Signal Analyzer,
Module For
Monitoring ofradial
Dod axial vibration,
air gap &
Input/output Modules
etc.)

 Manufacturing Quality Assurance Plan for On Line Air Gap Monitoring System

SJVN Manufacturer Name & Address Manufaeturine QuaUtv Plan Project: NJHPS

Shimla Item: AGMS

I QP No QAIlAGMS/OI Ref,No.
Rev. No.DD Supplier:

I Dated 25.08.09

-----
Page No.Q3 of04 ___

Sl.No, Component & Characteristic Class Type of Quantum

Reference Acceptance Fonnat Allencv Remarks
Operation Check ofCheck Document Norms Of M C s
Record
-I--:-­ 10 II
1 2 3 4 5 6 -­ .. 7 8 9
LlO Accelerometer Identification of the Major Visual 100% TC 'p P V
product I .­
Visual Inspection Major Visual 100% TC P P V
Dimensions Checks Major Measure 100%

Functional Check Major Test 100%"­ I

• Frequency response
•
•
Aceuracy
Linearity
TSf
Manufnctur
ITSI
Mnnufnclttrer
• Sensitivity er data data sheet!
• Repeatability sheet! Rcfevunt

f-
Relevant Slllndardi
• Degree ofpromction
DRO
• Maximum operating
DRO
temperature etc,
~--~-

1.11 Software Suitable for configuring Major Test 100% TC P P V

Package · data acquisition and I
I
monitoring, for
achieving/accessing the I
· dam and for ana Iyzing

and interpreting the dam

l_

.in accordance with

· contract/job requirement.

I L'-----_
--- - I
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~
 Manufacturing Quality Assurance Plan for On Line Air Gap Monitoring System
SJVN Manufilcturcr Name & Address Manufacturing Qu-"UIy}>lan ~~ _ Project: NJHPS
Shlmla
Item: AGMS I QP No, QAIlAGMSIOI ReE No,
Rev, No,OO , Supplier:
Dated:25,08,09 '

81. Component & I Characteristic Ciass

.
I ~j;.~:Y T~tu ~ Document
~:~::;~4"f04 I AccepianCe-Norols I ~rormat II ;u':l ,~ Remarks
AlIr
No, Opemtion Of M I lC I ~
Record
2 I3 7 8 9 ' 10 11
2 Preliminary test and pre-oalibration
Calibration Major I Test 100% Te p P V
ContinuUTest I Maior I ~T;;st 100% TSI Manufacturer TC P P V
Ftmctionality tests st 10000Al , , _~_ data sheet! Relevant TC 'P P V
StandardlDRG
Verification of I .lest 100"Al TC P 'p V
~~,L
iV.lUJVl

+_,,__ _____ m I ch.r.cteristics',~_~ __ L

3 Final Tests

1)Assembly of Configuration of Major Test 100% ~I TSI Manufacturer ~ TS/ Mmmmchlrcr ITC iP I P T w---r diP
various
components
2) Demonstration
of complete
AGMS by
modules, Sensors and
OS etc,
• Functionality tests
:. Dry Heat
• Temperature cycle
Major Test 100% I
data sheet! Relevant
SlIIndardlDRG
iSI Manufacturer
data shceU IRC 68­
2-30IlEEE-C­
data sheel1 Relevant
StandardlDRG
TSIMllI1ufacturer
data sheeU IEC 68-2­
3011EEE- C­
rc Ip IP Iw
I
I CHP

37,9Q.lIDRG 37,90~IIDRG
creating actual test
site condition at • Damp Heat Test

~---;---:;--, _ .' llLl j

works (to the • Surge withstand
extent possible)" test
'. Final Calibration
[ etc,
AP should be read in con'unction with the QuaU
Remarks: ­ Assunm"" Requirements,
~;:!:ur.r/ Contract! Sub- Contractor Legend ; ~';SJVN IDOC ~O,~_
M: Manufacturer p~ared
By ---,--t-----------­
Manufacturer- C : Contractor i':'';V\9'''\ () • f'~
S SJVN c..:--­ J\J-t.;y
Contractor~ "p" Perfonn V"'!..
<'<w" witness and Reviewed By
"vn verification
'--_ _ _ _ _ _ _ _ _ _~~ I ~~ _~_
 Field Quality Assurance Plan for On Line Air Gap Monitoring System

SJVN Manufacturer Name & Address Field Quality Plan -----r.==-",-;-:-:-:-c=-==-i Project: NJHPS
Shimle. item:AGMS QP No. QAJIAGMSf02 Ref. No,
Rev, No,OO Supplier:
D.ted;25.08.09
'--j_ Page No.O1 ofI)].
I-.---
51.No. Component & Operation Characteristic Class Type of Qwmtu i Referente: I A('cc ~tan« iFotmlri Agency a....r

f-c--- -
CheeR m of'
ClU!c~
Dorument Noru ~ Of
R«ord M Ie IS Il8

1 2 3 5 6 7 8 9 10 11
-- ----

L Tests during Ereelion

l-
,~-

-j,j,
1.1 Probes
f-U Conditioners
Leveling & alignment
align
rc.-
1.3 Junction
Boxes/Marshalling I· Checking of signal
sign flow at
stages.
different slages.
Boxes • Earthing test
tesl

1.4 Modules (power

• Check for proper
propel
placemenllLocalion etc.
placemenllLocal
Supply, Network
Interface, Signal Major I Test 100% I DRGITS! DRo, Inspection P CHP
Analyzer, Module For Comm;ssi Com Report
WI
Monitoring of radial oning , onin
,
and axial vibration, air !
Manual i Man
,! gap, Input/output
tJan . Tnnut/outnl1t
ModuleS etc.)

~- Accelerometer

1 16- Cables Marking and IR test

--

l -----
Continuity Tesl

I ~J_
,,_~I ---- -----
_LL
~~I~
•

 Field Quality Assurance Plan for On Line Air Gap Monitoring System
"" "~~~~~~~~~

SJVN ~Manufacturer Name & Address Field Quality Plan Project: NJHPS
Shlmta. Item:AGMS QP No~ QAl/AGMS/OI Ref No.
Rev. No.OO Supplier:
D.ted:25.08.09
Page No 02 of02,~
SI Component & Characteristic Class Type of Quantum Reference Acceptanc Format Agency ~;;:-- ~ RCIlll1rks
No. Operation Check of Check Document cNonns Of M C S
Record
1 2 3 4 5 6 7 8 9 10 II
2 TeslS during Functional tests
Commissioning! • Signal Checking
Commissioning • Cheek for
communication
• Cheek for Integration M~ior Test 100% DRGITS! DRGITS/ Inspection P W CHP
with old 0 SlIMS
Commissioni Commissi Report
system etc.
ng Manual oning
"" "~~~~~~~~~~~~~~
Manual
3 Final Tests at Site Run test to verifY/measure
different characteristics!
parameters under condition
from stand still to run away
including the diagnosis.
Major Test 100% DRGITS! DRGITS! Inspection P W CHP
Commissioni COJl1missi Report
ng Manual oning
Manual

Remarks: • QAP should be read in eon~iunellon with the Qu'dity~ Assurance Requirements.
Manulileturer! Contract! Sub. Contractor Legend ForSJVN DOC NO.
Signature Use
M : ManufllCturer

~ It: ~ ~1D1€)
Manufacturer· C : Contractor
S:SJVN
Contractor­ "P" Perfurm :.,.­ ,....n .1\/\ V n v.
"wn witness and
-n::~~~~~~~~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Reviewed By • N!lI!fe & lion orr oviD ~ Authority & 86.1

"VH verification