RDSS (Revamped Distribution Sector Scheme)

Quality Assurance
Mechanism : RDSS
Quality Assurance Guidelines

22.02.24
Quality Assurance Mechanism : Guidelines

• Section 6.5 of RDSS guidelines stipulates that Discoms shall be responsible & accountable for assuring quality in
the scheme works. To achieve this DISCOMs are required to formulate a comprehensive Quality Assurance (QA)
and Inspection Plan.

• The SBD ( Part- 2 ) of Distribution Infrastructure works under RDSS under Chapter -4 ,defines roles and
responsibilities of DISCOMs and Contractor w.r.t. Quality Assurance of RDSS projects.

• In addition to the in-house quality checks and processes followed by the DISCOM, the nodal agency , i.e. REC shall
carry out concurrent inspection of works through Third Party Quality Monitoring Agency (TPQMA).

• MoP has already approved the Comprehensive guidelines for Quality Assurance Mechanism for TPQMA in its 17th
MCM (Monitoring Committee Meeting) held on 08th Feb’23.
Quality Assurance Mechanism : Roles of TKC ( Turn key contractor ) 1/4
The roles of TKC in respect of Quality Assurance are defined in RDSS Infra SBD Part 2 under Scope of Works in Section 4.1 , which
are briefly pointed as below:

Material Inspection –
PDI (Pre-Dispatch Inspection) by DISCOM/PD at Factory Premises
• 100% inspection of all materials viz. as per MQP/GTP, Approved Drawings, Technical Specifications, Datasheet,
applicable national & international standards.
Pre-commissioning test record -
• All pre-commissioning test check list shall be documented properly and signed by the quality engineer of the
turnkey Contractor & countersigned by DISCOM representative.
Ensuring Quality of Material supplied to DISCOM –
• To keep strict control over manufacturing of materials by controlling procurements of right raw materials,
periodical stage inspections, to ensure process control and to get the materials invariably inspected in
manufacturing stage as well as after manufacturing but before dispatch at the works of manufacturer to
ensure quality of materials/equipment.
• To ensure stage inspection and final dispatch inspection, turnkey contractor should deploy his/her quality
assurance team to inspect the materials with Employer/third party inspector as well as independently as per
requirements.
Quality Assurance Mechanism : Roles of TKC ( Turn key contractor ) 2/4

Receipt Inspection of supplied material at DISCOM–

• TKC shall verify materials receipt on site physically in accordance to agreed technical specifications. Physical
parameters like dimensions (length, width, height, area of conductor), weight per unit, Insulation Value, length of
cable/conductor in sample drum(s), clear embossing on cables through sequential marking depicting name of
manufacturer, size of cable and length in meter.
• After TKC inspection, materials must be offered for joint inspection to DISCOM.
• Dispatch documents shall be verified jointly by DISCOM, Turnkey Contractor and materials supplier.
• Once, materials on receipt are accepted by turnkey contractor as well as DISCOM representative, they will be
eligible for erection, testing and commissioning and clearance for installation will be given.
Quality Assurance Mechanism : Roles of TKC ( Turn key contractor ) 3/4

• Field Sampling of materials – (Clause 4.1.6 of RDSS Infra SBD Part -2 subsequently amended vide REC letter dated 12th July 2023)

• Inspecting official ( at the option of DISCOM based on its requirements and perception of Risk ) will have right to pick any
of the supplied equipment whether it is lying in site stores, is under erection, is under local transportation from site stores
to erection location or is already commissioned
• The equipment shall be sealed jointly in presence of representatives of Employer, Employer’s appointed Third Party,
Contractor, and Supplier/manufacturer (if his representative is available at site)
• Sealed equipment shall be sent to test laboratory for verification of all routine and acceptance tests feasible to conduct
in the empaneled laboratory along with verification of type test reports ( as applicable , from the respective
labs ).
• The laboratory expenses including all other expenditures that shall be incurred towards packing , transport ,
inspection , testing charges etc. are to be borne by the DISCOM.
Quality Assurance Mechanism : Roles of TKC ( Turn key contractor ) 4/4

Field Works Inspection –

• 100% verification of all 66/11 or 33/11 kV sub stations (New & Augmented) for quality of material as per MQP/GTP,
Approved Drawings, Technical Specifications, Datasheet and erection works in the field as per FQP/approved drawings.
• 100% verification of feeders created under the scheme.
• 100% verification of materials utilized under the scheme.
• 100% verification of works done in Loss Reduction and Modernization & System Strengthening.
• Issue Site Observation Reports (SOR) and follow-up with the subcontractor/ manufacturer for implementation of any
remedial actions.
• Upon completion, carry out joint inspections together with the DISCOM staff and for final measurements and quality
inspections.
• Follow-up any on technical issues for corrective action during defects liability period with the subcontractor/ manufacturer.
Quality Assurance Mechanism : Roles of DISCOM/PD 1/2
Quality Assurance Plan (QAP)-
• Vendor approval/Issue list of approved vendors on web-portal of DISCOM/PD.
• Prepare FQP & Pre-commissioning checklist, formats etc., Empanel test lab.

Material Inspection – (Clause 4.3.1 of RDSS Infra SBD Part -2)

PDI (Pre-Dispatch Inspection) by DISCOM/PD at Factory Premises
• 100% inspection of Category- A* materials is mandatory to be done by DISCOM/PD in the factory before the dispatch of the material.
• All the tests shall be carried out in accordance with the latest relevant IS published from time to time by BIS.
Material Testing by DISCOM/PD at NABL Labs -
• Samples ( As per IS Standards ) from 1st lot and one other lot of Category-A* materials randomly selected by the DISCOM shall be
directly sent to NABL accredited test labs for third party testing , the expense related to testing to be borne by Turn key contractor.
• 1 lot of Category-B** (On-site inspection) materials may be sent to NABL for testing ( on DISCOM expense ) which is optional for the
DISCOM.
Testing of Power Transformer
• 1 PTR (Power transformer) shall be selected by DISCOM/PD from the supply schedule from the vendor, which shall be jointly sealed and
tested for Short Circuit Testing (SCT) on turnkey-Contractor’s expenses.
• DISCOM/PD shall inform regarding the scheduled PDI of power transformer to Nodal Agency ( REC-QAD/PFC) at least 10 day in advance.
The above inspections would be jointly witnessed and signed by the DISCOM/PD along with Turn key Contractor.
DISCOM/PD shall issue the material dispatch clearance certificate for all the above materials based on the test result for the
material tested as per Indian Standards (IS)
*Category A materials- Power Transformers, Distribution Transformers, Circuit Breakers, AB/XLPE Cables, Overhead Conductor
(AAAC/ACSR), Insulator
** Category B materials - This category includes the materials for which a factory inspection is not warranted and the material can be inspected upon
arrival at the site before the installation.
Quality Assurance Mechanism : Roles of DISCOM/PD 2/2

Coordination with TPQMA

• (a) For PDI , (b) Field sampling and testing of five major materials i.e. viz., (1) Distribution Transformer, (2) Overhead Conductor, (3)
Pole, (4) Insulators, and (5) Cables (ABC/XLPE/Others) in NABL accredited labs and (c) Field Work Quality Inspection.

Progress update on RDSS web Portal

• DISCOM/PD also needs to update MIS formats related to Quality in the RDSS Portal.
• DISCOM/PD shall punch the details of Category- A materials tested (PDI) at factory in RDSS portal in Form-1 within 2 two days
from the date of issue of material dispatch inspection. PDI reports need to be uploaded in Form-1.
• DISCOM/PD shall punch the details of category – A materials arrived at site/stores , after material clearance given by DISCOM in
RDSS web portal in Form – 2 within 2 two days from the date of receipt of material at site/store. The material arrived at store not
be used for 1 week (7days) from the date of approval by DISCOM/PD (i.e. from DDA login). PDI & DI reports need to be uploaded in
Form-2.
• DISCOM/PD shall punch the details of NABL testing of Category – A materials in RDSS portal as per Form -3 .
• DISCOM/PD shall ensure the physical work progress at site is uploaded in RDSS progress detail within 5 days after completion of
each month.
• Three level user id is created for DISCOMs ( DDE , DDR & DDA ).

Rectification of Identified defects-

• DISCOM/PD are required to rectify the defect notified by TPQMA, if any within a month from the date of receipt of inspection report
uploaded in the RDSS portal by REC- TPQMA ( section 6.5.3 of RDSS Guidelines )
• DISCOM/PD after rectification of all the defects shall need to upload the report along with photographs detailing the rectification of
each defects.
•
Quality Assurance Mechanism : Roles of TPQMA 1/3

Appointment of TPQMA ( Section 6.5.2 of RDSS Guidelines) -

• REC has appointed REC-TPQMA ( Third Party Quality Monitoring Agency ) for quality monitoring of RDSS works for REC
sanctioned States/UTs as per below :

Appointment of REC-TPQMA to carryout TPQMA works in

Package REC-TPQMA assignment awarded to
DISCOMs/PD covered under States/UTs
Package-1 Uttar Pradesh, Goa and Mizoram M/s Voyants solutions Pvt. ltd
Package-2 Tamil Nadu, Jammu & Kashmir, Ladakh and Manipur M/s National Power Training Institute
Package-3 Rajasthan, Tripura and Chhattisgarh M/s Voyants solutions Pvt. ltd
West Bengal, Assam, Arunachal Pradesh and Andaman &
Package-4 M/s Mercados Energy Pvt. Ltd.
Nicobar
Package-5 Bihar, Meghalaya, Nagaland and Sikkim M/s N ARC consulting Enggpluss Pvt. Ltd.

The TPQMA scope of work is as per followings :

Material Inspection-
1. Pre-Dispatch Inspection of PTR at factory
• Inspection of at-least 1 lot of Power Transformers at manufacturer premises covering 5% quantity spread across two
major manufacturer /suppliers.
• DISCOM/PD need to intimate to Nodal Agency ( REC-QAD/PFC) , TPQMA appointed giving at least 10-day time for PDI of
PTR.
• The inspection shall be mandatorily witnessed by representatives of DISCOM, TPQMA, TKC and ensure all the tests to be
conducted as per Indian Standards (IS)
Quality Assurance Mechanism : Roles of REC -TPQMA 2/3

Material Inspection-

2. Field Material Quality Testing & Inspection (FMQI):

• TPQMA on random sample basis shall pick up at least one sample of each 5 high ticket materials (1)
Distribution Transformer, (2) Overhead Conductor, (3) Pole, (4) Insulators, and (5) Cables (ABC/XLPE) from
the each project area ( i.e. District ) stores of DISCOM and send to NABL accredited labs for material testing to
carry out all the acceptance test for the material as per applicable Indian Standards (IS).
• The equipment shall be sealed jointly in the presence of TPQMA, representatives of the Employer
[(DISCOMs/Power Department (PD)], Contractor, and Supplier/manufacturer (if his representative is available
at the site).
• Also, the second sample has to be sealed jointly in the presence of a DISCOM official /TKC, which is to be kept in
the DISCOMs/PD store.
• In case, first sample fails in NABL Labs , then second selected sealed sample will be tested in NABL Lab as per
IS standards.
• TPQMA shall witness all the acceptance tests of the material sample tested at NABL-accredited laboratories as
per IS standards.
• In case both samples fails at NABL labs , then entire lot of material supplied will be rejected , whether the material
under the lot is supplied to other district/project , erected or commissioned at site.
Quality Assurance Mechanism : Roles of REC - TPQMA 3/3

3. Field Works Quality Inspection (FWQI):

TPQMA shall carry out the Field Works Quality Inspection (FQI) for each project area (District/Package), in 3 stages i.e., on
completion of :
(1) 30% (Stage-I)
(2) 80% (Stage-II) of 'Financial Progress corresponding to the Physical Progress' respectively
(3) Final inspection (Stage-III) for verification of rectification of defects/ discrepancies/non-conformities identified in the
previous two stages of inspections after completion of the work.
• The inspection calls for field inspection shall be given by REC by the respective Chief Program Manager (CPM) of the REC’s
Regional Office of the state to REC-TPQMA.
• The TPQMA shall carry out field inspection works on random sample basis covering quantities:-

• 100% New and Augmented Power Substations.

• 5% of HT feeders (in terms of sanctioned length of Project i.e., District, covering at least 5% of the total sanctioned number of feeders)
for each voltage level and /configuration (OH/AB/UG/HVDS), including Bay extensions as applicable.
• 5% of HT feeder reconductoring/replacement/renovation work (in terms of sanctioned length of Project i.e., District, covering at least
5% of the total sanctioned number of feeders) for each voltage level and /configuration (OH/AB/UG).
• 5% of New Distribution Transformer (DTR) Substations (11/0.4kV) for each KVA level.
• 5% of Capacity augmentation of DTR Substations (11/0.4kV) for each KVA level.
• 5% of LT lines (in terms of sanctioned length of Project i.e. District/Circle) for each configuration (OH/AB/UG)
• 5% of LT Lines reconductoring/replacement/renovation work (in terms of sanctioned length of Project i.e., District/Circle) for each
configuration (OH/AB/UG).
• IT/OT/SCADA/Smart meters as per the scope .
• 1% or 1,000 meters of consumer smart meters implemented under the scheme, whichever is less, including the LT auxiliary works.
• 2% of DT/Feeder/Boundary meters implemented under the scheme including the auxiliary works.
Progress update on the RDSS Portal

The DISCOM have to ensure Monthly filling of data on RDSS web portal
( Link : https://rdss.powermin.gov.in/ )

Form No. To be Details of the Format Excel File

Uploaded by
F-1 DISCOM Pre-dispatch Inspection (PDI) of Category-A material carried out
by DISCOMs/PDs
Microsoft Excel
Worksheet

F-2 DISCOM Details of materials arrived at DISCOMs/PDs stores after Pre

Dispatch Inspection at factory premises [to be offered for field
Microsoft Excel
material quality testing and inspection (FMQTI) by REC-TPQMA]. Worksheet

F-3 DISCOM Details of test carried out on the sample at NABL lab for
Category-A materials by DISCOMs/PDs & result thereof
Microsoft Excel
DISCOMs/Power Dept. (PDs). Worksheet

F-4 DISCOM Physical and Financial progress of the RDSS scheme.

Microsoft Excel
Worksheet
THANK YOU
Penalty Provisions
PDI :
• If material fails the pre-dispatch inspection, and also fails the subsequent repeat inspection, the complete lot
of material under inspection will be required to be replaced by the manufacturer/supplier.
• If in subsequent inspection of the new lot, the material again fails the inspection, then materials shall be
rejected, and approval of vendor/sub-vendor shall also be cancelled for all RDSS projects.

Field Material Testing : Failure of material at third party NABL Labs

• Entire lot of materials/equipment shall be Rejected.
• All costs related to removal of such rejected materials and reinstating fresh lot of materials shall be borne by
TKC.
• Sub-vendor/ Manufacturer’s registration shall be discontinued for 5 years for wilful defaulter manufacturer.
• Registration of TKC shall be discontinued for 5 years in case of repetitive failures.

Field Works Inspection:

• Penalty provisions on TKC based on nature of defects ( Critical , Major & Minor ) reported during field
inspection works.