QA PROCESS

1.1 Responsibility of Tests and Inspection

Test and inspections are in the complete purview of the AMISP and its sub-
vendors. It shall be ensured that there are no conflicts in roles played between
AMISP personnel carrying out tests / inspections, and those assigned
responsibilities of quality assurance (QA) and quality control (QC).
The QA/QC organization of the AMISP shall be an independent administrative
and functional structure reporting via its manager to the AMISP’s top management.
The QA/QC manager(s) shall have the authority within the delegated areas of
responsibility to resolve all matters pertaining to quality when actual quality
deviates from that stated in the Work Statement. The personnel performing
QA/QC functions shall have well-defined responsibility, authority, and
organizational freedom to identify and evaluate quality problems and to initiate,
recommend, or provide solutions during all phases of the Contract.
The QA/QC Manager designate for the project shall be the custodian of all
inspection and test records/certificates. QA/QC Manager either directly or
through its authorized representative shall be responsible for all witness
testing, approval of test records and in general, management of the QA/QC
program of the project.

The responsibility for inspections and tests is borne by the Inspections and
Tests Manager. This team is responsible for creating the various inspection and
test procedures and under the general supervision of the QA/QC Manager,
conducts the tests.
In the event any imports are required for the purposes of this AMISP Contract,
such imports shall be in accordance with all applicable laws including those
issued by Ministry of Power (Order No. No.9/16/2016-Trans-Part(2) dated 18
November 2020; as amended and/ or modified from time to time) for testing of
imports including those from prior reference countries.

1.2 In-Process Inspection

9.2.1 Type Testing and Data Exchange Protocol Testing

Type Tests shall be defined as those tests which are to be carried out to prove
the design, process of manufacture and general conformity of the product as
per BIS standards . The Data Exchange Protocol Tests are defined as those
tests which establish compliance with DLMS/COSEM application layer. The Type
Testing and the Data Exchange Protocol Testing shall comply with the following
general conditions.
a) The QA/QC Manager shall document, within scheduled period as per
project plan, copies of test reports and certificates for all the Type
Tests that are specified in the specifications and that have previously
been performed. These certificates shall apply to items and
equipment that are essentially identical to those due to be delivered
under the Contract and test procedures and parameter values shall
be identical to those specified in this specification. The type tests
shall be carried out at nationally/Internationally accredited labs and
type test certificates shall not be more than three years old.
 b) Type Tests shall be performed for all equipment types for which
certification is not provided as required above. If any of the type tests
are required to be carried out, the same shall be carried out by the
AMISP.
c) For direct connected Smart Meters, the Type Tests shall follow IS
16444 read in conjunction with IS 13779. The test schedule adopted
for running the Type Tests along with the sampling criteria and the
criteria for conformity shall follow IS 13779.
d) For transformer operated Smart Meters, the Type Tests shall follow IS
16444 (Part 2) read in conjunction with IS 14697. The test schedule
adopted for running the Type Tests along with the sampling criteria
and the criteria for conformity shall follow IS 14697.

e) For pluggable NIC modules, the type tests shall be carried out with
the NIC module integrated in the field device, that is meters and
DCUs being supplied under the project.

f) Type Tests and Data Exchange Protocol Tests shall be certified or

performed by nationally/internationally reputed laboratories using
material and equipment data sheets and test procedures that have
been developed for the project. The test procedures shall be
formatted as in the specifications and shall include a complete list of
the applicable reference standards before commencement of test (s).

g) The AMISP shall prepare a detailed schedule for performing all

specified type tests.

h) The AMISP shall ensure that all type tests can be completed within
the time schedule offered in its Technical Proposal.

i) In case of failure during any type test, the AMISP shall follow the
conformance criteria as laid out in corresponding standard (refer
serial number c and d above)

j) For direct connected Smart Meters, the Data Exchange Protocol Tests
shall follow IS 16444 (Part 1) read in conjunction with IS 15959
(Parts 1 & 2). The sampling criteria for running these tests shall be
[one per one lakh] smart meters under production.

k) For transformer operated Smart Meters, the Data Exchange Protocol

Tests shall follow IS 16444 (Part 2) read in conjunction with IS 15959
(Parts 1 & 3). The sampling criteria for running these tests shall be
[one per one lakh] smart meters under production.

l) Documentation for all factory, field, and availability tests that apply to
the AMI system shall be provided in accordance with the
requirements defined in this section of specification
9.2.2 Quality Assurance and Quality Control Program

The QA/QC Manager shall maintain a Quality Assurance/Quality Control

(QA/QC) program that provides that equipment, materials and services under
 this specification whether manufactured, designed or performed within the
AMISP’s plant, in the field, or at any sub-contractor’s source shall be controlled at
all points necessary to assure conformance to contractual requirements.
The program shall provide for prevention and ready detection of discrepancies
and for timely and positive corrective action. The QA/QC Manager shall
document objective evidence of quality conformance.
Instructions and records for quality assurance shall be controlled and
maintained at the system levels. The AMISP shall outline its QA/QC program
plan along with any supporting documents in the Technical Proposal and
update the QA/QC program document following site the survey.

A Quality Assurance Program of the AMISP shall cover but not be limited to
the following:

a) The organization structure for the management and implementation of

the proposed Quality Assurance Program

b) Documentation control system

c) Qualification data for key personnel

d) The procedure for purchase of materials, parts/components and
selection of Sub- contractors’ services including vendor analysis,
source inspection, incoming raw material inspection, verification of
material purchases, etc.

e) System for shop manufacturing including process controls

f) Control of non-conforming items and system for corrective action

g) Control of calibration and testing of measuring and testing equipment

h) Inspection and test procedure for manufacture

i) System for indication and appraisal of inspection status
j) System for quality audits

k) System for authorizing release of manufactured product

l) System for maintenance of records

m) System for handling, storage and delivery

n) A Quality Plan detailing out the specific quality control procedure
adopted for controlling the quality characteristics of the product.
The QA/QC Manager shall be required to make available to the Inspection and
Testing Team, all the Quality Assurance Documents as stipulated in the Quality
Plan at the time of inspection of equipment/materials.

9.2.3 Scope and Duties of QA/QC Program Manager

The QA/QC Manager of the AMI Project shall have the right to carry out
Quality Audit and Quality Surveillance of the systems and procedures of the
AMISP’s/his vendor's Quality Management and Control Activities. The scope of
the duties of the QA/QC Manager, pursuant to the Contract, will include but
not be limited to the following:
 a) Review of all the AMISP’s drawings, engineering data etc.

b) Witness or authorize its representative to witness tests at the

manufacturer's works or at site, or at any place where work is
performed under the Contract.
c) Inspect, accept or reject any equipment, material and work under
the Contract in accordance with the specifications.
d) Issue certificate of acceptance
e) Review and suggest modification and improvement in completion
schedules from time to time; and
f) Monitor the Quality Assurance program implementation at all stages
of the works.

9.2.4 Inspection and Test

All materials furnished and all work performed under this Specification shall be
inspected and tested. Deliverables shall not be shipped until all required
inspections and tests have been completed, all deficiencies have been
corrected, and the equipment has been approved for shipment by the QA/QC
Manager
Documents identified in the hardware and software quality assurance plan and
procedures shall be inspected to verify that the required quality assurance
activities have been performed in the manufacturing process of hardware and
software.
Inspections will include visual examination of hardware, enclosure cable
dressings, and equipment and cable labelling.
Should any inspections or tests indicate that specific hardware, software or
documentation does not meet the Specification requirements, the appropriate
items shall be replaced, upgraded, or added by the AMISP as necessary to
correct the noted deficiencies. After correction of a deficiency, all necessary
retests shall be performed to verify the effectiveness of the corrective action.
The test shall be considered complete when (a) when all variances have been
resolved;(b) all the test records have been filed; (c) QA/QC Manager
acknowledges in writing the successful completion of the test.

9.2.4.1 Test Plans & Procedures

Test plans shall be provided by the QA/QC Manager, for all tests to ensure that
each factory and field test is comprehensive and verifies all the features of the
equipment are tested.
The Inspection and Test Manager in AMISP shall prepare detail testing
procedure in line with specification. The procedure shall be modular to the
extent possible, which shall facilitate the completion of the testing in the least
possible time.
During the development of test plans and test procedures for the system,
emphasis shall be placed on testing each conditional logic statement, checking
error conditions, and documenting the simulation techniques used. The test
plans and test procedures shall be modular to allow individual test segments to
be repeated as necessary.
 9.2.4.1.1 Test Plans
The test plans shall describe the overall test process, including the
responsibilities of individuals and the documentation of the test results. The
following shall be included in the test plans:

a) Test schedule on a day-by-day basis

b) Responsibilities of test engineer and QA/QC personnel

c) Record-keeping assignments, procedures, and forms

d) Procedures for monitoring, correcting, and retesting

variances

e) Procedures for controlling and documenting all changes

made to the hardware and software after the start of
testing
f) Block diagrams of the hardware test configuration, the
external communication channels, and any test or
simulation hardware.

9.2.4.1.2 Test Procedures

The test procedures shall describe the individual tests segments and the steps
comprising each segment, particularly the methods and processes to be
followed. The test procedures in general shall include the following items:

a) Name of function to be tested;

b) References to the functional, design, user, and any other

documents describing the function;

c) List of test segments to be performed and the purpose of

each test segment;

d) Set-up conditions for each test segment, including

descriptions of the test equipment;

e) Descriptions, listings, and instructions for test software

tools and displays if any;

f) Step-by-step descriptions of each test segment, including

user actions for each test step;

g) Expected results for each test segment, including pass/fail

criteria;

h) Descriptions of the techniques and scenarios to be used to

simulate system field inputs and controlled equipment;

i) Copies of any certified test data to be used in lieu of

testing.

9.2.4.1.3 Test Records

The complete record of all factory and field acceptance tests results shall be
maintained by the designated QA/QC Manager of AMISP. The records shall be
 maintained in a logical form and shall contain all the relevant information. The
test reports shall be signed by the inspection & testing Engineer and the
QA/QC representative witnessing the tests. The records shall be keyed to the
test procedures. The following items shall be included in the test records:

a) Reference to appropriate test procedure

b) Date of test

c) Description of any test conditions, input data, or user

actions differing from that described in the test procedure

d) Test results for each test segment including a pass/fail

indication

e) Identification of AMISP’s test engineer and QA/QC

representative.

f) Provision for comments by test engineer and QA/QC

representative

g) Copies of any variance reports generated

h) Copies of reports, display copies, and any other hardcopy

generated as part of the test.

9.2.4.1.4 Reporting of variances

Starting from the dry run test period, a variance report shall be prepared by the
inspection and testing engineer each time a deviation from the requirements of this
Specification is detected in areas such as system functions, design parameters,
performance, documentation, test plans, and test procedures. Record of all such
variances and their resolution shall be maintained by the QA/QC Manager.

However, at any stage if QA/QC Manager feels that quality of variances calls for
suspension of the testing the testing shall be halted till satisfactory resolution of
variances, which may involve retesting.

The report shall include a complete description of the variance, including:

a) Sequential identifying number assigned to the variance

b) Date and time the variance was detected

c) Appropriate references to the test procedures and this

Specification

d) Description of test conditions at the time the variance was

detected

e) Identification of testing and QA/QC representatives

f) Estimated date and time when variance is expected to be

fixed
 g) Description of the corrective actions taken (to be
completed as part of the variance resolution process

h) Dated signature lines for the QA/QC and test

representatives to signify reporting and correction of the
variance.

i) Each variance shall be assigned to one of three classes

defining the action to be taken to resolve the variance:
a) Class 1: Testing will immediately stop and the AMISP will
evaluate and correct the variance before testing is
resumed

b) Class 2: Testing will continue, and the variance will be

evaluated and corrected by the AMISP at the end of the
current session but prior to further testing
c) Class 3: Testing will continue, and the variance will be
evaluated and corrected at a mutually agreed upon time
between QA/QC Manager and the Inspection and
Testing Manager.

The class shall be assigned by the QA/QC representative.

The QA/QC Manager shall maintain and periodically distribute a variance summary
that lists for each variance the report number, a brief description of the variance, its
class, and its current status (open or resolved).

All actions taken to correct variances shall be documented on the variance report by
the AMISP. Sufficient information shall be recorded to enable QA/QC representative
to determine the need for and extent of retesting, the need for testing interactions
of the correlation with any previously tested hardware or software, and the need for
updating appropriate documentation. A variance shall be deemed resolved after
retesting has been performed satisfactorily and the test engineer and QA/QC
representatives have acknowledged correction of the variance on the variance
report.
9.2.4.2 Test Initiation
The following conditions must be satisfied before starting any test
a) All test plans and procedures for the test shall be available.

b) All hardware and software engineering design change orders shall

be incorporated into the system under test.

c) All relevant documentation including drawings, lists of deliverables,

and software functional and design documents, and user manuals
shall be available.
d) A complete regeneration of the software under test shall be
performed immediately prior to the start of factory testing.
e) All operating system parameters, files, and configuration
information shall be saved to archive media so that the AMI
 systems operating environment can be recreated starting with an
un-initialized system. The existence and completeness of this data
shall be demonstrable.

f) All database, display, and report definitions shall be saved to

archive media so that the databases, displays, and reports can be
recreated if necessary.
g) The image backup of all applications of AMI Systems shall be
taken on the archive media so that AMI systems software can be
regenerated if necessary.
h) A complete dry run of each factory test (excluding the integrated
system test) shall be conducted by the AMISP using the test plans
and test procedures.
9.2.4.3 Test Completion

A test shall be deemed to be successfully completed only when:

a) All variances have been resolved

b) All test records have been documented and issued QA/QC acknowledges, in writing,
successful completion of the test.