Tele : 26194491

Government of IndiaMinistry of Defence (DGQA)Directorate of Quality Assurance (Naval)West Block-5, R K PuramNew Delhi - 110066

File No. 66301/Policy-07/DQAN/QA-03

All DQA (N) Establishments

\0 Jan 2007

GUIDELINES FOR TESTING AT

CQA~,BANGAlORELABORATORY

A Testing Laboratory for conduct of Environmental Tests as perJSS-55555 and other Defence Specifications, as a part of Type Testingon Defence Equipment! components has been setup and is operational atCQAE (WE), Bangalore. The Laboratory also provides the EnvironmentalTest facility to Private Industries, whenever the faCility can be spared.

2. A comprehensive document titled "Guidelines for Testing at CQAE(WE), Bangalore" indicating the following aspects has been prepared andplaced at Enclosure for reference and compliance:-

(a) Organisation Structure

(b) Procedure for Technical/Financial Approval

(c) Guidelines for Testing

(d) Procequre for undertaking Tests

(e) Applicable rates for testing.

- Section I

- Se9tion II

- Section III

- Section IV

- Section V

3. It is requested that all equipmenUsubunits/components requiringtesting at the laboratory be forwarded to CQAE (WE), Bangalore as perprocedure specified in the guidelines ibid.

4. All DQAN orders issued earlier on the above subject are herebysuperceded.

<OkdrS"h).eVIn er '"9Captain, INDQAN

Enel : As above.

COpy to : OQA (WP)

Enclosure to DOA (N) letter No66301/Policy-07/DQAN/0A-03

dated 1 u Jan 07.

GUIDE LINES FOR TESTING

AT

CQAE (WE)~BANGALORE

A. Major Testfacilities

B. Detailsof Environmentstress Screening(ESS)

C. RequisitionForm for Testing

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S.No.

SECTION I

SECTION II)

SECTION III

SECTION IV

SECTION V

APPENDICES

INDEX

DescriDtion

Record of Amendments I Revision

Organisational StnIcture of the Lab

P~edure for Technical Approval andFinan~ia.lsanction of the tests to be carried out

Guidelines for testing

Pro~edure for undertaking the test

Applicable Rates for testing

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RECORD OF AMENDMENTS I REVISIONS

S.No Amendment LetterSeniOR of tbePage No. andRemarksNo. and Date

Guid~liDesParaReference

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SECTION -I

DCQAO

TAISTA(MAINTENANCE)

ACQAO(LAB) n(MAINTENANCE)

PAINTER I I CARPENTER

DACQAO(LAB) II(TESTING)

ORGANISATION CHART OFLABORATORY

STENO

ACQAQ(LAB) ITESTING

4

ole II TAISTA II TAfSTA(RECORDS) (CLIMA.TIC (DURABILITY)TESTING)

DACQAO(LAB) I(PLANNING)

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SECTION -II

Procedure for Technical Approval andFinancial sanction

Technical approval

1. Technical approval for various tests to be carried out is approvedby CQAE(WE) Bangalore in consultation with DQA(N) HQ on a case tocas~ basis , depending upon the specification and end user requirementas laid down in the Purchase order. \

Financial'sanction

2. The financial sanction for purchase of new test facilities~ repair andcalibration of existing equipment as well as involved expenditure inconducting various tests wiU be obtained as per the delegation offinancial powers by MoD letter 639211 DGQA I ADM 1RMD / Budget/1352 / D (QA) dated 31 May 05 promulgated vide DGQA letter vide63921 / Delegation / DGQA / ADM / RMD / Budget dated 07 100 05.

3. The delegated financial powers are also referred in DGQAstanding orders Vol I (Para 4.1.3.15 refers).

4. The delegated financial powers by DGQA may be amended fromtime to time based on MoD orders in force.

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SECTION -DI

GUIDE LINES FOR TESTING

1. Test Laboratory at CQAE (WE)7' Bangalore is primarily meant forconducting Environmental tests as per JSS - 55555 and other related Defencespecifications, as a part of Type Testing on Defence equipment/components. ThisLaboratory also providesenvironinental test facility to other Private Industries, ~asand when the facility can be spared. The list of Test Facilities available in theLaboratory is placed at Appendix - A. Limited Environmental Stress Screening(ESS) can also be carried out in the Laboratory at CQAE (WE) (except for randomvibration te~ 20-2000 Hz). Details of ESS are given in Appendix - B. These infact are extracts ofDQA (N) document DQA (N) I EL I QAP -ESS 1065 dated 31Dee 05_ The guidelines for undertaking the tests are enumerated in the succeeding,paragraphs.

2. The Laboratory will undertake Environmental Testing free of cost, for theNavy/Anny equipment/components for which Supply Orders ofMOD/NHQ/DRDO/Shipyards exist and where DGQA organ17'ltion has beenassigned the responsibility of Inspection Agency QA)! Inspecting Officer (IO),unless otherwise specified in the Supply Orders. In case the tests have to berepeated due to failure of equipment/components, the tests win be repeated free ofcost only once.

3. The Laborntory will undertake testing on payment basis in the followingevents:-

(a) The equipmentsfcomponents not ordered by Navy/Army authorities or byDGQA organi73tions (unless otherwise specified in the Pmcbase Orders).

(b) Repeat tests on equipments/components for supply orders placed byArmy/Navy authorities or DGQA organization, where DGQA organi7.abon hasbeen assigned the responsibility of Inspection Agency (IA)/Inspecting Officer (10)but where·the samples have aiready failed in the initiai testing and aiso once in freetesting. ,(c) The ESS or environmental test which are required to be conducted as a partof production process (which are the responsibility of the firm as per purchaseorder)

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4. Equipment will be test{(don a 'First Come FiTst Served" basis. Howcvec~ the .,. priority of the testing will be accorded as given below in the event of concurrent

Tequests from various agencies" unless otherwise directed by DQA(N).

(a) Items ordeTed for Navy by MOD I NHQ I DQA (N)/ DQA (WP) UDits IShipyards.(b) Items ordered by DRDO as part of Development Projects for Navy.(c) Items ordered by Coast Guard auth()rities for Coast Guard.(d) Items ordered by Army.(e) Items ofother CentralGovernment Agencies! Privateagencies~ onpayment.

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SECTION-IV

PROCEDURES FOR UNDERTAKING THE TESTS

F~ of Cost Testiu«

1. The procedure followed for undertaking tbe tests free of cost will be as

.follows:-

'(a) The items to be tested should be forwarded by the respective QAOs tothe Laboratory with specified Test Requisition Form. The copy of TestRequisition Form is placed at Appendix: - C. The Test Requisition should containthe list of tests to be conducte<L Test Specifications along with details / reference toTest name~ Test procedure, Test number and Test conditions. Details ofpre andpost performance tests as applicable will also be specified by the fmns through therespective QAOs and ratified by QAOs.

(b) The Laboratory will scrutinise the Test Requisitionwith reference to theTest Specifications and availability of test facilities. If all the details of the tests tobe conducted are clearly mentioned, the Laboratory will carryout the testsaccording to the Test Plans and monitor the progress. In case of any specificteclmical difficulty, the Lab will seek clarification from the :firm/respective QAOs.Specific pre- performance and post- performance tests beyond thecapability/capacity of the lab (on account of Jack of instrumentation, requirementof special setups etc.,) will be arranged by the respective QAOs" assisted by thefirm as necessazy.

(c) The firm will provide test jigs for conducting the tests. Concerned QAOswill authorize and intimate to the Manger (Lab) details of firm' s reps who willliaise with the lab during the conduct of the tests.

(d) On completion of the tests, the Test Report will be retained at the lab with acopy to respective QAO. Monthly summary of the tests carried out is to befOIWarded to DQA (N). However" the test records will be maintained at the labfor reference and future use.

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~"ment Testin2;

2. The following procedt\re will be adhered to for undertaking the tests on

payment basis: -

(a) The firm will submit their request in the specified Test Requisition fonnalong with the relevant Specificatio~ Test name, Test procedure,. Test uwnberand Test conditions:> directly to CQAE (WE) Lab or through the regional QAOs.

(b) CQAE (WE) Lab will scrutinize the requisition of the firm with reference toTest Specifications and availability of test facilities_ If all the details of tests to beconducted are clearly mentione~ the rates for conducting the available testfacilities will be forwarded by CQAE (WE) Lab to the firm.

(c) On receipt of the mtes sent by CQAE (WE) Lab, the firm will submit theitems to the Lab along with the test charges through Demand Draft drawn in favourof CQAO:>CQAE (WE), and Bangalore.

(d) The firm will provide Test Jigs for conducting the tests_ The representativeof the firm can be present during the conduct of the tests:> with prior iIitimati.on ofthe Manager(Lab)

(e) On completion of the tests, Test Report will be fOIWaJ-ded to the firm.

(f) The test charges thus received from firms will be credited through MRO toMajor Head XL Vll, sub major head I, Army Main head N, Sub head F. othermiscellaneous of the Defence Services Estimates.

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APPENDIX-A

(Refers to Para 1 of Section III)

MAJOR TESTFACILlTIES AT CQAE (WE) LABO-,"TORIES ..BANGALORE

S\ Tdt Chamber sizeMaL weight &Parameterssped(KationMaL perwissable

aDd toleraDcesize or test sample (widthXheigbtXdentb) (a:)1 .

Dry Heat . lxlxl m200 kg,Amb to 300-u-CJSS 55555(High

\ 05xO.5xO.5m+/-3~C<100°CIS 9000,.Temperature)

+/_5°C<IOOoeDEF 133,MIL 810 &JSS 501012

Damp heat L5xL5xL5m300 kg40oC+/-22°CJSS 55555( Steady state)

0.75xO.75xO.7595o/oRH(Min)IS 9000,m

DEFI33&JSS 501013

Damp heat ( 15xl.5xl.5m300 kg25 to 55OC+/-JSS 55555Cyclic) I

O.75xO.75xO.752°C, 95%IS 9000,Tropical

mRH(Min)DEF 133,exposure

MIL 810 &JSS 501014

Damp heat 1.5xl.5xl.5m300 kg25 to 65"C+/-JSS 50101(Moisture

0.75xO.75xO.752°C, 95%Resistance)

mRHlM-in\

5Dry Cold lxlxlm300 kgUp to -65-uC+/-JSS 55555

(Low0.5xO.5x05m3°CIS 9000,

Temperature)DEF 133,

MIL 810 &JSS 501016Mould 1.2xl.2xl.2m200 kg29°C+/-IoCJSS 55555

Growth!0.6xO.6x.0.6m90o/oRH(Min)IS 9000,

FungusDEF 133,

ResistanceMIL810&

JSS 50101

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SI Test Chamber sizeMu.-weight &Panmeters.Spec-iticatie&.iM2x.. 2Dd toIenuu:e

--pttmissable

size of testsample(width X heightX depth) (2t)7

Corrosion 1.5xl.5xl.5m500 kg35uC+/-2oCJSS 55555(Salt)

O.75xO.75xO.790 to 95%RHIS 9000,5m

DEF 133,MIL810&JSS 501018

Immersion 0.5mdi~50 kgUp to 2600 kPaJSS 555551.Omdepth

0.3mdia05m IS 9000~depth

DEF 133,lv1IL 810 &JSS 501019

Rain 2x2x2m1000 kg200kPa+/-15%JSS 55555lxlxlm

450 li1res+/-l0% .IS 9000:>perham

DEF 133"lv.1IL810 &JSS 5010110

Drip proof LOxLOmNA1m from top ofJSS 555550.75xO.75m

equipmentDEF 133,JSS 5010111

Contaminationlxlxlm200 kg50oC+/-2oCJSS 555550.5xO.5xO.5m

DEF 133.12

Rapid lxlxlm100 kg-40 to +40uJSS 55555temperature

0.5xO.5xO.5mC,,+/-2°CIS 9000,cycling/

95%RH(Min)DEF 133,Thermal shock

MIL 810& .JSS 5010113

Shock O.75xO.75m500kgfocNSSI&ll,JSS 55555base size

NSS-I& 800Half Sine pulseIS 9000,kg for NSS-II

onlyDEF 133,including jig

MIL 8100.75xO.7Sxl.O hi

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14Shock on N.A50 kg4 positions-EN 5/IN 405

pressure

including jig

gauges

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SI Test Chamber sizeMax. weight &ParametersSpecification.Max. and tolerance

permissable §ueoftestsample(widthX heightX deotb) .(tt)15

Vibration i)lxl mi) 500 kgi)O.125 romJSS 55555,

(Manual

base sizeincluding jigconstant disp.DEF 133

sweep &

Ixlxl m5 to 33 Hz

Endurance at

ii)O.5xO.5 mii) 50 kgii)Up to 13 mm

fixed

baSe sizeincluding jigconstant disp.I

frequencies )

O.5xO.5xO.55 to 50 Hzm

displacementtolerance +/-25%16

Vibmtion 0.15x0.1S m2kg7to350~2GJSS 50101

(Endurance

base sizeincluding jigtolemncein

by sweep)

O.lxO.lxO.laccelerationsm

<150Hz+/-15%

>1 50Hz +/-.25%17

Bump Ixi ill250 Kg10,25,40g,JSS 55555

base size

including jig6,16MsIS 9000,0.75xO.75xO.

+/-10 bumpsDEF 133,75m

JSS 50101

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Drop! Portable10 kgThickness ofJSS 55555

Toppling

0.2xO.2xO.2steel plate 12IS 9000,m

mm(min)DEF 133,MIL 810 &JSS 5010119

Ship motion1.2xl.2m200 kg+/- lSufixed-base size

O.9xO.9xO.9m20

Tensile test onN.AO.3m250kgfAs applicable

rubber & cotton etc .21Current N.A.N.A1500A. IS 2516 Etc.,

injection (AC) \(Continuous) ~

6000 A(instantaneous)

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Sf T-est Chamber sizeMax. WeightPal1lllletenSpec.••••••

& MaL aDd tolenmcepermis~ible size of testsaDlple(width X. height X

deotbl (*)22

Current N.A.N.A800AIS 2516 Etc .•

injection (DC)(Continuous)

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2000 A

'(instantaneous)23

BreakDown N.AN.AlOKVSES,NES24

Insulation N.AN.AUp to 1000 VSES, NESDC

(*) - Following tolerances are permissible on the sample size mentioned in CoL 4 above.

(i) +30010of anyone side, if only one side of the sample exceeds the maximumpermissible size of the sample.

(ii) +15% of any two sides, if only 2 sides of the sample exceeds the maximumpermissible size of the sample.

(iii) +100.10 of ail three sides. if all the three sides of the sample exceeds the maximumpermissible size of the sample.

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(Refers to Para I of Section Ill) 1DETAILS OF ENVIRONMENTAL STRESS SCREENING ( DQA (N) document DQA (N) lEU os I QAP -ESS I 065' dated 31 Dee 05)S.NO.

TEST SEVERITY APPLICAUH.ITY

(a)

Thermal shock o -SO degree C ,60 Min (for1000/0 on all PCB

commercial grade components), '

,-40 to 70'degree C. 60 Min (for MH.. components)Change over time - 03 min'No. of cycle - 06(para 17 of guidelines for reference)

(b)

Vibration Test Random vibration Fully wired ami20-2000 Hz

cages, power

Power density O.02g2{Hzamplifier~ power

in atleast two axis

suppl;es, modules, sub

(as per pam 11 of the guidelines)

assembly etc

(c)

Endurance 168 brs at room temperatureComplete system! set

for sonars, communication equipment AlO systems, NA V aid equipment etc_and08 hrs for Radar equipment with4hON(d)

Hemi sealing ofConformal Coating and SolderOn all PcBs and

PcBsmarking for all EquipmentEquipments

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APPENDIX-C(Refers to Para 1 (a) of Section IV)

REQUISITION FOR TESTING AT COAE(WE) BY GOVl:~MENTESTABLISHMENT

1- Name & Address of establishment

Requesting foT testing.

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Name & address of manufactureJs/

Supplier

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3.

Supply Order No. & date

4.

Equipment details( complete)(Attach aSeparate sheet if necessary)I. Accessories if anyII.Quantitym.Weight & dimensions

.

5. Whether Test Jigs forwarded with item! YESINOWill be

ed...

(See note below)

6.Preliminary inspection reports/functional

Test reports(to be enclosed with thisrequisition)1.ion seal of Inc

8.Tests to be conducted Indicate in the fonnat at the backside of the

..

reQuisition

9.PreIPost Perfonnartcecheekstobecarried

out(Attach step by step Authenticated TestProcedure)

.

10.Free t . ~avmeD.ttesting

II.Purpose ofconducting·tests(In case of

payIllent testing)

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12.Any other details .cOnsidered essential

Note: It is mandatory that jigs and fixtures are to be provided by the firm for conducting shoc~vibration and bump tests. However, ~e of available jigs and fixtures in CQAE labs can bemade. If not, information of local fabncators can be had from the laboratory.

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Details of tests required to be undertaken:(a) S~ification(b) Testsin sequence

Sl. Name of Test Specification clause procedureObservations to be madecondition & severityetc

during and after test

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FOR OFFICE USE ON!. Y (f & A)

2. Job Card No. & date given3.Commenced on , completed on """4. Test Report No date dispatched on .S.Certified that the charges were realized in full vide ChequeIDemand Draft No ....... forwarded to ACQAO(Adm) vide ISMNo date .

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Date:Place :

1. Approval for work by TECHNICAL MANAGER

IN-CHARGE (P&A)DATE;

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Signature and Designationof the Initiating Agency

YesINo

lECHNICAL MANAGER

TECHNICAL MANAGER.DATE :

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SECTION V

Applicable Rates for testine:

1. The Present Rates for Testing the sample equipment are as per CQALaudited rates.

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2. In this regard CQAL letter No, 108108/Policy dated 05 Jun 2006 isrelevant. copy of which is placed at Annexure 1.

ANNEXURE-l

Grams: ASSURElCBAN GALORE

Phone: 2333111 Ext 471

Govt. of India

Ministry of Defence (DGQA)Controllerate of Quality Assurance (L)JC Nagar, Bangalore - 560 006

Ref No 1081081P0licy 05 Jun 2006

To

The· Controller

COAE(WE)Jalahalli Camp RoadYeswanthpurBangalore -560 006(kind attn BV Seshachalam

The Control~rCQAR. B'loie -6

TheSQA,

SQAE(L)J Mumbai

2.

1.

3.

4. The$OAOsOAfE(l), Kolkata

TESTING ON PAYMENT

The Schedule of testing charges for componentslequipments has been revisedand the same is enclosed herewith as Appendix 'N & 'B' for your information/guidanceplease.

2. The revised test charges has been approved by LAO Bangalore.

Sd/xxxx

Ene! : As above

(in duplicate)(KASOKAN)It Colfor Controller

Internal distribution

JC(T), JC(P), JC(l) ,... for info along with one copy each of Appx 'A' & 'B'.

DC(l). DC(T), DC(X), DC(P), DC( C), DC(E)

APPENDIX 'A'TEST CHARGES FOR ENVIRONMENTAL TESTING

Sri Type of Test Formula for TestRemarksNo

cha£R~1

Vibration test a) 274+n (705.00)(#) Based on 60mins observation timeb) 274+n (346.00)2

Acceleration test 274+n (310.00)3

Bump test 274+n (159.00)Based on 30 mins observation4

Bounce test 274+n (155.00)5

Shock test 274+n (308.00)6

ShockIHeavy 274+n (281.oo)($) This rate is fixed as 2 ClMs areImpact

required during the test.7

Dry/Damp Heat 274+n (175.00)(%) Based on 10 mins observation for less(for eopt/sub assy)

than 4 Cft in volume8

Dry/Damp Heat test274+n (228.00)(&) For items more than 4Cft in volume

274+n (v x 28)

(*) When shared with other projects.Where 'V' is the volume of the sampleunder test (diviser B)9

Contamination Test274+n (319.00)10

Dry/Damp Heat test274+n ( 60.00)(for components) 11

Life Endurance 274+n( vx 5 )(A) When shared with other projects~under temp

where 'V' is the volume of the samplecondition! Damp

under test.

Head Steady state for components12Dry Cold Test 274+n (177.00)(") Based on 15 mins observation(s). For

items less than 4 cft in volume andtemperature upto deg C (diviser 32)274+n (356.00)

(b) For items less than 4 cft in volume andtemperature upto 65 deg C.

548+n (597.00)

(c) For items less than 4·cft in volumeand temperature upto 30 deg C.

274+n ( 68.00)

(d) For small components

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Thermal Shock Test 274+n (403.00);

14

Mechanical 274+n ( 30.00)«) Based on 05 mins observationEndurance Test 15

Low Air Pressure 274+n ( 60.00)Test

Sri No Type of TestFormula for TestRemarks

chaO!es16Mould Growtha) 274 +n (v x28)(»F or equipments, where.' V' is the

Testvolume specimen in eft (diviser 8)

b) 274 +n (14.00)

(?) For components (diviser 16)17

Dust Testa) 274+n(269.00)b) 2192+n

(**) This rate is exclusively for(418.00)

Ingress protection test as 4 eMs arerequired one br before and one brafter the test.18

Driving rain test548+n(194.oo)($$)As two CI Ms are requiredWater test

during the test19

Corrossion(a) 274+n (161.00)Test(Salt)

(b) 274+n( v x 20)(&&) When shared with otherprojects where v is the volume of thesamples under test (divisor B)

(e) 274+n(79.00)

(# #) This formula is used forcomponents and sub assemblies.20

Altitude test (low274+n(358.00)Alt Pressure) Temp combined21

Solar Radiation274+n (317.00)test 22.

Sealing test548xnTwo CI Ms are required for the test23

DroplPush over274xntest 24

Water immersion274xn

testlDrip Proof test25Pre/post274xn

Environmental (Electrical test)

Note:

1. InCol10 'n' is the number of Hours for which facility is engaged. Full hour is chargedeven if partly used. The duration excludes setting up time/raisingtimellower time

2. For tests at sri No. 1,2,3,4,5 & 14, the jigs, if required exclusively, have to beprovided by the firm/Authority submitting samples for the test.

3. For tests at sri No. 7,8,9,10,11,17(b) & 19. the DustlSaltslAcidslAlkali andcontamination, if required exclusively have to be provided by the firm/Authoritysubmitting the samples for tests.

4. The 'V' in Sri Nos 8.16.19(b)&(c)is the volume of the specimen in cubic feet.Minimum of one eft is charged. The higher whole no. volume is charge. if the calculatedvalue obtained if it is in fractions

APPENDIX 'B'

PAYMENT TESTING CHARGES

1.2.3.4.

The staff Employedpayment of maximum of pay scaleDearness payAllowances a) DA@ 21%

b)HRA@ 15%c) CCAd)TATotal

Charge man Grade IRs. 9000.00Rs.4500.00Rs. 3240.00Rs. 2025.00Rs. 300.00Rs. 100.00Rs. 19165.00

5.6.7.8.9.

Average No of working hoursAverage No of working daysLabour charges per hourCharges @ 150% of LabourTotal charges per hour (7+8)

rounded off to

07 Hours25 daysRS.109.51Rs.164.27RS.273.78Rs.274.oo

10. The formula for each testltest facility is arrived at by adding Rs. 268/- to the sumof electrical & Labour charges including 150% of overhead charges for minimum 5minutes of each test period in Rupees.

11. The Labour charges calculated for observation period full hour of testing as thepresence of NGO in full time is required sri No at 1(a), 1(b), 2,5,6, 12( c), 13,17 (b) ofAppx 'A'.

12. The Labour charges calculated for observation period 30 minutes of testing asthe presence of NGO is required for 30 minutes at sri Nos at 3,4, 17(a), '18 & 21 of Appx'A'.

13. The Labour charges calculated for observation period 15 minutes of testing asthe presence of NGO is required for 15 minutes at sri Nos at 12(a), 12(b), 20 of Appx'A'.

14. The Labour charges calculated for observation period 10 Minutes of testing asthe presence of NGO is required for 10 Minutes at sri Nos at 7.,8,9,10, 11,12(d), 15, 16, 19 and 5 minutes for Sri No 14 of Appx 'A'.

15. The charges are calculated based on useful volume of test facility as per cubicfoot of volume utility. Minimum of 1 cubic foot is charged. The higher the whole Nos ofvolume is charged, if the specimen with fractional volume is tested, accept for smallcomponents were columeis less than O.5cft.