for a 20 circuit breaker eed 50 47(ekm) apr 15 ......section 2 2. reference documents.following...

STATEMENT OF TECHNICAL REQUIREMENTS

FOR

A 20 CIRCUIT BREAKER

EED 50 47(EKM)

Apr 15

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M A T E R I A L B R A N C HDIRECTORATE OF ELECTRICAL ENGINEERINGI N T E G R A T E D H E A D Q U A R T E R S

M O D ( N A V Y ) ‘D’ WING, SENA BHAWAN

N E W D E L H I 1 1 0 0 1 1

II. REVISION NOTENo revision incorporated.

III. HISTORICAL RECORDThis standard supersedes the following: NIL.

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INDEX

Sl No Description Page No

A 20 CIRCUIT BREAKERS

1. Introduction (Section1) 5

2. Reference Documents (Section2) 6

3. General (Section3) 7

4. Technical Parameters (Secion4) 89

5. Table 4.4 (Electrical Data for Breaker) 10

6. Circuit Breaker & Selection (Section5) 1112

7. Design of Air Circuit Breaker (Section6) 1315

8. Construction (Section7) 16

9. Inspection & Testing (Section8) 1720

10. Drawings & Documentation (Section9) 21

11. Spares (Section10) 2223

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SECTION 1

1. Introduction

1.1 This specification covers the A 20 Circuit Breaker (CB) which act as a feeder breaker to Main Switch Boards (MSBs) from 1 to 4. The circuit breakers are air circuit breakers and designated as CB 1 in First compartment, CB 2 and 3 in Motor Room and CB 4 in Third compartment. MSBs 2 and 3 are designated as Primary Switch Boards and MSBs 1 and 4 acts as the Reserve Switch Boards. EKM submarines are fitted with four circuit breakers type A20. The document specifies the design, performance, tests and test procedures, requirement of document, supply of onboard and Base and Depot spares. The design is to cater for the satisfactory operation in the most adverse environmental and electrical conditions. The CB shall conform to specifications NES 530 and BS 4752.

1.2 Consideration to departure from the specification will be given when difficulties are encountered during the construction of CBs but no departure may be made without prior approval DQA (N) / DGQA or DEE / IHQ MOD (N).

1.3 Statement of requirement is to be deemed to take precedence over this specification and any other documents quoted therein.

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SECTION 2

2. REFERENCE DOCUMENTS. Following documents are referred while formulating the EED :

(a) NES 530

(b) NES 511

(c) NES 534

(d) NES 532

(e) BR 2031

(f) JSS 55555 Ver 2012 and 50101

(g) NES 609

(h) IEC 363

(J) IS: 139472 / IEC 9472

(k) BS 4752

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SECTION 3

3. General

3.1 Circuit Breakers used in the Indian Navy are normally type approved and their manufacturers are registered with DQA (N), which have been adapted to meet service requirements. The CBs shall be manufactured in accordance with the specifications and in strict conformity to the approved drawings by Naval Headquarters. Approval of IHQ MOD (N) / DEE shall be obtained in case of any deviations whatsoever.

3.2. Any approved alteration or addition of a minor nature found necessary during the construction of the CBs, are to be carried out by the manufacturer without extra charges. The manufacturer is to keep in mind continuously the fact that, economy of weight and space is of utmost importance.

3.3. Wherever items are described in specification and are not indicated in the drawings or are indicated in drawings but not described in specifications; such items are deemed to be the requirement of both specifications and drawings.

3.4. The manufacturer shall ensure attaining specified quality, workmanship, endurance and electrical characteristics of the CBs.

3.5. All components, fittings, fixtures etc. shall be of standard make (DQAN approved) and their installation work shall be in accordance with the standard marine practice and shall satisfy IHQ MOD (N) / inspecting Agency.

3.6. All parts, subassemblies and components shall comply with the requirement of drawings and specification to the satisfaction of the IHQ MOD (N) / Inspecting Agency. 3.7. No materials, parts, components or complete units which have been rejected shall be retreated or adjusted without the approval of the IHQ MOD (N) / Inspecting Agency.

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SECTION 4

4. Technical Parameter

4.1. Circuit Breakers (CB) are to be electrically operated; microprocessor based with facility for emergency hand operation and should be suitable for electrical supply characteristics onboard. Wiring in the circuit breakers should be LFH type. All CBs are of withdrawal type on front side. Facility should be provided to disengage it from fixed busbar connection with locking arrangement in service, isolated and maintenance position. The following protections are to be incorporated in the CBs:

(a) Overload protection.

(b) Short Circuit protection.

(c) Earth fault protection.

(d) Over voltage protection.

(e) Under voltage protection.

(f) Current unbalance protection.

(g) Reverse power protection.

(h) Voltage unbalance protection.

4.2. All Circuits Breakers are to meet the requirements as per BS 4752. Where a Circuit Breaker falls below this standard, approval of the IHQ MOD (N) / DEE must be obtained before it is accepted for use. The succeeding clauses define the minimum standards which are considered acceptable for such Circuit Breakers in addition to following special service conditions :

(a) Ship motion.

(i) Roll : +/ 300

(ii) Pitch: +/ 100

(iii) Trim : 50

(b) Mechanical shock. : NSS Grade I (for equipment fitted

below waterline)

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120G, 8ms (vertical) & 70G, 8ms (lateral)

(c) Vibration. : 533 Hz +/0.125mm constant displacement

(d) Minimum ruggedness. : Mil Grade

(e) Temperature range. : 50 to 550 C

(f) Humidity : 100%

(g) Number of Poles : 4

(h) Rated Voltage : 175 to 320 V DC

(j) Endurance (number of operation cycle)

(i) Mechanical : 20000

(ii) Electrical : 20000 (p) Impulse with stand voltage : 8 KV

(q) EMI / EMC : Mil Std – 461E/F {OEM would be required to formulate an EMI/EMC Acceptance Plan (EMI AP) post placement of order for approval of IHQ MoD (N)/ NEC (MB). The EMI/EMC testing would be done as per test plan vetted and stamped by NEC (MB)}.

(r) Fire characteristics of materials : LFH type

4.3 Electrical Data for the breaker :

SI Parameters Rated Limit

Board Rated Parameters

(a) Voltage 175320 V

(b) Main circuit current 1500 A

(c) Voltage in control and signaling circuit 127 V 50 Hz 1Ф

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4.4 Electrical Data for the breaker:

Input Voltage (V) DC

Nominal Current (A)IN

Current Settings for tripping coil (A)IT

Current Setting for Short Circuit Current ISC

(times IN)

Time of operation of short circuit triptSC (Sec)

Settings for overload trip IOL(times IN)

Time of operation of overload trip tOL (Sec)

Time for operation of tripping coil tTRIPCOIL (Sec)

Electrodynamic Reserve Maximum Current that is allowed through contacts without damage IMAX(KA)

Maximum Current that is allowed through contacts during dropping of breaker without damage IMAXDROP(KA)

Maximum Current that is allowed through contacts during making of breaker without damage IMAXMAKE(KA)

Thermal ReserveITH2 tTH(KA2Sec)

Thermal Equivalent impulse of short circuit current over time

175 320 1500 A

125015002000

2 8

0.180.380.631.0

1.55 2 4 12 0.04 110 45 70 3000

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SECTION 5

5. Circuit Breakers Selection

5.1 Circuit Breaker is to be selected to suit the particular supply system requirement in terms of rated voltage, current and fault handling capacity in accordance with the methods described in NES 532 and IEC 363.

5.2. Temperature Rise.

5.2.1. The ambient air temperature surrounding the Circuit Breaker will be determined by the heat dissipated within the board and the air flow through it, which is again determined by the design. The maximum temperature rise for component parts of Circuit Breakers is to be as shown in BS 4752 subject to be specified temperature rise being reduced by Tc 40 degree C where Tc is the maximum temperature of the air surrounding the Circuit Breaker when fitted in the board and operating under the most adverse conditions of service.

5.2.2. The maximum temperature limit for any assembly or component fitted in a Circuit Breaker which is not covered specifically by BS 4752 (eg. an electronic/ processor protection unit) is not to be exceeded.

5.3. Material.

5.3.1 Materials used in the construction of CBs are to be selected in the first instance from the range shown in NES 507. Where the required material is not covered by NES 507, approval of the DEE must be obtained before it is used.

5.3.2 High conductivity electrolytic grade copper bus bars are to be provided in accordance with BS 1433. Bus bars are to be rated in accordance with BS 159.

5.3.3. Materials that could pose a health hazard are not to be used, eg asbestos cadmium and all forms and compounds of these materials.

5.3.4 Plastic and similar combustible materials used for mouldings and insulation are not to be used unless they have been tested for fire characteristics and approved for use by the IHQ MOD (N) / DEE. Where there is doubt the details of the material proposed are to be forwarded to the DEE for approval. The material should meet the following main fire retardant characteristics:

(a) Oxygen Index : greater than 30.

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(b) Toxicity Index : less than 5.

(c) Smoke Index : less than 50.

(d) Fire Propagation Index: less than 12.

5.4 Painting and Finishing :

5.4.1 Painting and finishing to the manufacturer’s usual commercial standards will normally be acceptable subject to the limitations on hazardous materials stated in Clauses 5.3.4 above.

5.5. Wiring. Internal wiring of Air Circuit Breaker are to be of the LFH type cables selected from the range shown in DEF STAN 6112 Part 18.

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SECTION 6

6. Electrical and Mechanical Design of Air Circuit Breakers

6.1. Electrical Design of Air Circuit Breakers

6.1.1 Auxiliary switches, which mimic the operation of the main contacts, are to be provided on the CB or cassette as required. Where these are cassette mounted, a mechanical linkage is to be fitted to enable them to be operated when the CB is in the “isolated” position. Auxiliary switches are to be readily accessible for maintenance or replacement.

6.1.2. If over current protection is fitted to the CB, it is to comprise a compact electronic unit.

6.1.3. Over current protection fitted on the CB must be designed for maximum reliability and provide the necessary monitoring arrangements to ensure integrity of control lines. CB’s protecting incoming supplies when used with offbreaker protection systems are to incorporate a direct acting backup device to provide protection against short circuit in case of failure of normal control.

6.1.4. Connections to the CB for electrical control and auxiliaries are normally to be by flying leads and approved sealed multipin connectors.

6.1.5. The A20 circuit breaker is to be operated as follows:

(a) Automatic switching on/off breaker from remote location.

(b) Automatic switching on/off breaker locally from battery post.

(c) Manually switching on/off breaker locally from battery post.

6.1.6. Provision is to be made for the fitting of a shunt trip and/or under voltage release with time delay. Alternatively such devices may be incorporated in an integrated protection system on or off the CB as stated in the SOTR.

6.1.7. All structural metal work in the CB is to be electrically continuous and is to be bonded to the cassette framework via substantial earth strap. This strap must provide continuity with the cassette when the CB is in either the “service” or “isolated” undertaken with the CB fitted in the switchboard in the “maintenance” position.

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6.1.8. Contacts are to be of silver, silverfaced or approved equivalent and be capable of making and breaking rated current without undue arcing, burning or any tendency to weld. The main and arcing contact shall be of ample size and of such form and disposition so as to ensure:

(a) A wiping or self cleaning action on closing.

(b) Efficient contact when closed for long periods of time under conditions of considerable temperature changes which may occur in service.

(c) Satisfactory current breaking (45 KA) by limiting the fault current at the time of breaking so that material damage to the main contacts is prevented.

(d) Should have a reasonably high MTBF.

6.1.9. Means are to be provided for adjusting the pressure of CB main contacts to the correct value should changes occur during service. The main contact must be easily accessible for cleaning and the arcing contact must be readily accessible and easily renewable when in the ‘’Maintenance’’ position.

6.1.10. Insulation. F Class or of high grading to be used.

6.2. Mechanical Design of Air Circuit Breakers:

6.2.1. CB’s are to be of the withdrawable type designed as a self contained unit, eg. including a housing or cassette. Means are to be provided to disengage it from the fixed (busbar) connections and to lock it in the following positions within the cassette:

(a) “Service” connected to busbars and fully operational.

(b) “Isolated” disconnected from busbars but operational.

(c) “Maintenance” fully disconnected and withdrawn.

Position locks are to engage automatically as the CB is moved in either direction, and be unlocked manually.

6.2.2 The CB should be of robust construction and capable of being handled by Ship’s Staff using the appropriate handling gear under the most adverse conditions of ship motion.

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6.2.3. The mechanical interlock is to be provided to ensure that the main contracts are in the open condition before the CB connects to or disconnects from the fixed (busbar) connections.

6.2.4. In the “maintenance” position the CB is to be adequately supported to allow inspection and limited maintenance work to be undertaken. There is no requirement for the CB or its supports to withstand the specified levels of mechanical shock in this position.

6.2.5. The CB is to be fitted with clearly defined lifting points designed for attachment of a frame or strap. Any such strap when in use is not to cause damage to component parts of the CB.

6.2.6. In addition to the mechanical endurance requirements specified in BS 4752 the CB is to be capable of 20,000 closeopen operations without damage or catastrophic failure. This requirement assumes that the CB is not passing current and that periodic routine maintenance and adjustment is permitted.

6.2.7. The CB is to be fitted with a counter to record the number of close open operations. The counter is to be 5digit selfresetting to zero after 99999.

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SECTION 7

7. Construction

7.1. Enclosure. The cabinet is to be totally enclosed, drip proof construction conforming to IP56 protection comprising of MS angle frame work enclosed by means of bolted sheet metal plates. The doors are to be provided with fasteners and door stoppers. Handrails with insulating sleeve are to be provided on the front of the switchboard. All bolts, nuts, washers, etc used in the CB are to be cadmium plated to inhibit corrosion.

7.2. Shock Standard. The CBs shall withstand shock standard NSS1 (INHERENT) in conjunction with BR3021.

7.3. Vibration Standard. 533 HZ. (Conforming to specification JSS 55555 Ver 2012).

7.4. Limiting Dimensions. The estimated overall dimensions of the CBs are not to exceed the dimensions specified below:

Description Location Length (mm)

Width (mm)

Height (mm)

CB 1 FIRST COMPARTMENT 753 580 880

CB 2 MOTOR ROOM 759 580 910

CB 3 MOTOR ROOM 760 575 915

CB 4 THIRD COMPARTMENT 754 575 910

7.5. Due to small opening of the submarine hatch, circuit breaker panel is required to be dismantled and individual components are to be reassembled to form the circuit breaker at the required location. Based on the location of the circuit breaker, the assembly would be undertaken to cater for a form fit.

7.6. Creepage and Clearance Distances. Electrical creepage and clearance distances between live parts and earthed metal work are to be in accordance with NES609.

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SECTION 8

8. Inspection and Testing:

8.1 Quality Assurance.

(a) The supplier is required to submit draft Quality Assurance Plan (QAP) & Drawings to the field unit of DQAN & ATP to IHQMoD (N) for approval within 01 months of placement of order. The approving authority reserves the right to amend/ modify the QAP/ ATP. The approved QAP will form basis for inspection/quality check/ acceptance of items/ equipment’s. The equipment supplied by the vendor would be accepted subject to evaluation and clearance by team comprising of reps from the DGQA and IHQ MoD (N)

(b) The list of all bought out/ imported items which are sourced from OEM/ subcontractors and delivered in "asitis" condition would be approved by IHQ MoD (N). The items would be accepted based on functional checks (as per ATP/ FATs document approved by IHQ MoD(N), scrutiny of CoCs endorsing the standards to which the items comply, physical values of test conditions the items have been subjected to and the values obtained thereof (for ET, EMI/EMC & ESS) and conduct of Burnin testing.

(c) Burn in test would be conducted in accordance with guidelines issued vide 66301/Policy10/DQA(N)/QA10 dated 14 June 13.

(d) The items should be of the latest manufacture conforming to current production standard.

8.2 Inspection.

(a) Inspection Authority. Directorate of Quality Assurance (Naval) or IHQ MoD (N) nominated.

(b) Inspection Officer/ Agency. Concerned field unit of DQA(N) or IHQ MoD(N) nominated.

8.3. Trials and Tests

8.3.1 Type Testing: The CBs should be type approved or to be submitted for type testing after placement of order if not tested earlier.

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8.3.2. Type Test. Following type tests are to be carried out as specified in NES 511:

(a) Withstand voltage test.

(b) Insulation Resistance test.

(c) Short circuit test.

(d) Temperature rise test.

(e) Thorough fault test.

(f) Operation of protective devices.

(g) Mili volt drop test.

(h) Functional test to prove the correct operation of safety devices.

(j) Tripping characteristic with rise in temp (IS: 139472/IEC 9472).

(k) Electrical Endurance (IS: 139472/IEC 9472).

(l) High Voltage Test. (As per NES511)

8.3.3. Environmental Tests. A list of limited environmental tests (which do not drive the equipment to yellow banding) required to be conducted on CBs are as per table given below:

Ser Test Test Condition / Severity(a) Vibration Test JSS 55555 Ver 2012, Test No.28

Frequency 533Hz, +/0.125mm constant displacement

(b) High Temp JSS 55555 Ver 2012, Test No.17, procedure 6, Test Condition 'K'+55degC (Operational) for 24hrs+70degC (Storage) for 24hrs

(c) Damp Heat JSS 55555 Ver 2012, Test No.10 Operating Temp 40degC, RH95 for 16hours

(d) Low Temp JSS 55555 Ver 2012,Test No.20,procedure 4,Test condition 'H'10degC (operational) for 24hours20degC (storage) for 24hrs

(e) Drip Proof JSS 55555 Ver 2012,Test No.11Vertical water drip 1mtr height for 15min

(f) Tropical JSS55555 Ver 2012,Test No.27 Temp.

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exposure variation from 20degC to 35degC, RH95 Test Condition A, 7Cycles, Dwell time 12hrs

(g) Mould Growth(Representativesamples)

JSS 55555 Ver 2012, Test No.21 29degC, RH90, 28days

(h) Corrosion salt(Representativesample)

JSS 55555 Ver 2012,Test No.9, Procedure 2

(j) Shock test JSS 55555 Ver 2012,Test No.24 NSS Grade I (for equipment fitted below waterline) 120G, 8ms (vertical) and 70G, 8ms (lateral)

(k) Inclination/Tilt CL 0563 Sec19

(l) Ship Motion Roll +/30 deg, Pitch+/10 deg and Trim 5 deg

(m) Ingress Protection

IS/IEC 60529:2001

8.3.4. FATs and HATs. The supplier is to offer the system for FATs and HATs as per schedule provided by the OEM and approved by IHQ, MoD (N).

8.3.5. Factory Acceptance Trials (FATs). The supplier shall prepare a Factory Acceptance Trials (FATs) schedule. Personnel from Indian Navy will be present for such trials. The schedule should state how the supplier would demonstrate that the delivered system will meet the functional and performance requirements indicated as per RFP. The factory acceptance trials procedure shall comprise of :

(a) Functional Tests of complete system

(b) Verification of design, especially firmware and software

(c) Test equipment used, calibration requirements

(d) Pass/Fail criteria

(e) Expected duration and time schedule

8.3.6. The FATs schedule after being formulated by the supplier should be forwarded to IHQ, MoD (N) for vetting and approval at least 02 months prior to the trials.All EMI/EMC and Environmental Qualification tests need to be completed prior to FATs.

8.3.7. Harbour Acceptance Trials (HATs) The supplier is required to provide necessary representative(s) to assist during the HATs (procedure to be approved by IHQ MoD(N) ) and system will be accepted by IN team.

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8.3.8 EMI / EMC. Compliance to Environment and EMI/EMC test specifications would involve conduct of physical tests or scrutiny of test reports.

8.4 Description of Tests.

8.4.1. Insulation Resistance Test. All CBs are to be tested for insulation resistance and minimum insulation resistance shall not be less than 2 Mega Ohms. The test voltage is to be 500 volts. The test for measuring, insulation resistance is to be carried out after withstand voltage test.

8.4.2. Short Circuit Test. All the circuit breakers are to be tested for time of operation by actually passing short circuit current. Where practical, the test shall be made on the complete assembled equipment and not on the individual parts, unless special instructions are given by the naval authority.

8.4.3. Functional Test. Function, control and performance of all control circuits indicating lamps, alarms etc are to be demonstrated.

8.4.4. Protection Relays . Performance of all protective relays is to be demonstrated throughout their range of setting and recorded.

8.4.5 Endurance Test. The Electrical Endurance test are to be conducted in accordance with IS: 139472/IEC 9472. In addition to the mechanical endurance requirements specified in BS 4752, breaker is to be capable of 20,000 closeopen operations without damage or catastrophic failure. This requirement assumes that the CB is not passing current and that periodic routine maintenance and adjustment is permitted.

8.4.6 Burn in Test. Burn in Test is to be conducted on the breaker by continuous operation for a period of 168 hrs at room temperature or 48 hrs at +55 deg elevated temperature prior to shipment. Burn in test is to undertaken on 10 % of the breakers being supplied. If one batch of supplies undergo burn in test successfully, the additional batches / supplies under repeat order are to be exempt from Burn in Testing.

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SECTION 9

9. DRAWINGS AND DOCUMENTATION 9.1 Documents, as per JSS 025101, are to be submitted to IHQ MOD (N)/DEE. Manufacturing drawing and other document are to include the following:

(a) Drawing and Document list.

(b) General Arrangement and associated illustrated parts catalogue.

(c) Wiring Diagram.

(d) Busbar arrangement.

(e) Schedule of services.

(f) Technical Description including circuit diagram, block diagram, component layout drawing.

(g) Detailed drawing of all component including part list parts.

(h) Production Test Specification.

(j) Type Test Reports.

(k) Cable Gland Diagram.

(l) List of Recommended Spares.

(m) Instruction and Maintenance Manuals for Proprietary Equipment.

(n) Drawing of special Jigs, Tools and Fixtures required for manufacture of modular parts.

(p) Drawing comprising three clear prints of the out line of the equipment showing overall dimension, fixing arrangement and estimated weight.

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SECTION 10

10. SPARES.

10.1 Spares. The onboard spares, base and depot spares and test equipment is to be recommended by the supplier. Such recommendations are to be commensurate with the reliability of critical components and component use in the system. Special tools and test equipment is to be supplied for onboard maintenance.

10.2. Onboard spares. An itemised list of OBS, special tool and special test equipment, which will be supplied with the main equipment, is to be furnished along with the quotation for the main equipment. The OBS are to cater for all of the ships’ staff onboard maintenance routines and possible repair requirements. The OBS should include the following:

(a) All spares required for exploitation up to 2 years.

(b) One set of generalpurpose maintenance tools.

(c) One set of special tools required for disassembling / assembling of components to effect repair by replacement.

10.3. Base & Depot spares/Comprehensive Part Lists. Base spares recommendation is to cover maintenance / overhaul requirements for 5 years including two refits. Recommendations for insurance holding of long lead items are also to be indicated. Itemised cost of B & D spares are to be forwarded with the main offer.

11. Installation . The supplier shall supply one set of installation and commissioning spares. The manufacturer is required to provide the necessary representative(s) to assist in carrying out inspection and supervise the work that is done on the equipment, during the following phases:

(a) Onboard erection and connections.

(b) Setting to Work.

(c) Harbour and sea trials.

(d) Final machinery trials.

(e) Inspections on completion of CSTs (if applicable)

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12. Warranty. The equipment with associated controls/instrumentation is to be guaranteed for stipulated performance for 24 months after commissioning. The equipment supplied shall be warranted from defects, manufacturer and performance for the said period and cover all the defects arising from malfunction through design faults, inappropriate material, bad production and nonconformance to specifications. Any expense on account of repair/supply of spares against guarantee defects is to be borne by the supplier.

13. Product Support. The supplier should confirm product support for next 20 years for the equipment offered by them.

Interface Definition

14.1. The manufacturer shall provide all information required for integration of the equipment onboard the ship. The equipment shall be designed and constructed so that it can be fully integrated with the subsystem to which it interfaces. All components shall be compatible in order that the functional performance of the equipment is not degraded as a result of its integration within the system as a whole.

14.2. In case of discrepancy, failure, deficiency, the Consultant/Shipyard will be entitled to investigate and the supplier is bound to rectify, as necessary, if reported by the investigation to be a nonconformity to the contract specification.

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