Book II Section J_Quality Management

Client: SEWA Sharjah Electricity & Water Authority ILF CONSULTING ENGINEERS

Tender No. SEWA/HPS/60615 Project: Hamriyah Phase III Power Block Expansion Project

Book II- Sec J of 69 03-Aug-2015

BOOK II

UNITED ARAB EMIRATES

SHARJAH ELECTRICITY AND WATER AUTHORITY

HAMRIYAH PHASE III EXPANSION PROJECT: TWO ADD-ON (FOR EXISTING 4

FRAME 9E GTs) + 1CC POWER BLOCK (2 NEW GTs AND 1 ST)

HAMRIYAH POWER STATION

SHARJAH EMIRATE

SECTION J

QUALITY MANAGEMENT




LIST OF CONTENT

1 General ............................................................................................................................................... 5 1.1 Purpose .............................................................................................................................................................. 5 1.2 Scope ................................................................................................................................................................. 5 1.3 Definitions ........................................................................................................................................................... 5 1.4 Contractor’s Quality Management ...................................................................................................................... 5 1.4.1 Quality systems .................................................................................................................................................. 5 1.4.2 Quality planning .................................................................................................................................................. 6 1.4.3 Quality documentation ........................................................................................................................................ 6 1.5 Engineer’s Quality Control .................................................................................................................................. 7 1.5.1 Evaluation of quality systems ............................................................................................................................. 7 1.5.2 Assessment of effectiveness of quality control ................................................................................................... 7 1.5.3 Surveillance ........................................................................................................................................................ 7 1.5.4 Inspection ........................................................................................................................................................... 7 1.6 Procedural Requirements ................................................................................................................................... 8 1.6.1 Quality control plans ........................................................................................................................................... 8 1.6.2 Notification of readiness for inspection/test ........................................................................................................ 8 1.6.3 Right of access ................................................................................................................................................... 9 1.6.4 Contract waivers ................................................................................................................................................. 9 1.6.5 Quality control records ........................................................................................................................................ 9 1.6.6 Quality control certificates ................................................................................................................................... 9 1.6.7 Cost of additional visits ....................................................................................................................................... 9

2 WORK TESTS .................................................................................................................................... 9 2.1 General Test Requirements ................................................................................................................................ 9

3 Manufacturers’ Inspection and Testing Programme ................................................................... 10 3.1 Materials and Material Tests ............................................................................................................................. 10 3.1.1 General requirements ....................................................................................................................................... 10 3.1.2 Specific requirements ....................................................................................................................................... 11 3.2 Welding ............................................................................................................................................................. 11 3.2.1 Welding Procedure Tests ................................................................................................................................. 11 3.2.2 Welders Performance Qualifications ................................................................................................................. 11 3.2.3 Welding Procedure Approval ............................................................................................................................ 11 3.3 Mechanical Plant Tests ..................................................................................................................................... 12 3.3.1 Gas/steam turbine tests .................................................................................................................................... 12 3.3.2 Lubrication and control oil systems ................................................................................................................... 13 3.4 Electrical Plant Tests ........................................................................................................................................ 14 3.4.1 Generators & exciters ....................................................................................................................................... 14 3.4.2 Rotating parts ................................................................................................................................................... 16 3.4.3 Excitation, regulator equipment ........................................................................................................................ 18 3.4.4 Generator/exciter auxiliaries ............................................................................................................................. 18 3.4.5 Generator main connections ............................................................................................................................. 19 3.4.6 HV and LV switchgear (including switchgear at generator voltage) switchboards ............................................ 19 3.4.7 Components i.e. Isolators, earthing devices, etc .............................................................................................. 20 3.4.8 Motors ............................................................................................................................................................... 20 3.4.9 Insulating oil and gas ........................................................................................................................................ 22 3.4.10 Surge arresters ................................................................................................................................................. 22 3.4.11 Batteries, chargers and inverters & VFDS ........................................................................................................ 22 3.4.12 Chargers ........................................................................................................................................................... 23




3.4.13 VFD units .......................................................................................................................................................... 23 3.4.14 Transformers tanks ........................................................................................................................................... 23 3.4.15 Neutral earthing resistors and associated equipment ....................................................................................... 28 3.4.16 Miscellaneous electrical equipment .................................................................................................................. 29 3.5 Control and Instrumentation ............................................................................................................................. 30 3.5.1 Works components tests .................................................................................................................................. 30 3.5.2 Works system tests ........................................................................................................................................... 30

4 SITE INSPECTION, TESTING AND COMMISSIONING TESTS ..................................................... 30 4.1 General ............................................................................................................................................................. 30 4.1.1 Arrangements for testing .................................................................................................................................. 30 4.1.2 Supplementary tests ......................................................................................................................................... 31 4.2 General Test Requirements .............................................................................................................................. 31 4.2.1 Procedure ......................................................................................................................................................... 31 4.2.2 Standards and methods .................................................................................................................................... 32 4.2.3 Tests and commissioning inspections .............................................................................................................. 32 4.3 Mechanical Plant .............................................................................................................................................. 32 4.3.1 Alignment checks.............................................................................................................................................. 32 4.3.2 Calibration of instrumentation ........................................................................................................................... 32 4.3.3 Setting of regulating and control devices .......................................................................................................... 32 4.3.4 Auxiliary systems .............................................................................................................................................. 33 4.3.5 Orifices ............................................................................................................................................................. 33 4.3.6 Auxiliary pumping systems ............................................................................................................................... 33 4.3.7 Welding and welding tests ................................................................................................................................ 33 4.3.8 Hydraulic and vacuum tests .............................................................................................................................. 33 4.3.9 Pumps .............................................................................................................................................................. 33 4.4 Electrical Plant .................................................................................................................................................. 33 4.4.1 General requirements ....................................................................................................................................... 33 4.4.2 Main generator, exciter ..................................................................................................................................... 34 4.4.3 Generator main connections ............................................................................................................................. 34 4.4.4 Motors ............................................................................................................................................................... 34 4.4.5 Switchgear, control panels, earthing resistors .................................................................................................. 34 4.4.6 Transformers .................................................................................................................................................... 35 4.4.7 Batteries and battery charging equipment ........................................................................................................ 36 4.4.8 Inverters & VFDs .............................................................................................................................................. 36 4.4.9 Instruments and instrument transformers ......................................................................................................... 37 4.4.10 Synchronising equipment ................................................................................................................................. 37 4.4.11 High voltage surge arresters ............................................................................................................................. 37 4.4.12 Interlocking ....................................................................................................................................................... 37 4.4.13 Cables and earthing .......................................................................................................................................... 37 4.4.14 Electrical protection equipment ......................................................................................................................... 38 4.4.15 Protection, control, alarms, measurement and indication equipment................................................................ 38 4.5 Site Tests - Control and Instrumentation .......................................................................................................... 40 4.5.1 Item tests .......................................................................................................................................................... 40 4.5.2 Loop tests ......................................................................................................................................................... 40 4.5.3 System tests - control and instrumentation ....................................................................................................... 40

5 TESTS ON COMPLETION ............................................................................................................... 40 5.1 Gas/Steam Turbine Plant ................................................................................................................................. 40 5.1.1 Cooling water systems ...................................................................................................................................... 40 5.1.2 Lubricating oil systems ..................................................................................................................................... 41 5.1.3 Control tests ..................................................................................................................................................... 41 5.1.4 Fire protection test ............................................................................................................................................ 41 5.1.5 Load rejection test ............................................................................................................................................ 41




5.1.6 The contractor shall demonstrate safe shut down of the unit from full load with A.C. power supply not available........................................................................................................................................................................... 41

6 GUARANTEE TESTS ....................................................................................................................... 41 6.1 Test Procedures ............................................................................................................................................... 41 6.1.1 Method of execution ......................................................................................................................................... 41 6.1.2 Instruments ....................................................................................................................................................... 42 6.1.3 Analysis of data ................................................................................................................................................ 42 6.1.4 Test Reports .................................................................................................................................................... 43 6.2 Gas/Steam Turbine Tests ................................................................................................................................. 43 6.2.1 General ............................................................................................................................................................. 43 6.2.2 Guarantee tests ................................................................................................................................................ 44 6.2.3 Rated conditions ............................................................................................................................................... 44 6.2.4 Plant operation ................................................................................................................................................. 44 6.2.5 Spare control cards ........................................................................................................................................... 44 6.3 Plant Reliability Tests ....................................................................................................................................... 44 6.4 Combined Cycle Electrical Output .................................................................................................................... 45 6.4.1 The test ............................................................................................................................................................. 45 6.4.2 Rated conditions ............................................................................................................................................... 45 6.4.3 Procedure ......................................................................................................................................................... 45

7 Appendix - Workshop Inspection &Testing ................................................................................. 47 7.1 Common – All Packages .................................................................................................................................. 47 7.2 Gas Turbine ...................................................................................................................................................... 50 7.3 HRSG ............................................................................................................................................................... 52 7.4 Steam Turbine .................................................................................................................................................. 56 7.5 Steam Systems................................................................................................................................................. 59 7.6 Condensate & Feed water System ................................................................................................................... 59 7.7 Fuel Oil System ................................................................................................................................................ 61 7.8 Closed Cooling Water System .......................................................................................................................... 62 7.9 Instrument and Service Air ............................................................................................................................... 63 7.10 Fire Fighting System ......................................................................................................................................... 65 7.11 De-mineralized Water Plant and System .......................................................................................................... 66 7.12 Cranes and Hoists ............................................................................................................................................ 67 7.13 Air Conditioning and Ventilation ........................................................................................................................ 69




1 GENERAL

1.1 Purpose

This section of the Specification outlines the general and detailed requirements for a Quality Control Programme,

which shall be implemented by the Contractor, to ensure that the quality of all the Works is controlled in full

compliance with the Contract.

In addition, this section identifies the role of ENGINEER / SEWA in the overall Quality Control Programme for

this Contract.

1.2 Scope

These requirements shall apply during design, procurement, manufacturing, inspection, testing, packaging,

shipping, storage, site erection and commissioning stages.

The Contractor shall have sole responsibility for ensuring compliance with the overall quality requirements of the

Works, and shall ensure that sub-contractor’s implement those quality control activities that are appropriate to

the extent and nature of their supply.

The general requirements of this section apply to all plant and equipment included in the scope of work whether

or not specific items are included in the detailed requirements.

In certain cases specific requirement are included for plant and equipment not included in the scope of supply

and in such cases these requirements are not applicable.

The principle to be adopted where specific references are made to items of plant and equipment is “where

included in the scope of work”.

1.3 Definitions

(a) In this section of the Specification, the word ‘Contractor’ shall be deemed to include those subcontractors

and Manufacturers who, under the control of the Contractor, have direct responsibilities for implementing

specified controls, inspections and tests on any part of the contract works.

(b) The Quality Control Programme shall mean all those activities, procedures and documents which are

established and implemented by ENGINEER / SEWA and the Contractor, to control and verify the quality of

materials, products and processes relevant to the Works, from design through manufacturing and testing

until final acceptance by ENGINEER / SEWA. The part of the Quality Programme applicable to each item

shall include all those controls, inspections and tests that are normal elements of the Contractor’s QA or

QC system, together with any additional or revised controls necessary to ensure compliance with the

Contract.

1.4 Contractor’s Quality Management

1.4.1 Quality systems

In carrying out the Works, the Contractor shall adopt and implement the Quality Management principles specified

in the ISO Standard 9001-1987: “Quality Systems Model for Quality Assurance in Design/Development,

Production, Installation and Servicing”.




Wherever the Contractor’s established organisation and procedures for controlling quality do not comply with the

requirements of the Standard, appropriate modifications and changes shall be made and implemented on a

priority basis, in order that full compliance is achieved throughout the Contract duration.

1.4.2 Quality planning

Immediately after award of Contract the Contractor shall completely review the Contract and take all necessary

action to establish quality control procedures in accordance with the requirements of these Conditions of

Contract.

Particular care shall be taken to identify any specified requirements that are different from or additional to, the

Contractor’s normal design or quality control practice, and to initiate the necessary measures to ensure that such

additional requirements are implemented satisfactorily.

The Contractor shall prepare a quality control plan for each main item of equipment, and shall require sub-

contractors to prepare detailed quality control plans for all sub-contracted items of equipment. Quality control

plans shall identify all inspections and tests, which are to be carried out, including those necessary to verify

compliance with the Specification. (Sub-Sections or Works Tests, Site Tests and Commissioning Tests)

1.4.3 Quality documentation

In addition to any document submittals required by other parts of the Contract, the Contractor shall forward the

following Quality Control documentation to ENGINEER / SEWA.

(a) Initial Documentation Required after Award of Contract

Documents shall be supplied to indicate the following:

i. Identification of main items to be supplied, with names of supplier and manufacturer (if different from supplier) and location of place of manufacture.

ii. Manufacturing programmes for each major item of equipment, showing main stages of design, procurement, manufacture, inspection and testing.

iii. Site erection and commissioning programme, showing all controls, inspections and tests.

(b) Documentation Required Prior to Start of Manufacture

i. Copies of purchase orders for all main items of equipment. ii. The Manufacturer’s Procedures for all special processes, such as non-destructive testing, welding, weld

repair, heat treatment, generator stator final inspection including for turbine, generator and generator rotor.

iii. The Manufacturer’s full quality control plan for each main item of equipment, showing every control, inspection and test that is to be carried out throughout manufacture.

iv. A quality control plan detailing actions which are to be taken by the Contractor to verify that all sub-contractors and Manufacturers are complying with all Contractual requirements.

(c) Documentation Required on Completion of Manufacture

On completion of manufacture of each item of equipment the Contractor shall submit to the ENGINEER / SEWA

3 (three) copies of reports which document verification that the item complies with all specified requirements,

including the following as applicable:

i. Material test reports.




ii. NDT reports.

iii. Dimensional inspection reports.

iv. Weld maps, weld repair records.

v. Hydrostatic and leak test reports.

vi. Final inspection reports.

vii. Electrical test reports, type, routine and sample tests.

viii. Performance test reports.

ix. Conformance certificates.

x. Generator Wedges test report.

Release of equipment will not be given until satisfactory documentation as indicated above has been received,

examined and approved.

1.5 Engineer’s Quality Control

ENGINEER / SEWA will verify that the Contractor is fully implementing all the Quality requirements of the

Contract by means of the activities listed below. ENGINEER / SEWA activities are designed to complement, not

to replace, the Contractors quality control and the extent of surveillance and inspection necessary will depend

upon the Contractors quality control performance, as determined by ENGINEER / SEWA evaluations and

assessments.

1.5.1 Evaluation of quality systems

The Contractor’s Quality Systems will be evaluated by the examination of Quality Manuals, control, inspection

and test Procedures, QC Plans and other such documentation. Evaluations will also be carried out at the

manufacturing plants of main sub-contractors or manufacturers of major parts of the Contract Works, before

manufacture commences.

1.5.2 Assessment of effectiveness of quality control

The effectiveness of the planned quality control will be assessed during early stages of manufacture, by

examining material and components together with manufacturer’s records of controls carried out, and by

witnessing the application of special processes to material and components.

1.5.3 Surveillance

Throughout manufacture, the continuing satisfactory implementation of all manufacturing and control procedures

will be verified by surveillance activities. Surveillance will include a visual inspection of the equipment, witnessing

of any special processes currently in progress, and examination of the manufacturer’s records of all controls,

inspections and tests carried out up to that point. The operation of associated QC Procedures will also be

checked.

1.5.4 Inspection




Inspection will be carried out on the equipment by ENGINEER / SEWA and may include visual examination and

witnessing of tests to verify conformance to the specified requirements. Final inspection will normally be

scheduled to allow examination of the product preservation, packing and preparation for shipment.

1.6 Procedural Requirements

1.6.1 Quality control plans

On receipt of the Quality documentation referenced in Clause 1.4.3(b) ENGINEER / SEWA will mark on the

Manufacturers Quality Control Plans the various inspections he wishes to make, the tests he requires to

Witness, and the stages at which he requires to carry out surveillance, and will issue these to the Contractor as a

formal record of the extent of ENGINEER / SEWA’s initial quality control activities.

The Contractor shall ensure that all manufacturers are aware of these requirements. If ENGINEER / SEWA

requires to modify the requirements during the execution of the Contract, the modifications will be formally

notified to the Contractor in writing.

1.6.2 Notification of readiness for inspection/test

The Contractor shall give to ENGINEER / SEWA at least thirty (30) day notice of the date of availability of the

Plant for the required quality control.

Before giving such notice the Contractor is required to have completed all his internal controls, including that

relative to the notification point and to have available documentation to that effect for ENGINEER / SEWA to

review.

Except where otherwise provided for in these Conditions, or agreed during the Contract, notification should not

be given until the appropriate drawings and procedures have been approved.

All notifications shall state: -

(a) The contract reference.

(b) The name and address of the place at which the control will be carried out.

(c) The reference to the control point given in the appropriate Quality Control Plan.

(d) The date on which the Plant will be ready for control.

(e) A description of the item of Plant to be subjected to control (including the Contract identification reference.

(f) Any applicable sub-order reference.

ENGINEER / SEWA will notify the Contractor of his intention to attend the place of control at least two days

before the due date of control.




1.6.3 Right of access

ENGINEER / SEWA requires free access to Contractor and manufacturer’s works to verify full compliance with

specified requirements. Access is also required to records of all the manufacturer’s controls, inspections and

tests carried out on each item of the Contract Works.

1.6.4 Contract waivers

Request for waive from contract quality requirements shall be made by the Contractor to ENGINEER / SEWA, as

soon as it is established that an item of equipment as designed, or in manufacture, cannot be made to comply

with a particular specified requirement. The subject item of equipment shall not be offered for final inspection

until such waiver requests have been approved by ENGINEER / SEWA.

1.6.5 Quality control records

At the end of each visit to a manufacturer to carry out quality control activity, Contractor Engineer’s

Representative will complete a Quality Control Record and hand one copy to a responsible representative of the

Manufacturer and ENGINEER / SEWA.

The Quality Control Record (QCR) will identify the item inspected, the stage of manufacture, and the nature of

the QC carried out, and will list all points which require remedial action by the manufacturer, before the subject

item can be released.

1.6.6 Quality control certificates

When each item of equipment is ready for despatch from the place of manufacture and ENGINEER / SEWA has

verified compliance with specified requirements up to that point, a Quality Control Certificate will be issued to the

Contractor.

The Quality Control Certificate (QCC) will identify the item to which it applies and will release that item from the

Engineer’s control only. The QCC does not constitute any form of acceptance of the item by ENGINEER /

SEWA.

1.6.7 Cost of additional visits

Where additional visits by ENGINEER / SEWA to the contractor’s or his sub-contractor’s premises are

necessary, for the purpose of inspection and/or witnessing of tests, due to the failure of the Contractor or his

subcontractor to comply with the requirements of the contact, the full cost of such visits shall be reimbursed to

ENGINEER / SEWA by the Contractor.

2 WORK TESTS

2.1 General Test Requirements

Works tests shall be carried out in order to determine whether the components and/or plant items comply with

the Specification and to provide the necessary functional data. Where appropriate, all tests shall be arranged to

represent the working conditions as closely as possible.

Unless an alternative place of testing is agreed or specified the test shall be carried out at the Manufacturer's

Works.




Not less than 30 (thirty) days’ notice of all tests shall be given to ENGINEER / SEWA, in order that he may be

present if he so desires. As many tests as possible shall be arranged together, in accordance with a programme

to be agreed with ENGINEER / SEWA. Two copies of the Contractor’s records of all tests shall be submitted to

Engineer / SEWA for approval immediately after the conclusion of each test. These records shall be clearly

marked so that the Contract equipment items or components to which they refer can be readily identified.

Certain type of tests will not be required in those cases where the Contractor can produce certified evidence to

the satisfaction of Engineer / SEWA that the required type tests have been performed successfully on identical

equipment or equipment which is for practical test purposes similar and produced in the factory where the

equipment offered is to be manufactured. Evidence to this effect shall be submitted at the time of tendering, or as

soon as practicable thereafter.

High voltage tests shall be conducted generally in accordance with IEC 60060.

Insulating oil or gas used in any equipment undergoing tests shall comply with the requirements of IEC 296 or

376 as appropriate.

Except where otherwise indicated all electrical tests shall be carried out at rated frequency and with the supply

voltage waveform approximately sinusoidal.

The Manufacturer’s test equipment shall be of satisfactory quality and condition and where necessary shall be

appropriately calibrated at the expense of the Contractor by any other body as may be agreed.

After the Contract has been awarded and the main features of the project design are known, then Manufacturers’

Inspection and Testing Programme will be established by the Contractor, in the form of detailed Quality Control

Plans for each item of plant and equipment.

The Contractors Quality Control Plans will be subjected to Engineer / SEWA approval.

ENGINEER / SEWA reserves the right to call for such additional tests as may be necessary to prove compliance

with the Specification. The cost of all such tests shall be borne by the Contractor.

3 MANUFACTURERS’ INSPECTION AND TESTING PROGRAMME

The Contractor shall carry out a Comprehensive Inspection and Testing Programme during manufacture of plant.

The Contractor shall allow in his Tender for the cost of carrying out the following stages of inspection and/or test.

These are not intended to form a comprehensive programme, as it is the Contractor’s responsibility to draw up

and carry out all necessary tests, and furnish evidence of certain “type tests” on certain items of equipment.

The Programme should therefore include, but not be restricted to, the following:-

3.1 Materials and Material Tests

3.1.1 General requirements

All materials used on the contract shall conform to recognized International material specifications, which shall

be quoted in full on drawings, process and quality documentation. It is acceptable to quote a material

identification number, type or designation alone.




Where specific applications require the use of materials not covered by such specifications, the proprietary

materials shall be specified in detail at the Tender stage. It is expected that the relevant specifications will fully

describe the chemical composition limits, the mechanical test and other specific

Test requirements, which are relevant to the claimed properties of the materials used for design purposes.

Material test certificates demonstrating conformance of each material to the appropriate specification shall be

supplied and in certain cases ENGINEER / SEWA may require to witness specific mechanical tests.

Where a number of components may be manufactured from a single cast, heat or heat treatment batch the

frequency of testing shall be as required by the approved specification or alternatively shall be agreed with

ENGINEER / SEWA.

It is expected that all components represented by a particular set of test results will be suitably identified by a

unique test number allowing the composition, heat treatment and properties to be traced to the relevant material

test certificate.

All non-conforming materials shall be the subject of material concession requests which should include the

specification requirements, the actual test results and non-conformances, the material use and where relevant

the design requirements.

3.1.2 Specific requirements

The material tests requirements will, to a large extent depends on the design use of the material and the relative

importance of the component or item. It is expected that wherever necessary, the primary material specification

requirements will be extended and supplemented by additional requirements relevant to the form, use and/or

criticality of the final component. Such supplementary tests and/or examinations shall be included in component

specifications/quality plans together with the test acceptance standards proposed.

In addition to the outlined material and supplementary component tests, the following plant tests shall be carried

out:

3.2 Welding

3.2.1 Welding Procedure Tests

On fabricated items of plant, evidence will be required in the form of up-to-date independently certified

documents, which give details of satisfactory weld procedure tests in accordance with the requirements of

Section 9 of the ASME Code.

If these are not available, provision shall be made to conduct such tests.

As a minimum requirement all welded joints shall be subjected to a 10 % random radiographic examination

unless otherwise agreed with ENGINEER / SEWA. In the case of gas piping all pressurized parts are to be

subject to 100 % radiography on all welds.

3.2.2 Welders Performance Qualifications

All welders making welds on pressure systems and load bearing structures must be qualified in accordance with

Section 9 of the ASME Code, irrespective of the code to which the equipment is being manufactured.

3.2.3 Welding Procedure Approval




All welding and weld repair procedures are subject to the approval of Engineer / SEWA. No welding should

commence until an approved procedure is available. Welds made without such a procedure may be rejected by

SEWA. Each welding station will be expected to have copies of the approved procedures appropriate to the

welds to be carried out and to be able to demonstrate this to ENGINEER / SEWA.

3.3 Mechanical Plant Tests

3.3.1 Gas/steam turbine tests

3.3.1.1 Rotors

All rotor parts shall be examined by approved “through thickness” non-destructive methods (radiography or

ultrasonic as appropriate) for sub-surface defects, surface crack detection by an internationally approved 3rd

party testing agency to demonstrate freedom from surface defects.

Each rotor intended for operation at elevated temperature shall be subjected to a thermal stability test at the

Contractor’s Works and details of the proposed tests and acceptance criteria shall be given in the Tender.

The complete rotor sub-assemblies shall be dynamically balanced during factory shop test, in accordance with

ISO 11342. The assessment on the balancing figures shall be done in accordance with ISO 1940-1.

3.3.1.2 Blading

All fixed and moving blading shall be tested by approved non-destructive means to standards to be approved by

ENGINEER / SEWA.

The proposed tests for cast, forged and machined blades shall be indicated in the Tender.

(a) Rotating Elements

Each rotating element shall be statically and dynamically balanced.

Each completed auxiliary pump-rotating element shall be similarly tested unless otherwise agreed by

ENGINEER / SEWA.

Upon completion of assembly, dimensional and run-out measurements shall be taken.

Each completed Gas/Steam turbine rotor shall be run in its own bearings for at least 5 minutes at 5% above the

nominal over-speed setting or 3% above the highest speed estimated to be reached by each part during an

emergency following failure of the governor to reduce the fuel supply, whichever is the higher.

Each assembled rotor shall be subjected to the turbine tripping speed at least three times.

Vibration shall be monitored during running tests and on completion the rotor assembly and bearings shall be

examined for any signs of distress/damage.

Any necessary rectification following shop running shall be reported to Engineer / SEWA and shall not be carried

out until approval is obtained.

Loop tests shall be carried out on sub-assemblies such as the fuel control system and the control system shall

be tested using simulated signals before incorporation into the turbine.




All auxiliary plant shall be run in the Manufacturer’s works, unless otherwise agreed, to check compliance with

the specified characteristics and requirements and that they run without unacceptable vibration and/or noise.

3.3.1.3 Turbine assembly and no load run

Each completed Gas/steam turbine shall be operated at the maximum operating speed for a minimum period of

4 hours to check bearing performance, vibration, air flow, temperatures, overall mechanical operation and

performance of the control, alarm and protective systems.

If dismantling is required for the improvement of mechanical operation, the test is to be abandoned and a further

test carried out after the correctness has been made.

3.3.1.4 Inspection after tests

Upon completion of the running tests, casings are to be opened for inspection of blading, bearings, seals and all

critical surfaces and components. Any damage found shall be reported to Engineer / SEWA and proposed

rectification procedures shall be submitted for approval.

3.3.2 Lubrication and control oil systems

3.3.2.1 Oil Tanks

i. All welds shall be continuous and subjected to magnetic particle or dye penetrant check.

ii. A thorough visual examination shall be carried out following shot blasting and cleaning.

iii. Each oil tank shall be subjected to a dead weight water test for a minimum period of 24 hours.

3.3.2.2 Oil Coolers

Tube plates shall be ultrasonically checked prior to drilling and all shell and water box welds shall be checked by

approved non-destructive tests. Tubes shall be eddy current tested at makers works.

Oil coolers shall be pressure tested at the manufacturer’s works. Tests shall be carried out separately on both

the oil and watersides of the cooler.

3.3.2.3 Oil Purifiers

The purifier shall be performance tested at the manufacturer’s works, and performance curves shall be drawn up

by the manufacturer.

3.3.2.4 Oil Piping

Pressure tests shall be carried out and all welds shall be subject to a magnetic particle check. Ten per cent (in

number) of each different size of weld shall be radiographed.

3.3.2.5 Pumps and compressors

(a) All cast or fabricated casings guide parts and impellers shall be subjected to an approved nondestructive

testing.

(b) Hydraulic pressure tests shall be conducted on pump casings.




(c) Impellers shall be dynamically balanced.

(d) Performance tests shall be carried out at OEM works.

(e) Each pump shall be subjected to a performance test at the manufacturer’s works under as near actual site

conditions as possible. The readings taken during the tests shall be recorded on a log sheet and

performance curves shall be drawn up by the manufacturer. These curves shall demonstrate the ability of

the pumps to fulfill duty conditions.

(f) A minimum of one pump of each type of miscellaneous small pumps shall be performance tested at the

manufacturer’s works.

3.4 Electrical Plant Tests

All tests shall be carried out according to relevant IEC Standards.

3.4.1 Generators & exciters

3.4.1.1 Housing and end shields

1) Approved crack detection of major strength welds.

2) Visual and dimensional checks.

3.4.1.2 Core springs, key-bars, core pressure plates etc.

1) Ultrasonic tests where applicable.

2) Crack detection tests where applicable.


3.4.1.3 Bearings, housings etc.

1) Ultrasonic tests and dye penetrant checks on liner bonding.

2) Insulation tests where applicable.


3.4.1.4 Core material - silicon and mild steel plates

1) Cold bending test where applicable.

2) Magnetizing characteristics and hysteresis loss.

3) Destructive checks on end packet stampings to verify the quality of the spot welding.

4) Stacking factor tests.

5) Electrical insulation tests.





3.4.1.5 Magnetic cores

1) Inspection at 50% assembly stage.

2) Heating check on completed cores immediately subsequent to their being excited so as to induce the

designed value of flux density in the core back. Core flux test shall be in accordance with IEEE Std. 56-1977.

Calculations and records shall be submitted for approval before winding of core shall commence.


3.4.1.6 Winding copper

1) Electrical conductivity

2) Visual and dimensional checks

3.4.1.7 Insulation materials

1) Dielectric tests.


3.4.1.8 Armature bar formation

1) Inter-run insulation test (after Roebell setting).

2) Capacitance and tangent delta tests on all bars.


4) Destruction tests of main insulation on one sample bar of both layers. Alternatively, test certification of such

tests made on identical bars may be accepted.

3.4.1.9 Terminal bushings

1) Capacitance and tangent delta tests.

2) Impulse and dielectric tests.


3.4.1.10 Armature windings.

1) Inspection of 50% stage and on completion, to include particularly brazing, overhang bracing etc.

2) Resistance measurement of main and resistance temperature detector circuits.

3) Three-phase impedance tests at such values of current as to permit accurate extrapolation to the rated

condition. (This test is to furnish data for excitation calculations but it can be replaced or dispensed with if the

Contractor can provide acceptable alternative methods).

4) Capacitance, tangent delta, partial discharges measurement on each phase of completed windings.




5) Charge/discharge - absorption tests or equivalent.


3.4.2 Rotating parts

3.4.2.1 Rotor and exciter forging, retaining, fan and centring ring.

1) Ultrasonic examination to approved standards.

2) Crack detection of all surfaces (including bores).

3) Run-out checks throughout manufacture.


3.4.2.2 Fan blades

1) Certification of chemical analysis.

2) Representative material tests to determine tensile and hardness properties.

3) Approved crack detection tests.


5) Certification of test results.

3.4.2.3 Slot wedges

1) Certification of chemical analysis.

2) Representative material tests to determine tensile, roughness and hardness properties.

3) Crack detection.


5) Wedge tightness tests and visual inspection after winding works- factory witness test by ENGINEER / SEWA.

6) Certification of test results.

3.4.2.4 Winding copper

a) Electrical conductivity

b) Visual and dimensional checks.

3.4.2.5 Insulation materials

a) Dielectric tests.




3.4.2.6 Bar formation

a) Approved inspection of jigging, brazing etc.

3.4.2.7 Radial winding connections studs and assembly

a) Visual and dimensional checks.

3.4.2.8 Bars (through shaft connectors)

a) Dielectric tests on formed assembly.

3.4.2.9 Rotor windings

a) Inspection at commencement, 50% and completion of winding. Tests to include particularly, inspection of

overhang support blocking, insulation cylinders under retaining rings, damper windings etc.

3.4.2.10 Completed rotors

a) Winding resistance.

b) Impedance measurement throughout speed range.

c) Over speed and balance.

3.4.2.11 Works running test of generators/exciters/permanent magnet generators (engineer / sewa witness test)

(a) Resistance of windings, heaters, and RTD’s, and insulation resistance (cold).

(b) Verification of voltage balance, polarity, phase sequence, shaft voltages, where applicable.

(c) Characteristic N.L. and S.C. curves and associated loss measurements. Zero Power Factor Characteristic

or Potier Reactance test/calculation.

(d) Vibration levels when cold and hot and at normal and over speed

(e) Temperature rise test on generator only.

(f) Sudden 3-phase short-circuits tests (see Note 4) with Oscillo-graphic records. (Not applicable to Exciters

(See Note 3).

(g) Exciter response test. (See Note 3).

(h) Load characteristics (Exciters).

(i) Waveform recordings of line and phase voltages shall be taken at no-load (not applicable to Exciters and

Permanent Magnet Generators).Harmonic analysis and telephone harmonic factors shall be recorded and

evaluated.

(j) A retardation curves shall be recorded between the speed range of 110% to 90% and all necessary data

furnished to permit evaluation of moments of inertia. (Not applicable to Exciters and permanent magnet

generators)




(k) High voltage tests on winding and heaters, and megger on instrumentation circuits.

(l) Dielectric tests.

M.1 H.V. (greater than 1000V) windings: Tan delta and capacitance measurements on

each phase and also on the whole windings together. Polarisation index: a charge/discharge current curve

from 0.5 min to 10 min shall be recorded. M. 2 L.V. (up to 1000V) windings: An insulation resistance test.

(m) Following the above tests the end windings, bearing liners, bearing insulation, journals etc. shall be

examined to confirm they remain satisfactory.

Note 1: Calibration records of instruments and associated apparatus used in the above tests shall be available

for examination.

Note 2: Brushless generators shall be tested with temporary slip rings for direct measurement of rotor current.

Note 3: Certified test by Independent Test Authority may be acceptable for SC test subject to prior agreement at

the contract stage, final data must be submitted at least 6 months before the programmed test date.

Note 4: For L.V. generators the SC test shall be carried out at 100% voltage and for H.V. generators, at 80% and

60% voltages unless otherwise specified.

3.4.3 Excitation, regulator equipment

(a) Inspection at intermediate (50%) assembly stage.

(b) Wiring and bus bar check printed circuit and card assembly.

(c) Examination of diode and thyristor certification for forward voltage drops, I2t capacity, and Reverse leakage

current.

(d) Characteristics check of diodes, thyristors, magnetic amplifiers and associated circuitry.

(e) Simulated test on exciter circuits to demonstrate control, response, discrimination, protection and limit

features.

(f) Function and high voltage tests on field breakers, if applicable.

(g) High voltage and insulation resistance tests.

(h) Visual and dimensional checks.

3.4.4 Generator/exciter auxiliaries

3.4.4.1 Coolers

1) Hydraulic tests (prior to painting) at 1.5 time’s normal pressure for air to water units.


3.4.4.2 Pump

1) Hydraulic tests.




2) Performance tests.

3.4.4.3 Motors

1) Inspection on completion of manufacture.

2) Type and/or routine, as applicable.

Note: See also Clause on Electric Motors.

3.4.4.4 Permanent magnet generators and exciters

1) Inspection at 50% core building stage and at completion.

2) Check on shrink fits and shaft locking features.


3.4.5 Generator main connections

(a) Type tests - temperature rise, short time current, impulse tests required on a sample section. If records

exist for these tests on comparable equipment these may be accepted in place of further type test. The test

shall relate to the most onerous section e.g. a right angle bend.

(b) Check erection of selected sections.

(c) High voltage tests.

3.4.6 HV and LV switchgear (including switchgear at generator voltage) switchboards

The following tests shall be carried out with the circuit breakers, contactors, etc. installed in the same type of

cubicles as will be supplied on the contract.

(a) Type tests comprising (IEC 62271-1 Clause 6 shall be applied):

1) Temperature rise

2) Short time current

3) Short circuit make and break switching tests (including switching of current with high asymmetry in the

case of the generator switchgear)

4) Mechanical endurance

5) Impulse voltage

6) Power frequency high voltage

7) Self-extinguishing tests on all types of solid insulating materials

8) Other mandatory test as listed in IEC 62271-1

9) If records exist for type tests on similar equipment these may be accepted in Lieu of further type tests




(b) Routine tests including (IEC 62271-1 Clause 7 shall be applied) :

1) Continuity

2) Power frequency high voltage

3) Insulation resistance Checks to diagrams

4) Check operation of mechanical and electrical interlocks, earthing devices.

5) All secondary wiring, tripping and closing coils shall be tested at 2500V 50Hz for 1 minute. Operational test

at maximum, normal and minimum control supply voltage.

6) Other mandatory test as listed in IEC 62271-1

(c) Injection tests to prove protection and instrumentation.

(d) Inspection at 10% assembly stage.

3.4.7 Components i.e. Isolators, earthing devices, etc

(a) Type tests - short time current, switching tests and mechanical endurance. The self-extinguishing tests on

all types of solid insulating materials. If records exist for these tests on comparable equipment, these may

be accepted in lieu of further type tests.

(b) Routine tests- including operational test at maximum, normal and minimum control supply voltage, power

frequency high voltage and insulation resistance tests etc.

3.4.8 Motors

(a) Type Tests - AC Motors

One motor of each type shall be subjected to the following tests which shall be carried out in accordance with

IEC 34

1) Inspection at 50% assembly stage on HV motors 6 KV and above.


i. Loss tangent measurement on each phase and also on the whole winding together of H.V. motors.

ii. Polarisation index on all H.V (greater than 1000V) windings, where vacuum impregnation is used, charge/discharge current curve from 1 min to 10 min shall be recorded.

3) Measurement of winding resistance also resistance measurement of detectors and heaters

where applicable and Insulation Resistance (cold).

4) Verification of direction of rotation relative to the phase sequence of the supply.

5) No load loss measurement at nominal voltage with check for balance with the machine unbolted from the

bedplate. All H.V. motors shall be run for 15 minutes at 120% nominal voltage.




6) Temperature rise test for one motor of each rating.

7) Locked rotor test.

8) Verification of load characteristics and momentary excess torque capability.

9) Verification of capability to produce rated output at minimum sustained voltage, with measurement of slip.

10) Measurement of breakaway, pull-up and pull out torque.

11) Measurement of breakaway starting current. When this test is carried out at a reduced voltage due to

limitation of test plant, allowance shall be made for the effects of saturation when deducing the value at

nominal voltage.

12) Over-speed test at 120% nominal speed for 5 minutes on H.V. motors and prototype

designs. (Visual examination on high speed or highly stressed rotors and welded rotor assemblies)

13) Noise measurement where applicable.

14) Vibration measurements.

15) High voltage test.

(b) Routine Tests - AC Motors

All other motors shall be submitted to test (1), (2), (3), (4), (5), (7), (13), (14) above where applicable.

(c) Type Tests - D.C. Motors

One motor of each type shall be submitted to the following tests which shall be carried out in accordance with

IEC 34 where appropriate.

1) Insulation resistances.

2) Resistance measurements of windings and heaters where applicable.

3) Winding polarity checks.

4) Light run figures and balance.

5) Load characteristics.

6) Temperature rises tests and checks of output/speed relationship at 90% volts and 115% volts.

7) Commutation tests.

8) Over speed tests.

9) High voltage test.

10) Noise tests where applicable.




11) The above tests shall be conducted on the first motor of each basic design although test certification for

tests (f) and (k) may be submitted for approval.

12) Where special series or ballast resistors are used, these shall be tested with the motor.

(d) Routine Tests - D.C. motors.

Tests as for (1), (2), (3), (4), (7), (9), (10) above.

3.4.9 Insulating oil and gas

(a) Sample Tests

Samples of oil and gas from each consignment shall be tested before despatch and shall comply with the

requirements of IEC 296 or 376 as appropriate.

3.4.10 Surge arresters

(a) Routine Tests

In accordance with the requirements of the IEC 99Type Tests (shall be applied and in accordance with the

requirements of the IEC 99

(b) Sample Tests

In accordance with the requirements of IEC 99, a residual voltage test shall be carried out.

3.4.11 Batteries, chargers and inverters & VFDS

(c) Routine Tests




3.4.12 Chargers

The normal low-rate (float) charge voltage shall be set in the works at the specified voltage per cell when

delivering 50% of rated load. At this setting it shall be demonstrated that the charger can maintain output voltage

within the prescribed limits under the specified variations of input voltage and frequency and output load current.

The operation of the boost charge facility shall also be demonstrated. The correct functioning of all control

indication and alarm devices shall be verified.

All secondary wiring shall be submitted to a high voltage test of 2 Kv AC for 1 minute. Type Tests (Clause 2.2

shall be applied)

One or more cells, as may be agreed, of each battery type shall be submitted to a suitable discharge test in

order to verify the guaranteed capacity. Continuous measurements of battery voltage shall be made together

with periodic readings of the electrolytes specific gravity and temperature.

No addition to the electrolyte is permitted during this discharge test.

3.4.13 VFD units

For custom made units, the type test shall be carried out. The details shall be discussed and finalized during

tender stages.

(a) Routine tests:

(b) Factory test on one VFD unit (rated 150kW or above) of each type will be witnessed by ENGINEER / SEWA

(c) To ensure quality, the complete VFD shall be tested by the manufacturer. The VFD shall drive a motor

connected to a dynamometer at full load and speed and shall be cycled during the automated test

procedure.

(d) All optional features shall be functionally tested at the factory for proper operation.

(e) The manufacturer shall provide start-up commissioning of the VFD and its optional circuits by a factory

certified service technician who is experienced in start-up and repair services.

3.4.14 Transformers tanks

(a) Inspection of weld preparations, approved crack detection of major strength welds.

(b) Hydraulic test of transformer tanks, conservators, oil pipework and air cooled cooling plant. These shall

withstand without leaking or permanent distortion, the application for 24 hours of a pressure which is such

that the test pressure at any point in the equipment is twice the working pressure at that point, or 0.7

Kg/cm2 plus the working pressure at that point, or 0.3

(c) Kg/cm2 plus the pressure exerted at that point when the pressure relief valve is opened slowly by oil

pressure whichever is the greatest.

(d) Vacuum test according to IEC.




3.4.14.1 Cores

(a) Material

1) Checks on flatness.

2) Checks for absence of burrs may be caused by such as slitting, cropping and punching.

3) Electrical insulation tests.


(b) Assembly

1) Inspection during assembly stage, whilst core is still horizontal.

2) Visual and dimensional checks on complete core.

3) Checks on straightness of clamps.

4) Checks on clamp welding.

5) High voltage tests between core packets, clamps and belts in all relevant combinations.

6) Check actual weight or core steel in magnetic circuit against design weight.

7) Check that all block and sheet insulation and all spacers are in position.

8) Check earthing of core packets to clamps.

3.4.14.2 Windings

(a) Windings

1) Copper checks

Fewest possible number of welds.

Quality of weld and finishing

2) Insulation on copper

Check for correct material

Check correct application to conductor


(b) Winding of Turns

1) Checks during winding of different sections of winding.




2) Checks on positions of starts and finishes of sections.

3) Checks on correct directions of windings of turn (Polarity).

4) Visual checks.

(c) Assembly of Windings Together

1) Check on relative positions and numbers of leads.

2) Check that vertical and horizontal coolant ducts are clear and to full design dimensions.

3) Visual checks.

(d) Assembly of Windings on Core


3.4.14.3 Leads

(a) Checks on disposition, insulation and support of tapping leads.

(b) Checks on insulation support and positioning of bushing leads and provision for connection to bushings.

(c) Checks on lead connections (crimping, brazing etc.)

(d) Checks on interphase connections.

(e) General visual checks.

3.4.14.4 Insulation

(a) Checks on arrangement of petalling.

(b) Checks on interphase and earth barriers.

(c) Checks on shields.

(d) Checks on clearance and creep age distances.


3.4.14.5 Coolant flow ducts

(a) Check that vertical and horizontal passages are clear and to full design dimensions.

(b) General visual checks.

3.4.14.6 Current transformers, links and connections

(a) Check that built-in current transformers are in the correct leads.




(b) Check that the connections and alternative connections are clearly marked and that the marked ratios are

correct.

3.4.14.7 Assembly of transformer in tank

(a) Check insulation between transformer and tank.

(b) Check security of fixing of transformer in tank and of any packing used.

(c) Check electrical clearances between tank and leads and windings.

(d) Checks for cleanliness and freedom from debris of inside of tank.


3.4.14.8 Valves

(a) Check action of valves after welding into position (especially butterfly valves)

(b) Checks for leaks under pressure.

3.4.14.9 Paintwork

(a) Checks for preparation of surfaces.

(b) Checks for use of correct paint system.

(c) Visual checks of general finish.

3.4.14.10 Conservator

(a) Check for leakage

(b) Check capacity.

(c) Visual checks.

3.4.14.11 Bushings

(a) Check against standards.

(b) Check that routine tests have been done.

(c) Checks for leakage when mounted on transformer.

(d) Checks for distortion flaw and chips

3.4.14.12 Tap changers (on-load and off-circuit as appropriate)

(a) Inspection on completion of manufacture, including a review of Manufacturer’s stage test records and

procedures.

(b) Mechanical and electrical checks in the Manufacturer’s works.




(c) Tests in accordance with the appropriate IEC or other standard as applicable.

(d) Check ten complete cycles from end to end of the range.

(e) Check five cycles on full current.

(f) Check five cycles at full voltage.

(g) Check transmitters for correct number of steps and impedance values.

(h) Check interlocks

(i) Check warning, alarms and trip contacts.

(j) Visual and dimensional checks.

3.4.14.13 Fans

(a) Checks for direction of rotation against motor terminal markings.

(b) Visual and dimensional checks.

3.4.14.14 Heat exchangers

(a) Checks on radiators for leaks.

(b) Checks on radiators for paint finish and inner cleanliness.

(c) General visual and dimensional checks.

3.4.14.15 Processing

(a) Checks on pressures and temperatures with Manufacturer’s process charts available.

3.4.14.16 Control cubicles, kiosks and terminal boxes

(a) Checks on functioning of contactors, overloads, isolators and general operation of control circuits for

cooling gear.

(b) Checks on operation of circuits for thermometers, thermal images, pressure relief valves, oil and gas-

operated relays, flow detectors, heaters, lights and power output sockets.

(c) Checks on wiring arrangements and terminal boards.

(d) Checks on weather sealing of doors, cable glands and other external features.

(e) Visual and dimensional checks.

3.4.14.17 Works tests on complete transformer

The following routine tests in accordance with IEC:

(a) Measurement of winding resistance.




(b) Measurement of voltage ratio and check of voltage vector.

(c) Measurement of impedance voltage, short-circuit impedance and load loss.

(d) Measurement of no-load loss and current.

(e) Dielectric test using separate source AC

(f) Dielectric test using induced overvoltage.

(g) Tests on no-load Tap changers.

The above tests shall be carried out on all transformers.

The following tests in accordance with IEC, to be carried out as type tests:

a) Temperature-rise test.

b) Lighting impulse test.

c) Measurement of zero-sequence impedance.

d) A noise type test in accordance with NEMA on the first unit of each type

In addition to the above tests, the following tests shall be made as routine/additional tests:

a) Tangent delta measurements on the insulation; the method to be agreed with ENGINEER / SEWA.

b) On windings of 30 KV rating or above:

Partial discharge measurements in accordance with IEC shall be carried out before and after all above tests for

all transformers.

Gas in oil analysis shall be carried out for all transformers before and after all tests

Transformer tanks, conservators, oil pipework and air-cooled cooling plant shall withstand, without leaking or

permanent distortion the pressure with stand test. The application for 24 hours of a pressure test should be such

that the test pressure at any point in the equipment is twice the working pressure at that point, or 0.7 kg/cm2 plus

the working pressure at that point, or 0.3 kg/cm2 plus the pressure exerted at that point, when the pressure relief

valve is opened slowly by oil pressure, whichever is the greatest.

3.4.15 Neutral earthing resistors and associated equipment

3.4.15.1 Routine tests

(a) A test pressure of 2.25 x phase voltage + 2,000 V for 2 minutes between the grids and the earthed frame

shall be applied.

(b) A test or certification to prove that the short time thermal rating of the earthing transformer and resistor in

its associated cubicle for the 5 minute rating as specified elsewhere in the equipment specification.




3.4.16 Miscellaneous electrical equipment

3.4.16.1 Instrument transformers

(a) Type tests comprising temperature rise, short time current, impulse tests where applicable. If records exist

for these tests on comparable equipment, these may be accepted in lieu of further type tests.

(b) Routine tests on all current and voltage transformers - insulation and accuracy tests.

(c) Magnetisation curve for each relating CT type, with check points on all current transformers.

3.4.16.2 Control, instrumentation boards etc.

(a) Inspection and tests of components and sub-assemblies at the appropriate stages of manufacture and at

completion of manufacture.

(b) Inspection at 10% assembly stage of complete boards.

(c) High voltage and insulation resistance tests.

(d) Final inspection of appropriate drawings.

3.4.16.3 Relays meters, instruments etc.

(a) Function, accuracy tests.

(b) High voltage tests.

3.4.16.4 Cable and accessories

Type, sample and routine tests as appropriate to the type of cable or accessory




3.4.16.5 Inspection on completion of manufacture of the following and similar items.

Lightning Arresters, lighting fittings, fire alarm equipment, lifts, marshalling boxes, communication system parts

etc.

3.4.16.6 Electrical protection

Set-up where required for high impedance differential schemes.

3.5 Control and Instrumentation

3.5.1 Works components tests

Tests on instrumentation components are to be carried out at the contractor works to prove that the component

meets the required specification and is sufficiently reliable to justify delivering to site. The component will not be

accepted as suitable for delivery until ENGINEER / SEWA is satisfied that it complies with the specification.

ENGINEER / SEWA can extend or repeat the tests as deemed necessary to meet with acceptance.

3.5.2 Works system tests

The works system tests are intended to prove that the modules and sub-systems are compatible and that the

complete system hardware and software conforms to the specification. This shall be achieved by configuring the

complete control system with the local and remote display systems at the manufacturer works and by simulating

plant interfaces and responses.

The works system tests schedule must be approved by ENGINEER / SEWA 3 months prior to the

commencement of the tests. The tests shall run for at last 400 hours and all functions of the system shall be

tested. During the test not less than 10 complete Gas/steam turbine generator operating cycles of starting,

loading and stopping shall be demonstrated. In the event of a serious malfunction ENGINEER / SEWA reserves

the right to demand that the 400-hour tests be repeated at the Contractors expense. The works system test

schedule shall also include a performance test to adequately prove the system.

At a convenient time during the tests the interchange ability of modules shall be demonstrated. A log shall be

kept by the contractor of all system faults during tests.

4 SITE INSPECTION, TESTING AND COMMISSIONING TESTS

4.1 General

4.1.1 Arrangements for testing

The Contractor shall carry out at his own cost all site inspections and tests and shall provide all apparatus and

personnel for conducting the tests and analysing the data. Such personnel shall collaborate closely with

ENGINEER / SEWA at site, who will witness the tests carried out under the responsibility of the Contractor.

The Contractor shall provide ENGINEER / SEWA with access to inspect all equipment during any phase of the

installation and shall provide all reasonable facilities for such access.

The Contractor shall notify ENGINEER / SEWA of impending tests in sufficient time to allow the Engineer to be

present.




Parts to be subject to witness tests will not be acceptable unless the relevant documentation is provided and has

been signed by ENGINEER / SEWA and the Contractor.

4.1.2 Supplementary tests

All apparatus shall pass such tests as are required by ENGINEER / SEWA to prove compliance with the

Contract independently of any tests, which may have already been carried out at the manufacturer’s works. In

particular all pressure tests and such temperature tests which have not been made in the manufacturer’s works

shall be carried out on site.

All items of lifting gear shall be tested together with associated structural members and all safe-working loads

shall be clearly marked. Test certificates for all lifting appliances shall be submitted to ENGINEER / SEWA.

On measurement, control and indication equipment selected tests previously carried out at the manufacturer’s

works shall be repeated on site before the start of tests in conjunction with the plant.

4.2 General Test Requirements

4.2.1 Procedure

Not less than 3 months before the commencement of site testing the Contractor shall submit to Engineer / SEWA

an electrical/mechanical test programme for all site tests to meet the erection and commissioning programme

agreed.

Together with this programme the Contractor shall provide an adequate time for approval by Engineer / SEWA

before site testing is due to commence, a set of pro-forma test forms for each item or type of equipment showing

details of the proposed tests, checks and method of recording results. A list of all general checks shall also be

included. The forms shall record type of equipment, serial numbers and any other identifying marks, station

name and machine/circuit identification and shall include space for the test Engineer’s and witnessing SEWA

Engineer’s signature.

No testing shall commence until the format and test procedures are agreed and all results shall be submitted on

the approved form.

Where testing of common equipment such as bus zone protection and voltage selection schemes are involved

as extensions to existing and operational sites the submission shall clearly state the outage requirements or ‘risk

of trip’ conditions which would apply to operational plant and where wiring modifications are involved on existing

plant marked diagrams shall be submitted showing any wiring additions and deletions if these have not been

previously submitted.

Testing shall be carried out during normal working hours as far as practicable. Tests, which involve existing

apparatus and outages, may be carried out outside normal working hours with approval from SEWA / Engineer.

The Contractor shall give sufficient notice to allow for the necessary outage arrangements to be made in

conformity with the testing program.

The Contractor shall advise Engineer / SEWA in writing at the time of commencement of site erection of the site

supplies, which will be required for the operation of the test equipment.

The Contractor shall provide the requisite experienced test personnel and all relevant test equipment, unless

otherwise agreed by Engineer / SEWA or stated in the Schedules.




On completion of any group of tests the Contractor shall submit two clean copies of the test result recorded, on

the approved form. Engineer / SEWA shall countersign the test sheets if found to be satisfactory and retain one

copy.

The Contractor shall subsequently provide to ENGINEER / SEWA six bound copies of all site test sheets as final

records. The test sheets shall be grouped by station, sub-divided by plant type and further on a machine/circuit

basis.

So that the records may be used for maintenance tests the final records shall be provided as soon as possible

after completion of testing.

No tests as agreed under the programme of tests shall be waived except upon the instruction or agreement of

the SEWA in writing.

All tests shall be carried out in the presence of Engineer / SEWA unless otherwise agreed.

4.2.2 Standards and methods

The method of testing, unless specified in the approved specification and/or Schedules, shall be agreed with

ENGINEER / SEWA.

Details of the test equipment and instruments used shall be noted in the test sheets in cases where the

instrument or equipment characteristics can have a bearing on the test results.

The Contractor’s test equipment shall be of satisfactory quality and condition and, where necessary, shall be

appropriately calibrated by an approved authority or standard at the Contractor’s expense.

The testing requirements detailed in this Specification may be subject to some variation upon the instruction or

agreement of ENGINEER / SEWA where necessitated by changed conditions at site or by approved differing

design, manufacture or constructional techniques.

4.2.3 Tests and commissioning inspections

During the commissioning period Engineer / SEWA will carry out inspections of the plant with the Contractor’s

representative and will issue lists of installation and commissioning defects/outstanding work to be completed by

the Contractor prior to commencement of the acceptance tests.

4.3 Mechanical Plant

4.3.1 Alignment checks

A complete record of alignment and clearance checks for the Gas/Steam Turbine Generator unit and other

rotating equipment shall be submitted to Engineer / SEWA before the plant is operated. The Contractor shall

permit SEWA to witness the taking of all final alignment and clearance checks.

4.3.2 Calibration of instrumentation

All gauges shall be checked against suitable test instrumentation to confirm correct calibration.

4.3.3 Setting of regulating and control devices

All regulating and control devices shall be checked for correct set point, control characteristics and control range.




4.3.4 Auxiliary systems

The installation of auxiliary systems shall be checked against the relevant schematic drawing.

4.3.5 Orifices

The sizes of all flow orifices, restrictors etc., shall be checked and recorded against the design requirements.

4.3.6 Auxiliary pumping systems

All auxiliary-pumping systems for cooling water, fuel oil, lubricating oil etc., shall be operated to ensure correct

pressure levels, flows and stable operation.

4.3.7 Welding and welding tests

All welds made on site shall be subject to inspection and non-destructive testing as required by ENGINEER /

SEWA.

4.3.8 Hydraulic and vacuum tests

Hydraulic pressure tests shall be carried out on all completed items of plant where appropriate. All parts shall be

subjected to test pressures 11/2 times the design operating pressure.

4.3.9 Pumps

All pumps shall be subjected to continuous running tests for a minimum period of six hours at initial running up of

the plant. If, for any reason, such runs are interrupted before the completion of six hours, they shall be

recommenced for a further period of six hours.

Alignment checks will be witnessed after the initial 6 hour running period.

4.4 Electrical Plant

4.4.1 General requirements

The site test program shall confirm that the Contract Works comply with the following paragraphs. It shall include

all commissioning work necessary at remote locations to commission pilot wire protection.

(a) Documentation shall be submitted outlining the Field Test Procedures showing details of inhibition of

protection, interlocks and any relevant warnings, wiring diagrams etc., at least three months before site

tests start.

(b) The equipment shall not operate incorrectly when secondary wiring isolating devices are removed or

operated, or when being removed or operated; this is to prevent spurious operations. The primary plant

shall not operate under conditions, which might endanger the system, the plant or personnel attempting to

operate the plant under these conditions.

(c) The procedures outlined may require minor modifications to suit either unusual site conditions, or technical

innovations requiring changes and/or extension to the testing procedures. Major departures from these

testing procedures are not expected, nor would be tolerated unless the substituted tests offer some clear

improvement over the procedures outlined in this document.




4.4.2 Main generator, exciter

The generator and exciter shall be subjected to a check to determine their state of dryness and if in the opinion

of ENGINEER / SEWA the windings are not dry, they shall be dried out. The method of determining the state of

dryness and of drying out shall be approved by ENGINEER / SEWA.

The following minimum tests shall then be carried out.

(a) Polarisation index on H.V. windings. For L.V. windings the insulation resistance shall be checked.

(b) Open circuit curve.

(c) Short circuit curve.

(d) High voltage pressure test.

(e) Shaft/pedestal insulation test.

(f) Bearing vibration test.

4.4.3 Generator main connections

(a) Inspection of site welds of bus bars and bus ducts.

(b) Insulation resistance to earth.

(c) Ductor resistance test.

(d) Sealing test including any pressurising auxiliary equipment.

(e) Power frequency test according to IEC Standard.

(f) Temperature rise test on full load on completed connections.

4.4.4 Motors

All motors shall be subjected to a check to determine their state of dryness and if in the opinion of the Engineer

the windings are not dry they shall be dried out by an approved method.

The following minimum tests shall then be carried out.

(a) Polarisation index.

(g) High voltage pressure test.

(h) Phase rotation check.

(i) Shaft/pedestal insulation where applicable.

4.4.5 Switchgear, control panels, earthing resistors

The following tests shall be carried out as a minimum by the Contractor after the equipment has been completely

erected and connected up on site:




a) Resistance (ducter) measurements on all site made joints.

b) All control circuit wire loop checks: continuity, IR and conformity with drawing.

c) A power frequency high voltage test at the appropriate value for one minute on the complete switchgear.

d) A power frequency test at 2 KV for one minute on all secondary wiring, tripping and closing coils.

e) Insulation resistance tests on all main and secondary circuits and a check of all earth links.

f) Primary injection tests to prove protection, instrumentation etc.

g) Secondary injection tests to prove protection characteristics etc.

h) Calibration tests on ammeters, voltmeters and any other instruments.

i) Tests at normal voltage and, when required, at reduced voltage to prove that closing and tripping from local

and remote control points, tripping from relays and protective gear, inter-tripping, interlocks, alarm and

indications, etc., are satisfactory. Reduced voltage test at 70% rated voltage to prove tripping of every

circuit breaker and 85% rated voltage to prove closing.

j) Any other tests deemed advisable by ENGINEER / SEWA to prove compliance with the Specification.

4.4.6 Transformers

The following tests shall be carried out as a minimum:

(a) Tests on the insulating oil for electrical breakdown and water content.

The tests shall be carried out on the oil in the main tank, on the separate body of oil in the tap changer and on

any other separate body of oil.

(b) Tests on the insulation between core and tank, between windings, between windings and tank and

between core and windings.

(c) All control circuit wire loop checks: continuity, IR and conformity with drawing.

(d) Tests on the operation of the Buchholz relay, the fans and pumps and their contactors and of the winding

temperature indicator (thermal image) contacts.

(e) Tests on the operation of the tap changer.

(f) Tests on the auxiliary wiring and on the current transformers for winding temperature indicator and cooler

control.

(g) Tests for phase vector ratio and magnetising current.

(h) The voltage control equipment shall be opened up after a period of service operation, at an approved time

before the expiration of the maintenance period, to permit inspection of the internal parts.

(i) Gas in oil analysis.




Note: The full range of tests will be as specified in the Commissioning Schedules.

4.4.7 Batteries and battery charging equipment

Check the erection of the battery, battery stand and charger equipment, with the cable connections and fuses.

The insulation to earth of the complete installation shall be tested.

All control circuit wire loop checks: continuity, IR and conformity with drawing.

Carry out tests on the battery to confirm its polarity. Tests shall be carried out on the battery and charger to

confirm the chargers ability to recharge the battery if discharged, also the chargers ability to maintain the float

charge of the battery, and not to overcharge the battery. Test also all the alarms.

Record the specific gravity, temperature and cell voltages of the battery when fully charged also confirm that the

battery test apparatus and safety appliances are available.

A 5 or 10 hour discharge test shall be made on each main battery at each voltage level. Each battery shall

demonstrate nominal ampere-hour capacity at the ambient temperature for which the nominal capacity is quoted

by the battery manufacturer. In addition, each cell shall demonstrate at least 90% of nominal ampere-hour

capacity at this same ambient. In the determination of cell capacity, the discharge period shall be assumed to

terminate when the cell voltage falls to that quoted by the battery manufacturer for the 5 hour or 10 hour test as

appropriate. Correction factors for site tests made at ambient temperatures other than that quoted by the battery

manufacturer for nominal capacity, shall be to approval.

Where applicable the site tests described for Switchgear Control Panels and Earthing Resistors, shall be carried

out on the Batteries and charging equipment.

During the operational tests on the units at various loading, a load schedule shall be prepared for each of the

D.C. Systems. The loads on the complete D.C. systems shall be estimated and submitted to confirm the design

estimates and ensure that the battery and charger ratings are adequate. Also during the operational tests, the

ripple current shall be recorded for each battery.

Complete switching and change over operation sequences shall be demonstrated to ENGINEER / SEWA and

documented as a part of commissioning. A clear and concise operating procedure and sequence chart shall be

submitted to ENGINEER / SEWA for all switching, change overs and isolation of charger/battery systems.

4.4.8 Inverters & VFDs

The site tests described for Switchgear, Control Panels and Earthing Resistors shall apply where appropriate to

the Inverters.

All control circuit wire loop checks: continuity, IR and conformity with drawing. Commissioning tests shall also

consist of voltage, frequency, current output and load checks.

During the operational tests on the units at various loading a load schedule shall be prepared for the secure AC

supply system. The load on each inverter shall be estimated and submitted to confirm the design estimates and

ensure that the ratings are adequate.

Complete switching and change over operation sequences shall be demonstrated to ENGINEER / SEWA and

documented as a part of commissioning. A clear and concise operating procedure and sequence chart shall be

submitted to ENGINEER / SEWA for all switching, change overs and isolation of inverters.




4.4.8.1 VFD units:

All control circuit wire loop checks: continuity, IR and conformity with drawing.

The manufacturer shall provide start-up commissioning of the VFD and its optional circuits by a factory

certified service technician who is experienced in start-up and repair services.

The commissioning shall include fine tuning of the VFD for optimization during load run.

Factory representative shall provide on-site training (minimum of 3 days) for ENGINEER / SEWA operating

personnel after the VFD system is fully commissioned.

4.4.9 Instruments and instrument transformers

Instruments and instrument transformers circuits shall be checked for polarity or direction and for calibration

including any interposing transformers or transducers. These checks shall be made on all current transformer

ratios where applicable.

Meters shall be checked for correct operation and rotation. The meters will subsequently be taken to the

employer’s test laboratory and if they are found to be inaccurate and out of limits will be dealt with as a defect

during the guarantee period rather than a commissioning defect.

4.4.10 Synchronising equipment

This shall be checked whenever possible by energising both sides of the circuit-breaker from the same source. If

both sides of the circuit-breaker cannot be energised from the same source, rotation and phases shall be

checked to ensure the correctness of the synchronising feature by an independent means.

4.4.11 High voltage surge arresters

General inspection shall be carried out to verify the condition and satisfactory mounting of the arrester and its

earth connections and electrodes.

Secondary injection tests shall be carried out on surge counters to prove their operational characteristics.

4.4.12 Interlocking

All inter-locking arrangements both electrical and mechanical shall be fully checked and tested including earthing

devices.

4.4.13 Cables and earthing

(a) High Voltage Cables

(i) Continuity tests of conductors including sheaths, where applicable, earthing and bonding.

(ii) Polarity checks

(iii) Dielectric test of main insulation.

(iv) Dielectric test of sheath insulation, where applicable.




(v) Type test and routine tests shall be according to IEC 62067 for 220KV cables and routine tests shall also

be carried out on site after installation including both ends termination.

(b) Low Voltage Cables

(i) Continuity test of all conductors, including sheaths, where applicable, and earthing.

(ii) Earth loop impedance test, where applicable.

(iii) Verification of polarity including check that all switches are in the phase conductor.

(iv) Insulation resistance test at no less than 500V.

Note: All H.V. & L.V. cables shall be tested according to IEC standards unless modified by this specification.

(c) Earth Electrodes & earthing grid

(i) Measurement of earth resistance by an approved earth resistance testing equipment for all test pits using

clamp on test kits.

(ii) Measurement of the earth grid resistance for each local grid using fall-of-Potential Method or 3-Point Test

(iii) Measurement of touch voltage throughout the Site

4.4.14 Electrical protection equipment

(a) Polarity checks on current and voltage transformers.

(b) All control circuit wire loop checks: continuity, IR and conformity with drawing.

(c) Primary injection tests to prove protection, instrumentation etc.

(d) Secondary injection tests to prove protection characteristics. At the end of the tests the protective relays

are to the approval of Engineer / SEWA.

4.4.15 Protection, control, alarms, measurement and indication equipment

(a) Wiring

Insulation Resistance Tests at 500 Volts D.C. are to be carried out on all AC and D.C. protection, control, and

alarm and indication circuits to ensure that wiring is in satisfactory condition. The insulation of all circuits shall be

checked before proceeding with other tests and it is also essential that all AC wiring is proved, relay contacts,

auxiliary contacts, etc., being closed, as necessary, to verify this. Checks shall be made on cable glands, cable

jointing, fuse or circuit breaker ratings and small panel items, such as indicating lamps. All control circuit wire

loop checks: continuity, IR and conformity with drawing shall be carried out.

Static equipment, which may be damaged by the application of test voltage, shall have the appropriate terminals

short-circuited.




Inter-relay, inter-unit and cubicle wiring carried out at Site is to be checked to the appropriate circuit and/or wiring

diagram. Where it is found necessary during pre-commissioning work to effect site modifications to the

secondary wiring, Site copies of the appropriate schematic and wiring diagrams shall be suitably marked as

agreed with ENGINEER / SEWA before the circuit is commissioned.

Loop resistance measurements are to be made on all current transformer circuits. Separate values are required

for current transformer and lead resistance and all measurements are to be recorded on lead resistance

diagrams.

Pilot cable impedance and phase angle measurements shall be made when pilot cables are to be used with unit

type protection. The Contractor providing the pilot cables shall measure these values.

(b) Mechanical inspection

All relays are to be examined to ensure that they are in proper working condition and correctly adjusted, correctly

labelled and that the relay case, cover, glass and gaskets are in good order and properly fitted.

(c) Secondary Injection

Secondary injection shall be carried out on all AC relays, using voltage and current of sinusoidal waveform and

rated power frequency.

For circulation current protection employing high impedance voltage operated relays, the points of injection for

relay voltage setting tests shall be across the relay and stabilising resistance. The fault setting for this type of

protection is to be established by secondary injection, where it is impracticable to ascertain this value by primary

injection. Injection is to be made across the appropriate relay bus wires with all associated relays, setting

resistors, and CT’s connected.

(d) Current Transformer Magnetising Tests

The magnetisation characteristic of all current transformers shall be checked at a minimum of two points to

identify the current transformers with reference to the manufacturer’s estimated design curve, and to determine

the suitability of the current transformer for its intended duty. It may be noted that it is not normally necessary to

check the characteristic up to the knee-point for this purpose. Special measures may have to be taken to ensure

that the core is fully demagnetised before commencing the test.

(e) Primary Injection

Primary current injection tests are to be carried out by the Contractor. Tests are to be carried out as follows:

I. Local primary injection to establish the ratio and polarity of current transformers as a group, care being

taken to prove the identity of current transformers of similar ratio.

II. Overall primary injection to prove corrects interconnections between current transformer groups and

associated relays.

III. Fault setting tests to establish, where practicable, the value of current necessary to produce operation of

the relays. If not practicable, these tests are to be carried out by secondary injection applied at the wiring

close to the current transformer.

(f) DC Operations




Tests are to be carried out to prove the correctness of all D.C. polarities, the operating levels of D.C. relays and

the correct functioning of D.C. relay schemes, selection and control switching, indications and alarms.

(g) On Load Tests

In view of the hazards inherent in these tests, they shall be carried out under the direct supervision of the

Contractor Engineer and witnessed by ENGINEER / SEWA.

An operation and stability test shall be carried out for on-load commissioning of unit type protection.

Test for resistant shall be carried out to prove the characteristics of protective systems with directional

characteristics.

On load checks shall be made after the protection gear has been placed in service to ensure that all connections

and test links have been replaced and test leads removed, as well as to confirm the integrity of the current

transformer circuits. Where ever necessary voltage readings shall be taken at the terminals on each relay to

ensure that loop connections between the relays are complete. Special attention shall be paid to broken delta

voltages and residual current circuits where zero voltage or current respectively may not be proof of the

completeness of the circuit.

4.5 Site Tests - Control and Instrumentation

An air-conditioned area, suitable for testing and calibration, shall be provided. The workshop shall include all

necessary test equipment, complete with test certificates from a local approved testing authority.

4.5.1 Item tests

The item tests shall conform to British Standards BS6739 : 2009.

4.5.2 Loop tests

The loop tests shall conform to British Standard BS 6739 : 2009.

4.5.3 System tests - control and instrumentation

The Contractor shall provide a complete test schedule 3 months prior to commencement of testing. The

schedule shall be designed to demonstrate that all aspects of the system meet the required performance and

functionality. The contractor shall then perform these tests to the approval of Engineer / SEWA. Completion of

the performance test for the first unit shall be the basis for take-over of the control and instrumentation system.

5 TESTS ON COMPLETION

The following Clauses 5 & 6 describe the Tests on Completion required on the Plant and related systems.

Section 5 covers specific commissioning tests and Section 6 covers the performance guarantee tests and

Reliability Run tests.

5.1 Gas/Steam Turbine Plant

5.1.1 Cooling water systems




All cooling water systems shall be tested to demonstrate that the plant is adequately and correctly cooled within

the design limits and that the water pumping system is stable under all operating conditions.

The Contractor shall supply the first fill of cooling water and any top up water required prior to take-over of the

plant.

Any dosing required for the cooling water system shall be supplied by the Contractor and the dosed water shall

be analysed and checked during the commissioning period.

5.1.2 Lubricating oil systems

All lubricating oil systems shall be tested to demonstrate satisfactory stable oil supply conditions using the

normal supply and any emergency supply systems. A full survey shall be taken of all oil supply and bearing drain

temperatures at full load to demonstrate satisfactory oil and bearing temperatures and adequacy of cooling

margins.

5.1.3 Control tests

When the Contractor has completed all commissioning of the local and remote/supervisory control functions,

every function of both panels shall be tested both systematically and at random to verify the correct and safe

operation of the unit.

5.1.4 Fire protection test

One isolated CO2 bottle is to be discharged by heating of a fire detector in the GT compartment and ST unit (if

applicable) in order to functionally prove the fire protection system. Refilling of this bottle is to be the

responsibility of the Contractor.

5.1.5 Load rejection test

It shall be demonstrated at site that instantaneous rejection of full load from the machine will not cause the over

speed trip or over-temperature trips to operate nor should the machine shut down for any reason.

5.1.6 The contractor shall demonstrate safe shut down of the unit from full load with A.C. power supply not available.

6 GUARANTEE TESTS

6.1 Test Procedures

The Contractor shall carry out the tests described hereunder and any further tests required by ENGINEER /

SEWA to demonstrate that the performance of the plant complies with the requirements of the Specification, and

with the Performance Guarantees given in the Section-I

The tests shall also provide information concerning the operational characteristics of the plant for future

operational use.

6.1.1 Method of execution




Within 6 months of the commencement of the Contract, the Contractor shall submit to Engineer / SEWA the

proposed procedure for the performance tests for approval and a meeting shall be held to discuss and agree the

procedure. Three months before the date of the tests the Contractor shall send to Engineer / SEWA all the

calibration and correction curves for all instruments and flow measurement orifice plates, nozzles and venturi

tubes to be used during the tests. From these calibrations and curves it shall be possible to determine the error

introduced by each instrument-measuring device.

The tests will not be allowed to commence unless this procedure has been completed and no allowance will be

made for delays so caused.

The test date shall be approved by ENGINEER / SEWA.

No test measuring orifice plates, nozzles or venturi tubes shall be installed in the system without the approval of

and witnessing by Engineer / SEWA.

The Contractor shall carry out an analysis of the fuel prior to the test and this data shall be submitted to the

Engineer / SEWA with other relevant test information.

Before each test every instrument shall be checked and adjusted if necessary.

Before the start of each test the plant shall run for a minimum period of 2 hours at the test load to allow stable

conditions to become established.

At the end of each test the Contractor shall give a brief report in writing to Engineer /SEWA giving a log of the

test recording all the significant events happening during the test.

These reports will be countersigned by Engineer / SEWA.

6.1.2 Instruments

All instruments used in the performance tests shall be of the standard and quality required for performance

testing in accordance with the agreed standards and shall be provided on loan by the Contractor.

A pre-test uncertainty analysis shall be carried out to confirm that the selected instruments and test design shall

provide test uncertainties on corrected heat rate and power no greater than those given in the Test Code. A post-

test uncertainty analysis shall also be carried out to validate the test, the results of which shall be included in the

test report. The details and results of the pre-test and uncertainty analyses shall be included in the test

procedure

All Bourbon tube pressure gauges shall be calibrated on Site by dead-weight tester immediately before the tests.

All other instruments shall be calibrated and certified by independent nationally or internationally approved

calibration authorities, at the expense of the Contractor.

Calibration certificates shall be provided for the test instruments at the time of test.

6.1.3 Analysis of data

With the exception of the differential pressure readings of flow measuring devices, the arithmetic average of the

instrument readings shall be corrected to take into account the correction curves of each instrument and such

corrections that are allowed by the agreed standards. The values so derived will be used in calculating the

performance of the plant.




The average of the square roots of the differential pressure readings of the flow measuring devices shall be used

for the calculation of the flow rates.

Exceptional readings, which depart widely from the normal range, may be disregarded but only after agreement

with ENGINEER / SEWA approved Third Party Agency. The reason for the exceptional readings shall be

investigated at the time of the tests.

The log sheets taken during the tests shall be counter-signed by the Contractor, SEWA, Engineer and Third

Party Agency immediately after each test.

Two copies of these log sheets shall be handed over to ENGINEER / SEWA as soon as possible after

countersigning.

6.1.4 Test Reports

As soon as possible after the tests the Contractor shall prepare and submit to ENGINEER / SEWA a draft Test

Report which shall consist of at least the following:-

(a) Brief description of the plant

(b) Procedure for testing and calculation

(c) Calculation

(d) Results (Corrected and uncorrected)

(e) Correction curves

(f) Copy of log sheets

(g) Calibrations of all instruments

Following up on approval of the draft report, copies of the final reports shall be distributed as follows: Two (2)

copies to Engineer / SEWA

6.2 Gas/Steam Turbine Tests

6.2.1 General

When the Contractor is satisfied that the Gas/steam turbine plant is fully erected and has successfully completed

the specific commissioning tests, he should demonstrate its availability for guarantee tests by operating the plant

for a minimum period of 24 hours up to a maximum of 48 hours at the plants nominal maximum continuous rating

but including short period at any higher rating included within the Performance Guarantees.

Following the successful demonstration, to the satisfaction of ENGINEER / SEWA, that the plant is ready for the

Guarantee Tests these Tests shall follow as detailed below and will then be followed by the Reliability Tests as

detailed below.

The Guarantee tests shall preferably be run during the hotter period of the year that is during the summer

months. If this is not possible then the Contractor shall demonstrate acceptability of the plant under the design

ambient conditions as soon as possible.




6.2.2 Guarantee tests

The Guarantee tests shall be conducted in accordance with CIMAC “Recommendations for Gas/Steam Turbine

Acceptance Tests”. The Contractor is responsible for the analysis of a fuel sample by an independent laboratory

to determine calorific value. The Contractor shall also provide pre- and post-calibrated kWh meters for the

CIMAC tests.

If it is not possible to complete the acceptance test within the period specified in Clause 3.1 of the CIMAC code,

then any derating factors shall be as agreed with ENGINEER / SEWA.

The Generator Tests shall include tests at 25%, 50%, 75% and 100% rated Load.

6.2.3 Rated conditions

The rated conditions for the performance guarantee tests shall be:

(a) Ambient air temperature 55oC, pressure 760mm mercury and relative humidity of 60 per cent.

(b) Output of Generator: Equal to the rated or part rated capacity required for each test.

Since it will be impossible to meet certain of the above items exactly, the difference between the actual mean

value of the test and the design and guarantee conditions will be taken into account using correction curves

which shall be submitted with the Tender. Corrections according to the curves shall be made on the results of

each individual test run.

6.2.4 Plant operation

For all generation operation by the plant prior to issue of the Taking Over Certificate, the plant is to be operated

by SEWA’s Operating Staff under the supervision of the Contractor.

6.2.5 Spare control cards

A complete set of turbine and generator control cards is to be held by the Contractor on site before the setting to

work period commences.

6.3 Plant Reliability Tests

When the Contractor considers that the Plant is ready for these tests he shall notify ENGINEER / SEWA. If

ENGINEER / SEWA agrees that the plant is ready for testing the Contactor shall prove the reliability of the plant

by operating it to the requirements of ENGINEER / SEWA and without failure, for an accumulated period of not

less than 30 days. The plant output during the test shall be not less than 95% of rated output at all times.

During the reliability test period the Contractor will be permitted to make minor adjustments, which may be

necessary, provided that such adjustments do not in any way, interfere with or prevent the commercial use of the

plant by the Employer, or result in reducing the output, decreasing the efficiency or exceeding the environmental

limits. However, all adjustments shall be first agreed by the Employer / Engineer.

Should any interruption occur in any portion of the Plant within the scope of the Contractor, due to or arising from

faulty design, material or workmanship, the Contractor shall recommence the reliability test run from the

beginning of the 30 day run in which the interruption occurs once the cause of the interruption has been rectified.

An interruption is defined as:




(a) Any plant failure resulting in a reduction in generation capacity from the requested power output.

(b) Any deviation from the requested power output at of more than ± 2.5 per cent of requested output

(c) Operation of equipment in manual mode which normally is operated in automatic mode

(d) Failure of plant to start.

No shutdowns are permitted during the RTR. Start-up and shutdown at the last phase of testing shall be carried

out as stated in Book I, Section N. If the RTR is interrupted for any reason other than a failure of a minor nature,

it shall be started from the beginning after the cause of the interruption has been removed by the Contractor to

the entire satisfaction of the Employer / Engineer.

If, in the opinion of ENGINEER / SEWA, the cause of the failure is of a minor nature then the test may continue

from that point in the test period at which the failure occurred.

A major failure may be defined as a failure of any major item of plant or a failure which causes a reduction of

required load for more than 6 hours.

Should minor failures result in cumulative failures which exceed 6 hours in loss of electrical load; this will be

regarded as a major failure situation.

The reliability test shall be carried out for each Gas/steam turbine and shall include the generator and all

auxiliaries associated with the steam turbine.

During the reliability test, functional testing shall be carried out to demonstrate specified requirements of standby

plant and auto-changeover of plant. Reliability Test Run (RTR) with the assistance of Company's staff under the

Contractor's supervision and full responsibility.

The date that the unit successfully completes the uninterrupted (30) days Reliability Trial Run (RTR) shall be

stated in a document signed both by the SEWA / Engineer and the Contractor.

6.4 Combined Cycle Electrical Output

6.4.1 The test

Following the completion of all the tests as described above in this section or as otherwise agreed by

ENGINEER / SEWA the Contractor shall carry out a test to establish the net gas/steam turbine generator

electrical output as guaranteed. This test shall be carried out on each of the gas/steam turbine units.

6.4.2 Rated conditions

The rated conditions for the tests shall be as per specification.

6.4.3 Procedure

The duration of each test shall be 2 hours with a minimum stabilising period of 1 hour before the test.

The electrical output of each turbine generator shall be measured by means of test standard calibrated kilowatt

meters preferably of the integrating type.




The auxiliary power consumption shall include all electrical consumers normally used to operate the plant. This

power shall be measured by calibrated kilowatt meters installed in the appropriate feeders.

The electrical losses in the main and unit transformers shall be calculated from the works tests of the

transformers.



Book II- Sec J-Rev01 of 69 03-Aug-2015

7 APPENDIX - WORKSHOP INSPECTION &TESTING

7.1 Common – All Packages

Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Fla

tte

nin

g T

est

Fla

rin

g test

Eddy C

urr

ent

Mate

rial C

ert

ific

ate

We

ld P

repara

tion

Mate

rial Id

entification

Hard

ness T

est

Radio

gra

phic

Exam

Ultra

son

ic T

est

Magn

etic P

art

Test

Dye-P

en

etr

ation T

est

We

lders

Qua

lific

ation

Check o

f w

eld

ing w

ork

Pre

ssure

Test

Functio

n T

est

Vib

ration C

heck

Bala

ncin

g

Ball

Test

Valv

e C

hara

cte

ristic

Tig

htn

ess / L

eakag

e

Surf

ace P

rep

ara

tion

Corr

osio

n I

nspection

(P

ack.P

: V

isu

al

Inspection)

Vis

ua

l/D

imensio

n C

hk.

Fin

al In

sp./

Doc C

hk.

Inspection o

f P

ackin

g

Assem

bly

Check

Control Valves

Body X X X X X X X X

Bonnet X X X X

Disc X X X X

Yoke X X X X

Stem X X X X

Weld X X X X

Actuator X

Valve assembly X X X X X X X X X X

Isolating Valves X X X

Body X X X X X X X X

Bonnet X X X X

Disc X X X X

Yoke X X X X

Stem X X X X

Actuator X

Valve assembly X X X X X X X X X

Safety Valves




Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Fla

tte

nin

g T

est

Fla

rin

g test

Eddy C

urr

ent

Mate

rial C

ert

ific

ate

We

ld P

repara

tion

Mate

rial Id

entification

Hard

ness T

est

Radio

gra

phic

Exam

Ultra

son

ic T

est

Magn

etic P

art

Test

Dye

-Pen

etr

ation T

est

We

lders

Qua

lific

ation

Check o

f w

eld

ing w

ork

Pre

ssure

Test

Functio

n T

est

Vib

ration C

heck

Bala

ncin

g

Ball

Test

Valv

e C

hara

cte

ristic

Tig

htn

ess / L

eakag

e

Surf

ace P

rep

ara

tion

Corr

osio

n I

nspection

(P

ack.P

: V

isu

al

Inspection)

Vis

ua

l/D

imensio

n C

hk.

Fin

al In

sp./

Doc C

hk.

Inspection o

f P

ackin

g

Assem

bly

Check

Body X X X X X X X

Bonnet X X X X

Disc X X X X X X

Lantern X X X X

Stem X X X X

Spring X X X X

Welds X X X X X X

Actuator (if applicable) X X

Valve assembly X X X X X X X X X

Metal Piping

Pipe X X X X X X X X

Fitting X X X X X

Butt weld on fitting or on pipe

(longitudinal or circumferential weld)

X X X X X X X X

Weld on branch connection (i.e.

weld between the branch and the

run pipe)

X X X X X X X

Fillet, socket, attachment and

seal welds

X X X X X X

Bending X X

Welding electrode X

Pump

Casing X X X X X




Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Fla

tte

nin

g T

est

Fla

rin

g test

Eddy C

urr

ent

Mate

rial C

ert

ific

ate

We

ld P

repara

tion

Mate

rial Id

entification

Hard

ness T

est

Radio

gra

phic

Exam

Ultra

son

ic T

est

Magn

etic P

art

Test

Dye

-Pen

etr

ation T

est

We

lders

Qua

lific

ation

Check o

f w

eld

ing w

ork

Pre

ssure

Test

Functio

n T

est

Vib

ration C

heck

Bala

ncin

g

Ball

Test

Valv

e C

hara

cte

ristic

Tig

htn

ess / L

eakag

e

Surf

ace P

rep

ara

tion

Corr

osio

n I

nspection

(P

ack.P

: V

isu

al

Inspection)

Vis

ua

l/D

imensio

n C

hk.

Fin

al In

sp./

Doc C

hk.

Inspection o

f P

ackin

g

Assem

bly

Check

Cover X X X X X

Shaft X X X X X X

Impeller X X X X X X X

Wear rings (if applicable) X X

Pump Assembly X X X X X X X

Heat Exchanger

Shell plates X X X X

Flanges and covers X X X X

Dividing plate X X X X

Heads X X X X

Tube sheets X X X X

Tube bundle X X X X X X

Weldings X X X X X

Water box assembly X X X

Shell assembly X X X

Exchanger assembly X X X X X X




7.2 Gas Turbine

Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Str

ess R

el. A

nne

alin

g

Eddy C

urr

ent T

est

ND

T a

t M

at. S

upplie

r

Coating I

nspection

Check A

nal. a

t M

an

uf.

Mate

rial V

erifica

tio

n

Hard

ness T

est

Radio

gra

ph.

Exam

.

Ultra

son

ic E

xa

m.

Magn

etic P

art

icle

Dye-P

en

etr

ation T

est

Etc

hin

g E

xam

ina

tio

n

Sulp

hur

Pri

nt. E

xam

Surf

ace C

rack Inspection

Gra

in S

ize I

nspection

Inclu

sio

n I

nspection

Boro

scope

Inspection

Check o

f w

eld

ing

We

lders

Qua

lific

ation

We

ldin

g P

roced

ure

Repa

ir W

eld

. P

rocedure

ND

T W

eld

s

Dim

ensio

na

l C

heck

Vis

ua

l In

spection

Pre

lim.

Assem

bly

Ch

eck

Therm

al S

tab

ility

Test

Concentr

icity C

heck

Dynam

ic B

ala

ncin

g

Overs

peed T

est

Hydro

sta

tic T

est

Vacuu

m T

est

Leakag

e T

est

Fle

xib

ility

Test

Fin

al A

ssem

bly

Test

Check o

f A

lign

men

t

Check o

f C

leara

nces

Runn

ing

Check

Functio

na

l T

est

Vib

ration T

est

Contr

ol S

etp

oin

ts

Perf

orm

ance T

est

Pain

t/C

oat In

spection

Packin

g Insp

ectio

n

Rotor

Shaft X X X X X X X X X X X X X X

Blading X X X X X X X X X X X X X

Bladed Rotor X a) X b) X X X X X X X X X

Casing

Compressor Casing X X X X X X X X X X X X

Turbine Casing X X X X X X X X X X X X

Vane Carriers X X X X X X X X X X

Combustion Chamber X X X X X X X X X X X X X

Casing Assembly X X X X X X X X

Exhaust Diffuser X X X X X X X X X X X

Burners

Burner X X X X X X X X X

Fuel Lance X X

Fuel System X X

Bearings X X X X X X X

Control Oil Pumps

Control devices: X

Governors, Gov. characteristics X X X

Overspeed Governor X X X

Hydraulic elements X X

Lube Oil Pumps, Tanks and Piping

Main oil pump casing X X

Impeller X X X X X X

Pump assembly

Auxiliary, emergency, turning oil pp: X X X X

Casing X X

Shaft X X

Impeller X X X X

Pump assembly X X X

Cylinder / casing bottle

HP/LP steam inlet pipes X

IP-LP crossing over X




Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Str

ess R

el. A

nne

alin

g

Eddy C

urr

ent T

est

ND

T a

t M

at. S

upplie

r

Coating I

nspection

Check A

nal. a

t M

an

uf.

Mate

rial V

erifica

tio

n

Hard

ness T

est

Radio

gra

ph.

Exam

.

Ultra

son

ic E

xa

m.

Magn

etic P

art

icle

Dye-P

en

etr

ation T

est

Etc

hin

g E

xam

ina

tio

n

Sulp

hur

Pri

nt. E

xam

Surf

ace C

rack Inspection

Gra

in S

ize I

nspection

Inclu

sio

n I

nspection

Boro

scope

Inspection

Check o

f w

eld

ing

We

lders

Qua

lific

ation

We

ldin

g P

roced

ure

Repa

ir W

eld

. P

rocedure

ND

T W

eld

s

Dim

ensio

na

l C

heck

Vis

ua

l In

spection

Pre

lim.

Assem

bly

Ch

eck

Therm

al S

tab

ility

Test

Concentr

icity C

heck

Dynam

ic B

ala

ncin

g

Overs

peed T

est

Hydro

sta

tic T

est

Vacuu

m T

est

Leakag

e T

est

Fle

xib

ility

Test

Fin

al A

ssem

bly

Test

Check o

f A

lign

men

t

Check o

f C

leara

nces

Runn

ing

Check

Functio

na

l T

est

Vib

ration T

est

Contr

ol S

etp

oin

ts

Perf

orm

ance T

est

Pain

t/C

oat In

spection

Packin

g Insp

ectio

n

Pipe work of alloyed material X X

Oil Piping X X X X X X X

Oil Tank X X X X

Oil Purifier X X X X X X

Oil Cooler

Shell X X X X X X

Water Boxes, covers X X

Tube plates X X X X

Tubes X X X X X

Cooler assembly X X X X




7.3 HRSG

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n

Che

ck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Testing of Piping, Valves, Pumps and

Heat exchangers as defined in

Common Systems

Steel Structure

Main Column X X X X X X X X X

Sec. Column X X X X X X

Main Beam X X X X X X X X X

Sec. Beam X X X X X

Main Bolts X X X

Pre-assembly X X X X

Welding electrode X

Carbon Steel Tubes (Low Temp.)

Tube X X X X X

Butt weld of tube X X X X

Tube bundle to be dispatched X X X X X X

Welding electrode X

Carbon Steel Headers (Low Temp.)

Header X X X X X X

Nozzle X X X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n

Che

ck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Butt weld of header X X X X X X

Weld of nozzle/header X X X X X X X

Complete pressure part

to be dispatched

X X X X X X X

Welding electrode X

Alloy Tubes (High Temp.)

Tube X X X X X X

Butt weld of tube X X X X

Tube bundle to be dispatched X X X X X X

Welding electrodes X

Alloy Headers (High Temp.)

Header X X X X X

Nozzle X X X X X

Butt weld of header X X X X X X

Weld of nozzle/header X X X X X X X

Complete pressure part to be

dispatched

X

X

X X X X X


Drum

Plate X X X X X X X

Head X X X X X X X

Nozzle X X X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n

Che

ck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Drum internals X X X X X X

Manhole X X X X X X

Longitudinal weld X X X X X X X

Circumferential weld X X X X X X X

Weld of nozzle/drum X X X X X X

Complete drum to be dispatched X X X X X X X

Welding electrode X

Spray Type Attemperators

Shell X X X X

Inner protection tube X X X X

Nozzle X X X X

Weld of nozzle/shell X X X X

Complete pressure part to be

dispatched

X X X X X X


Burner Equipment

Front plate X X X X X

Parallel flow nozzle X X X X X

Atomizer X X X X X

Swirler X X X X X

Lance gas burner X X X X X

Lighting-up burner X X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n

Che

ck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Welds X X X X

Assembled equipment X X X X X X X X

Forced Draught Fans (if applicable)

Impeller X X X X X X X

Shaft X X X X X X

Casing X X X X X X X

Bearing X X

Lubrication System X X X

Coupling X X X

Fan Assembly X X X X



Book II- Sec J-Rev01 of 69 03-Augs-2015

7.4 Steam Turbine

Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Str

ess R

el. A

nne

alin

g

Eddy C

urr

ent

Test

ND

T a

t M

at. S

upplie

r

Coating I

nspection

Check A

nal. a

t M

an

uf.

Mate

rial V

erifica

tio

n

Hard

ness T

est

Radio

gra

ph.

Exam

.

Ultra

son

ic E

xa

m.

Magn

etic P

art

icle

Dye-P

en

etr

ation T

est

Etc

hin

g E

xam

ina

tio

n

Sulp

hur

Pri

nt. E

xam

Surf

ace C

rack

Inspection

G

rain

Siz

e I

nspection

Inclu

sio

n I

nspection

Boro

scope

Inspection

Check o

f w

eld

ing

We

lders

Qua

lific

ation

We

ldin

g P

roced

ure

Repa

ir W

eld

.

Pro

cedure

N

DT

We

lds

Dim

ensio

na

l C

heck

Vis

ua

l In

spection

Pre

lim.

Assem

bly

Therm

al S

tab

ility

Test

Concentr

icity C

heck

Dynam

ic B

ala

ncin

g

Overs

peed T

est

Hydro

sta

tic T

est

Vacuu

m T

est

Leakag

e T

est

Fle

xib

ility

Test

Fin

al A

ssem

bly

Test

Check o

f A

lign

men

t

Check o

f C

leara

nces

Runn

ing

Check

Functio

na

l T

est

Vib

ration T

est

Contr

ol S

etp

oin

ts

Perf

orm

ance T

est

Pain

t/C

oat In

spection

Packin

g Insp

ectio

n

Chem

ical A

naly

sis

Liquid Penetrant examination can be applied as substitute for Magnetic Particle Examination for the respective items listed. Sulphur Prints on large forgings is not applicable. Etching examination, Grain Size Inspection, Inclusion Inspection for blades is not applicable.

Rotors

Steel Structure

HP, IP rotors only X X X X X X X X X X X X X X

LP rotors only: lashing welds

erosion shields

Blade assembly X X X X

X

Shroud assembly

Disc assembly

Complete rotor assembly X X X X X

Discs X X X X X

X

X

X

X X

X X

Casing

HP, IP cylinders X X X X X X X X X X X X X X X X X X

Horizontal Joint finish

machining

Axial Borings finish machining

Radial Borings finish machining X X

Nozzle chamber, steam inlet X

LP Cylinder X X X X X X X X X X X X X X X

Cylinder / casing bottle X X X X X X X X

HP/LP steam inlet pipes X X X X X X X X X

IP-LP crossing over X X X X X X

Pipe work of alloyed material X X X X X

Steam Bypass Control Valves X X

Valve body X X X

Valve stem, cover bolts

Hard metal surface and joint




Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Str

ess R

el. A

nne

alin

g

Eddy C

urr

ent

Test

ND

T a

t M

at. S

upplie

r

Coating I

nspection

Check A

nal. a

t M

an

uf.

Mate

rial V

erifica

tio

n

Hard

ness T

est

Radio

gra

ph.

Exam

.

Ultra

son

ic E

xa

m.

Magn

etic P

art

icle

Dye-P

en

etr

ation T

est

Etc

hin

g E

xam

ina

tio

n

Sulp

hur

Pri

nt. E

xam

Surf

ace C

rack

Inspection

G

rain

Siz

e I

nspection

Inclu

sio

n I

nspection

Boro

scope

Inspection

Check o

f w

eld

ing

We

lders

Qua

lific

ation

We

ldin

g P

roced

ure

Repa

ir W

eld

.

Pro

cedure

N

DT

We

lds

Dim

ensio

na

l C

heck

Vis

ua

l In

spection

Pre

lim.

Assem

bly

Therm

al S

tab

ility

Test

Concentr

icity C

heck

Dynam

ic B

ala

ncin

g

Overs

peed T

est

Hydro

sta

tic T

est

Vacuu

m T

est

Leakag

e T

est

Fle

xib

ility

Test

Fin

al A

ssem

bly

Test

Check o

f A

lign

men

t

Check o

f C

leara

nces

Runn

ing

Check

Functio

na

l T

est

Vib

ration T

est

Contr

ol S

etp

oin

ts

Perf

orm

ance T

est

Pain

t/C

oat In

spection

Packin

g Insp

ectio

n

Chem

ical A

naly

sis

Throttle X X X X

Valve actuator X X X X

Nozzle chamber X X X X X X X X X

Blades, Diaphragms, Bearings

Rotating blades X X X X X X X X X X X X X X

Last, last but one stage only:

Static + dynamic frequencies

Erosion shield X X X X

Stationery blades X X X X X X X X X X X X X

Diaphragms X X X X X X X X X X X

Borings, horizontal joint X X

Blade steam passages X X

Bearing pedestals X X X X X X

Shells and babbits X X X X X

Shell and babbit bonds

Control Oil Pumps

Control devices: X X

Governors, Gov. characteristics X X X X X X

Overspeed Governor X X X X X X

Hydraulic elements X X X X

Lube Oil Pumps, Tanks and Piping

Main oil pump casing X X

Impeller X X

Pump assembly

Auxiliary, emergency, turning oil pp: X X X X X X X X

Casing X X

Shaft

Impeller X X

Pump assembly X X X X X X

Cylinder / casing bottle

HP/LP steam inlet pipes X X

IP-LP crossing over X X

Pipe work of alloyed material X X X X

Oil Piping X X X X

Oil Tank X X X X X X X X

Oil Cooler




Chem

ical A

naly

sis

Mechan

ica

l T

est

Mic

roscopic

Test

Heat T

reatm

ent

Str

ess R

el. A

nne

alin

g

Eddy C

urr

ent

Test

ND

T a

t M

at. S

upplie

r

Coating I

nspection

Check A

nal. a

t M

an

uf.

Mate

rial V

erifica

tio

n

Hard

ness T

est

Radio

gra

ph.

Exam

.

Ultra

son

ic E

xa

m.

Magn

etic P

art

icle

Dye-P

en

etr

ation T

est

Etc

hin

g E

xam

ina

tio

n

Sulp

hur

Pri

nt. E

xam

Surf

ace C

rack

Inspection

G

rain

Siz

e I

nspection

Inclu

sio

n I

nspection

Boro

scope

Inspection

Check o

f w

eld

ing

We

lders

Qua

lific

ation

We

ldin

g P

roced

ure

Repa

ir W

eld

.

Pro

cedure

N

DT

We

lds

Dim

ensio

na

l C

heck

Vis

ua

l In

spection

Pre

lim.

Assem

bly

Therm

al S

tab

ility

Test

Concentr

icity C

heck

Dynam

ic B

ala

ncin

g

Overs

peed T

est

Hydro

sta

tic T

est

Vacuu

m T

est

Leakag

e T

est

Fle

xib

ility

Test

Fin

al A

ssem

bly

Test

Check o

f A

lign

men

t

Check o

f C

leara

nces

Runn

ing

Check

Functio

na

l T

est

Vib

ration T

est

Contr

ol S

etp

oin

ts

Perf

orm

ance T

est

Pain

t/C

oat In

spection

Packin

g Insp

ectio

n

Chem

ical A

naly

sis

Shell

Water Boxes, covers

Tube plates

Tubes X X

Cooler assembly X X X X X X X X




7.5 Steam Systems

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck



Common Systems

7.6 Condensate & Feed water System

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Feedwater Pumps

Barrel casing X X X X X X X X

Casing cover X X X X X X X X

Nozzle X X X X X X X

Shaft X X X X X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Contact surface X X

Balancing disc X X X X

Balancing counter disc X X X X

Impeller X X X X X X X X

Impeller and rotor X

Nuts X X X X X X X X

Weld seams X X X X X X X X

Stud X X X X X X


Deaerator/ Feedwater Storage

Tank

Plates X X X X X

Stiffening plates X X X X X X

Covers, heads X X X X X X

Tank internals assembly X X X X

Tower + tank assembly X X X X X X X X

Clean Drain Flash Vessel and

Tanks

Shell and head X X X X X X X

Nozzle X X X X X X X

Longitudinal weld X X X X X

Nozzle / tank weld X X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck


Vessel / Tank assembly X X X X X X

Gland Steam Condenser

Shell, water box X X X X X X

Tube plate X X X X X

Tubes X X X X X X X

Condenser assembly X X X X X X

7.7 Fuel Oil System

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck



Common Systems




7.8 Closed Cooling Water System

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck



Common Systems

Circulating Water Pump

Guide blade casing X X X X

Pump casing X X X X X

Shaft X X X X X

Impeller X X X X X X

Wear rings (if applicable) X X

Shaft sleeve X X

Column pipe X X X X

Discharge elbow X X X X


Blade pitch adjustment X




7.9 Instrument and Service Air

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck



Common Systems

Air Compressor

Crankshaft X X X

Connecting rod X X X

Piston rod X X X

Piston X X X

Crankcase X X X X

Cylinder X X X X

Compressor assembly X X X X X X

Cylinder values X X X

Air Drier

Shell plate X X X X

Covers X X X

Tubes-stubs-forged X X X

Tank assembled X X X

Drier assembly X X X X X X X

Air Cooler

Shell plate X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Covers X X X X

Tube sheet X X X X

Stubs-flanges X X X X

Tube bundle X X X X X X X

Shell assembled X

Tank separator X X X X X

Unit assembly X X X X X X

Air Receiver

Shell plates X X X

Covers X X X

Stubs-flanges X X X

Welding shell-covers X

Receiver assembly X X X X X X X X

Safety valve X X




7.10 Fire Fighting System

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Piping (various) X X X X X X

Drain valves X X X X X X

Butterfly valves X X X X X X

Motorized butter fly valves X X X X X X X

Gate valves X X X X X X

Check valves X X X X X X

Overflow valves X X X X X X

Solenoid valve X X X X

Manometer X X X X

Safety valve X X X X X X X

Spray nozzle X X X X

Automatic sprinklers X X X

Heat detector X X X

Fire detectors X X X

Gas detector

Fire alarm control X X X X

Bottle (CO2) X X X X X X X

Fire water storage tank X X X X X X X X

Pressure tank X X X X X X X X

Fire fighting pumps X X X X X X X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Driver for FF pumps X X X X

Jockey pump unit X X X X

Fire pump controller X X X X

7.11 De-mineralized Water Plant and System

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Testing of Piping, Valves, Pumps

and Heat exchangers as defined in

Common Systems

Mixed Bed Filter

Plate X X X X

Head X X X X

Nozzle X X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Longitudinal weld X X X X X

Circumferential weld X X X X X

Weld of nozzle / vessel X X X X

Complete filter X X X X X

Rubbing X X

Welding material X

7.12 Cranes and Hoists

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Gantry Crane

Main girder X X X X X X X

Welding preparation X X X

Drum X X X X X

Drum shaft X X X




Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Rope X X X X X

Hook X X X X X

Bolts and nuts X

Reduction unit X

Trolley frame X X X X

Electric motor X X

Control panel X X X

Assembly crane X X

Turbine Hall Crane

Main girder X X X X X X X

Welding X X X

Drum X X X X X

Drum shaft X X X

Rope X X X X X

Hook X X X X X X

Bolts and nuts X

Reduction unit X

Trolley frame X X X X

Electric motor X X

Control panel X X X X

Assembly crane X X




7.13 Air Conditioning and Ventilation

Che

mic

al A

na

lysis

Me

ch

an

ical T

est

Mic

rosco

pic

Te

st

Hea

t T

rea

tmen

t

Fla

tten

ing

Test

Fla

ring

Test

Ed

dy C

urr

en

t

Ma

teria

l C

ert

ific

ate

We

ld P

rep

ara

tio

n

Ma

teria

l Id

entifica

tio

n

Hard

ne

ss T

est

Rad

iog

rap

hic

Exa

m

Ultra

son

ic T

est

Ma

gne

tic P

art

Te

st

Dye

-Pe

netr

atio

n T

est

We

lde

rs Q

ualif

ica

tio

n

Che

ck o

f W

eld

ing

Wo

rk

Pre

ssu

re T

est

Fu

nctio

n T

est

Vib

ratio

n C

he

ck

Ba

lancin

g

Ba

ll T

est

Va

lve C

ha

racte

ristic

Tig

htn

ess /

Le

aka

ge

Su

rfa

ce

Pre

pa

ratio

n

Corr

osio

n I

nspe

ctio

n

Vis

ual/D

ime

nsio

n C

heck

Fin

al In

sp

./D

oc C

heck

Inspe

ctio

n o

f P

ackin

g

Assem

bly

Ch

eck

Electric motor X X X

Heat exchange battery X X

Fans X X X

Electric panels X X X

Refrigerator X X

Pumps X X X X X

Piping X X X X X

E-Heaters X X

Tanks. valves X X X X

Insulation X

Ducts, dampers, louvers X X

Single complete plant X X X X

Book II Section J_Quality Management

Documents

Transcript of Book II Section J_Quality Management