Pttme SP T 001 000

PTT Maintenance and Engineering CO., LTD.
STANDARD SPECIFICATION FOR
SHOP INSPECTION & TESTING

DOCUMENT NO. PTTME-SP-T-001
REV.
ISSUED DATE
DESCRIPTION
REV. TO SHEET
ADDED SHEET
MADE BY
CHECK BY Niwat R.
APPROVE BY Weerachat I.
9 June 2010
First Issued
TOTAL PAGES
47
(INCLUDED THIS PAGE)
PTME-SP-T-001 PAGE 2 OF
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SECTION 1. SCOPE
CONTENT
PAGE 3
2.
GENERAL
3.
VESSELS (PRESSURE VESSELS, HEAT EXCHANGERS, AIR COOLERS, STORAGE TANKS, DEAERATORS, FLARE SYSTEM)
4.
MECHANICAL EQUIPMENT
5.
STRUCTURAL STEEL
20
6.
PIPING
22
7.
INSTRUMENTATION
24
8.
ELECTRICAL AND COMMUNICATION EQUIPMENT
34
9.
FIRED PROCESS HEATERS
43
10.
COOLING TOWERS
45
11.
STEAM GENERATORS
46
12.
MISCELLANEOUS ITEMS
47
13.
PACKING
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1.
SCOPE
1.1
This specification covers the basic requirements for inspection and testing of equipment, materials and supplies in the manufacturer's workshops to be performed and to be guaranteed by the CONTRACTOR. The scope of inspection and testing described in this specification does not claim to be complete. The CONTRACTOR is responsible to cover in his detailed Inspection Specification all necessary inspection and testing requirements to guarantee that all equipment, materials and supplies are of first class quality and quantity as specified and required. In addition, CONTRACTOR's Inspection Specification shall show the CONTRACTOR's inspection organization.
The CONTRACTOR's Inspection Specification is subject to review by the COMPANY.
1.2
This specification is in general accordance with the relevant Project Specifications for equipment, materials and supplies and enlarges these specifications.
1.3
Irrespective of the results of any inspections and tests, the CONTRACTOR shall retain the primary responsibility for the quality and quantity of all equipment, materials and supplies.
2.
GENERAL
2.1
Percentage Extent of Inspection and Testing
The inspection and testing percentages are related to the items of supplies and shall not indicate the degree of inspection to be performed, e.g. :
a) Where 100 % inspection is specified, each item shall be inspected. b) Where 10 % inspection is specified, only 10 % of the total quantity of items purchased on each order shall be inspected. Wherever less than 100 % inspection is required, at least one item shall be examined.
Vendor shall retain his full inspection responsibility for the quality of the purchased equipment and materials in regardless of the percentage extent specified.
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2.2
Inspection Schedule
The CONTRACTOR shall provide the COMPANY a monthly updated inspection/testing schedule showing in detail inspection dates of all items to be purchased/handled. The COMPANY will review this inspection schedule and inform the CONTRACTOR about the scope of intended inspections.
2.3
Inspection Notification
The CONTRACTOR shall give the COMPANY at least 20 days notice in writing of the date and place at which the equipment, materials or supplies will be ready for inspection.
20 days notice shall be read as 25 days notice in order to bring 20 days advance notice for PTTME timely.
2.4
Rejections
The CONTRACTOR shall reject equipment and material which :
do not comply with the requirements of the purchase order cannot be identified in any applicable specification are of unacceptable workmanship are damaged by transport or shipping
2.5
Inspection Reports
The CONTRACTOR shall issue inspection reports of each inspection performed and submit these to the COMPANY. Any problem that could affect quality or delivery time should be marked, showing the reason and the actions to be taken to solve the problems.
Inspection reports defined herein shall be understood as data, records and certificates which are prepared by Vendor and compiled in the inspection dossiers.
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2.6
Inspection Agency
Independent of CONTRACTOR's engaged Third Party Inspection Agency the COMPANY reserves the right to engage an Independent Inspection Agency to Provide a Quality Control Service on his behalf to inspect and witness tests in the manufacturer's workshops to ensure compliance with the requirements of the applicable Codes, Standards and Project Specifications.
2.7
Shop visits by the COMPANY
If the COMPANY or the Inspection Agency intends to visit any manufacturers together with the CONTRACTOR, this will be arranged by the CONTRACTOR (refer to Para 2.3)
The CONTRACTOR shall take care that the COMPANY / Inspection Agency will have free access to the manufacturer's workshops at all reasonable time. Inspections by the COMPANY / Inspection
Agency shall in no way relieve the CONTRACTOR of his responsibility as mentioned in Para 1.3.
2.8
Testing and Inspection Procedures
The CONTRACTOR shall review the manufacturer's testing and inspection procedures established for the CONTRACTOR's purchase orders. Final procedures shall be submitted to COMPANY 4 weeks before shop inspection takes place.
Contractor used in this paragraph shall be understood as Purchaser but not as Vendor.
Vendor shall submit such testing and inspection procedures according to documentation schedule as per requested by Purchaser.
2.9
Supplements to Purchase Orders and Spare Parts
All supplements to purchase orders and all spare parts shall be tested and inspected as stipulated in this specification.
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2.10
General Inspection Activities
The following activities have to be performed by the CONTRACTOR in general :
- Check manufacturer's drawings and calculations to ensure correctness and compliance with the specifications and Codes.
- Review the manufacturer's established quality control procedures and monitor the efficient application thereof by the manufacturer's staff.
- Review the manufacturer's fabrication plan with the manufacturers to establish hold points for inspection before fabrication starts.
- Collect the required number of equipment test dossiers from each manufacturer. Verify that the contents are complete and correct.
3.
VESSELS (PRESSURE VESSELS, HEAT EXCHANGERS, AIR COOLERS, STORAGE TANKS, DEAERATORS, FLARE SYSTEM)
3.1
General
Each vessel and the materials used in the fabrication thereof shall be tested and inspected for conformance with the requirements of the applicable Codes, of the CONTRACTOR's detailed Specifications including Project Specification requirements, and of this specification.
3.2
Additional Inspections
Additional inspections by the CONTRACTOR shall include but not be limited to the following :
- Review welding procedure qualification and welders' performance qualification records.
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- Record diameters of tube holes in tube sheets as fabricated and compare them with TEMA requirements.
- Witness non-destructive testing on weld seams: Liquid Penetrant Examination (PT), Magnetic Particle Examination (MT), Ultrasonic Examination (UT), Hardness Testing (at random, but min. 10 %)
- Review radiographs (at random, but min. 10 %)
- Review postweld heat treatment records.
- Ensure that repairs are welded and tested only to approved and qualified procedures.
- Carry out final inspection including check of dimensions and quality of workmanship.
- Audit the performance of the appointed Inspection Authority.
4.
MECHANICAL EQUIPMENT
4.1
General
- Inspection and Tests shall be governed by the relevant sections of API, ISO, NFPA, IGC-Standards and by the Project Specifications.
- The supplements and modifications in this Specification shall have precedence over API, ISO, NFPA, IGC.
- The term "Purchaser" as per API means CONTRACTOR. Deviations from this specification and/or from the corresponding Standards (for example API, ISO) shall be approved by COMPANY.
- All Project Specifications Referring to Standards mentioned in the relevant API sections shall also be applicable.
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- Reference paragraph numbers are shown for all modifications, substitutions and additions to, or deviations from API, ISO, NFPA, IGC-Standards the all paragraphs not mentioned remain fully valid. The kind of change is shown in brackets behind the paragraph.
- Detailed test procedures shall be prepared by the CONTRACTOR and submitted to the COMPANY not later than 4 weeks before the first shop inspection tests.
Vendor shall submit such test procedures according to documentation schedule as per requested by Purchaser.
4.1.1
Heavy Duty Pumps acc. to API-610
Section 4 - Inspection and tests.
4.3.1.3
(clarification)
1.
Witnessed hydrostatic test acc. to S 4.3.2 shall be performed for pumps in critical services in accordance with Project Specification PTTME-SP-M-021 Special process requirements for machinery equipment.
2.
A witnessed performance test acc. to S 4.3.3 shall be carried out for each pump.
3.
Witnessed NPSH-test acc. to S 4.3.4 shall be performed for all pumps if the difference between NPSHA and NPSHR is equal to or less than 1.0 meters.
4.3.3.3
(addition)
The test speed of the pumps shall be equal to the rated speed of the pump.
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4.1.2
General Duty Pumps
Inspection and Tests shall be performed acc. to API-610 Standard, 6 Edition, Jan. 1981 and to the clarifications and additions mentioned under Point 4.1.1.
4.1.3
Positive displacement Pumps - Reciprocating - acc. to API 674
Section 4 - Inspection and Tests
4.2.7
(clarification and modification)
Paragraph 4.3.3.7 of API 614, Second Ed. Jan. 84 shall apply.
4.3.1.6
(clarification)
1.
Witnessed and certified performance test acc. to S 4.3.3 or 4.3.4
2.
Certified hydrostatic test in acc. with S 4.3.2
5.
Pumps shall only be dismantled in case of mechanical failure during the test run.
4.3.4.3
(Addition)
The test speed and discharge pressure of the pumps shall be equal to the rated speed and pressure of the pump.
4.1.4
Positive Displacement Pumps - Controlled Volume - (Metering Pump) acc. to API 675
Section 5 - Inspection and Testing
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5.2.2.1
(Addition)
Hydrostatic test shall be certified.
5.2.3
(Addition)
Performance test shall be witnessed and certified.
5.2.3.4
(clarification)
Flow repeatability and linearity shall be demonstrated during performance test.
4.1.5
Positive Displacement Pumps - Rotary - acc. to API 676
Section 4 - Inspection and Tests
4.3.2
(Addition)
Hydrostatic test shall be certified.
4.3.4.1
(Addition)
Witnessed and certified performance test shall be carried out.
4.3.4.4
(Addition)
Performance data and curve shall be supplied.
4.1.6
Fire Water Pumps acc. to NFPA 20, Edition 1983
Section 2 - 15 Shop Tests
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2-15.1
(clarification)
Each pump shall be tested acc. to API 610, 6th Edition, Jan. 1981 and to the clarification and additions to section 4 Inspection and Tests shown under Point 4.1.1 for Heavy Duty Centrifugal pumps.
2-15.2
(Addition)
Hydrostatic test acc. to API 610 S 4.3.2 shall be performed and certified.
4.1.7
Diesel Engines acc to DEMA and NFPA
4.7.1.1
The following witnessed and certified tests shall be performed as a minimum:
a)
Performances test of engines acc. to
ISO 3046/I 1984-10 -01
- Standard reference conditions and declarations of power, fuel consumption and Lubricating oil consumption.
ISO 3046/II 1977-10-01 ISO 3046/III 1979-02-01 ISO 3046/IV 1978-09-01 ISO 3046/V 1978 ISO 3046/VI 1982
- Test methods
- Test measurements
- Speed governing
- Torsional vibrations
- Overspeed protection
4.1.7.2
Hydrostatic pressure test - Certificates of cylinders and cooling-chambers shall be furnished.
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4.1.8
Centrifugal Compressors acc. to API 617
4.1.3
(clarification)
The following Tests shall be witnessed and certified as a minimum:
a)
Hydrostatic test of pressure containing parts acc. to S 4.3.2
b)
Tracer-gas test of casing
c)
Overspeed test of each impeller acc. to S 4.3.3
d)
Mechanical running test for spare and mainrotor as specified in Project- Spec. PTTME-SP-M008 and acc. to API S 4.3.4
e)
Clearance check and record with main- and spare rotor after mech. test run.
f)
Performance test of mainrotor.
g)
During the test run the critical speed of the rotor shall be demonstrated.
4.3.6
(Addition)
1.
Performance test shall be performed acc. to ASME Power Test Code 10 Class III as a closed loop test.
2.
Complete unit test shall be performed with gears, if applicable.
7.
Post-test inspection of main- and spare rotor incl. clearance record after mechanical test run has to be carried out.
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4.1.9
Screw Compressors for instrument air
4.1.9.1
General
The test of the screw compressor shall be performed according to API 619, First Edition, Sept. 1975.
4.1.9.2
API 619 Section 4 - Inspection and testing
The following test shall be witnessed and certified:
a)
Mechanical running test with air acc. to S 4.2.3
b)
Performance test acc. to S 4.2.4
4.1.9.3
API 619 S 4.2.4 (Additional)
Paragraph 4.2.4 of optional tests shall apply completely, with the exception of Point 5, Post Test Inspection.
4.1.9.10
Lube - and Seal Oil System acc. to API 614 for Process Compressors.
4.3.2.7
(new Paragraph)
All hydrostatic tests shall be certified.
4.3.3
(clarification)
Operational tests of the oil system shall be witnessed and certified.
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4.3.2.4
(additional)
For all components to be considered as pressure vessels Inspection and Tests shall be in acc. with Chapter 3 of this Specification.
4.1.11
Centrifugal fans acc. to API 673
4.1.3
(clarification)
The following test shall be witnessed and certified as a minimum.
a)
A tracer-gas test shall be carried out for fans handling toxic or harmful gases and local environmental requirements shall be taken into account.
b)
A performance test acc. to S 4.4.1
4.4.1
(additional)
Performance test shall be carried out acc. to ASME POWER TEST CODE 11.
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4.1.12
Special - Purpose Steam Turbines acc. to API 612.
4.3.2
The following tests shall be witnessed and certified as a minimum:
a)
Hydrostatic test of pressure parts acc. to S 4.3.3.
b)
Mechanical running test acc. to S 4.3.4 for the main and spare rotor as specified in Project Spec. PTTME-SP-M-012, Section 4.
c)
clearance check and record of main-and spare rotor after mech. running test in the turbine casing.
d)
During the test run, the critical speed of the rotor shall be demonstrated.
4.2.10
(New Paragraph)
Balancing reports of main an spare rotor shall be certified.
4.1.13
General - Purpose Steam Turbines acc. to API 611
4.2.1.5
(clarification)
a)
Hydrostatic test acc. to S 4.2.2 for turbine drives of critical equipment.
b)
Mechanical running test acc. to S 4.2.3 for main and spare rotor as specified in Project Specification PTTME-SP-M-13, Section 4.
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c)
Clearance check and record of main- and spare rotor after mech. running test in the turbine casing for multistage turbine.
d)
For multistage turbines, the critical speed of the rotor during the test run shall be demonstrated.
4.1.14
Special purpose gear units acc. to API 613
4.1.1.5
(Addition)
Certified reports of tooth hardening shall be verified.
4.2.1.2
(clarification)
The following Tests shall be witnessed as a minimum:
a)
Mechanical running test acc. to S 4.2.3.
b)
Post-Test inspection of gear teeth and bearings.
4.2.3 1.
(Addition) Gears shall be tested at full load and full speed.
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4.1.15
Instrument Air Dryer
4.1.15.1
All pressure parts, such as absorbers, heaters, filters etc. as shown in Chapter 3 of the Project Specification shall be hydrostatically tested.
4.1.15.2
The following witnessed and certified tests shall be performed.
a)
Test run of the completely assembled unit to check mechanical and functional properties.
4.1.16
Industrial Combustion Gas Turbine acc. to API 616
Section 4 - Inspection and testing
4.3.1.2 (clarification)
a)
Hydrostatic test of all pressure part acc. to S 4.3.2
b)
Balancing test of main and spare rotor
c)
Mechanical test acc. to $ 4.3.3 for the main and spare rotor as specified in Project Specification PTTME-SP-M-016, Section 4
d)
Post-Test-Inspection of machine and bearing.
4.3.4
(Addition)
6.
A post-Test-Inspection of gasturbine for main and spare rotor incl. clearance report shall be performed.
7.
Post-Test-Inspection of bearings after mech. running test are necessary.
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4.1.17
Reciprocating Compressor for Oxygen Service acc. to IRC 10/81
Section 5 - Inspection, Dispatch and testing
5.4.1
(Clarification)
All pressure parts shall undergo a witnessed and certified hydrostatic test according to Project Specification PTTME-SP-M-017.
5.4.2
(clarification)
A witnessed and certified porosity and leakage test (Tracer-gas test) shall be performed.
5.4.3
(Addition)
A witnessed and certified running-in and mechanical integrity test shall be performed at the manufacturer's workshop.
4.1.18
Air conditioning and Ventilation
The following tests and inspections shall be performed and certified as a minimum :
4.1.18.1
Fans and Air-handling units
a)
Mechanical test run of supply and exhaust air fans shall be performed and certified.
b)
witnessed functional tests of air handling units shall be carried out.
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4.1.18.2
Cooling compressors
a)
A witnessed performance test of the cooling compressor shall be carried out and certified as a closed loop test for the entire unit.
b)
For all components to be considered as pressure vessels, Inspections and Tests shall be in acc. to Chapter 3 of this specification, if applicable. Deviations shall be approved by the COMPANY.
4.1.19
Cranes and Hoists
4.1.19.1
In addition to the check of completeness, the following inspections shall be carried out:
- Functional check to bottom-flange mounted and two-beam trolleys
- Check the following dimensions: - track gauge, wheel base including clearance - length of end girders across buffers - overall dimensions for crane passage - highest hook position - trolley clearance
- Visual check to workmanship of - bottom flanges, hooks, ropes, equalizing rolls - power supply (cable, cable buggy, power pick-up, bars) - safety equipment (wind protection, limit switches) - control panel - electric installation - railings
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- Check the contents of the following documentation - crane inspection book - rope and hook certificates - general drawings - lubricating plan - operating instructions.
4.1.19.2
Scope of Inspections
Structural Steel Portion of equipment
100 %
Mechanical portion, (such as drives, wheels)
100 %
Electrical portion
100 %
Accessories such as operating units
100 %
5.
STRUCTURAL STEEL
5.1
General
Structural Steel shall be tested and inspected for conformance with the requirements of the applicable Codes, of the CONTRACTOR's detailed Specifications including Project Specification requirements, and of this specification.
5.2
Steel Structures, Hold-down and Internal Parts
In addition to the check of completion, the following inspections shall be carried out.
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- Check contents of certificates: - Material Certificates - Qualification documents for welders and welding procedures as per AWS D 1.1 - Results of non-destructive tests as per AWS D 1.1
- Check the - main and connection dimensions - connection points on frame-type structures - base rings (without brackets) of column platforms
- Visual check of - proper workmanship on finished parts as per AWS D 1.1 - Surface prior to painting (derusting) - first prime coat - preservation
- Measure thickness of first prime coat.
Scope of Inspections
Columns, beams, trusses, purling, bracings, for pipe racks and structures
10 %
Frame Corners
100 %
Mounting plates
100 %
Hold-down and internal parts
100 %
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6.
PIPING
6.1
General
Piping components and/or piping, materials and semi-finished parts shall be tested and inspected for conformance with the requirements of the applicable Codes, of the CONTRACTOR's detailed specifications including Project Specification requirements, and of this specification.
6.2
Additional Tests and Inspections
The CONTRACTOR shall be required to maked the following minimum scope of tests and checks:
- Ascertain whether any necessary qualification documents for welders and welding procedures are available.
- Visual check of the marking for correctness, completeness and proper execution. - Ascertain whether the specified scope of material tests has been carried out and whether the materials have not given rise to objections.
- Check the material certificates for correctness and completeness.
- Check heat treatment records.
- Check whether the documentation can be clearly assigned to the components.
- Visual check for proper execution.
- Check the main overall dimensions.
- Pressure test and leak checks of valves.
- Check whether any tests by an official inspection authority have given rise to objections.
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6.3
Scope of inspection
- Welded pipes - seamless pipes - Flanges - Fittings - Bolts - Gaskets - Valves - Safety valves - Thermal expansion valves - Strainers - Dirt traps - Inspection glasses - Liquid level gauges - Expansion joints - Spring hangers - Insulation materials and paint - Hangers and supports - Special purpose items
10 % 2% 2% 2% 1% 1% 2% 10 % 2% 2% 2% 2% 10 % 10 % 2% 2% 1% 2%
The percentage is related to each size and each manufacturer.
Percentage indicated herein is defined as the extent of shop inspection and tests to be performed by Purchaser.
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7.
INSTRUMENTATION
7.1
General
This specification shall be applicable to the inspection and testing of all instrumentation in the manufacturer's works.
7.2
Types of inspections and tests
The inspections and tests stated below have to be conducted one the basis of the applicable standards, project specifications, data sheets, arrangement drawings and dimension sketches. Moreover, a completeness check has to be carried out.
7.2.1
Pressure, Differential Pressure, Temperature and Level Transmitters. - Visual check of - type data and identifications - connections - accessories
- Check of - main dimensions - connecting dimensions - material data - measuring and signaling ranges
7.2.2
Flow Measuring Instruments
- Visual check of - type data and identifications - connections
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7.2.3
Pressure Gauges, Thermometers, Level Gauges
- Visual check of - type data and identifications - connections - accessories
- Check of - main dimensions - connecting dimensions - material data - measuring ranges
7.2.4
Analysis Systems
- Visual check of - type data and identifications - connections - accessories - measuring method
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- Functional test of the analyses system
7.2.5
Distributed Digital Control System
- Visual check of - type data and identification - peripheral equipment - cable connections
- Functional tests of - I/O functions - control configuration - displays of measurements trending reporting graphics with live data
- Check of alarm settings interlocking, calculations advanced control algorithm
- Check of redundancy functions of controllers, busbars, CPUs and power supply.
- Check of max. ambient temperatures in the cabinets after 24 hours of operation.
- All checks to be carried out with the original equipment.
7.2.6
Panel Instruments
- Visual check of - type data - lettering and identification
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- scales - connections - accessories
- Check of main dimensions
- Functional tests of the signaling range for - correct indication - output signal - behavior in the event of failures
7.2.7
Correction Units (control valves) with Accessories
- Visual check of - type data and identification - connections - attached accessories
- Check of - main dimensions - connecting dimensions - material data - pressure and leak tests
- Functional test for - valve stroke - valve characteristic (CV-values) - behavior in the event of failure
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7.2.8
Control Panel, Semi-graphic Panel, Consoles, Local Panel, Instrument and System Cabinets
- Visual check of - design and execution - ease of access and operation - type data and identification of internals - wiring and terminal connection - venting
- Check of - main dimensions - overall and cut-out dimensions - mimic diagram - power supply
- Functional test for - instrument loops - displays - alarms - behavior in event of failure - under simulating of inputs and outputs
7.2.9
Cables and Wires
- Visual check of the cable drums for - proper condition and marking - cable type and specified length
- Visual check of cables for - conductor and insulation execution according to type - conductor diameter - sheath color
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- color and identification of the conductor insulation and/or individual tubes - protection by means of end caps
- Check of conductor and cable outside diameters
- Tests of the electric cables for - dielectric strength - insulation resistance - resistance, capacity and inductance
- Testing of the pneumatic cables/tubes for - pressure resistance - continuity
7.2.10
Installation Material
- Check - for grouping and identification - of main dimensions - of connecting dimensions - of surface finish - of material data
7.2.11
Spare Parts
- Check - for grouping and identification - of main dimensions
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7.3
Scope of Inspections and tests
The detailed scope of inspections and tests has to be shown in the checklists for the relevant equipment. The checklists have to be prepared by the Contractor.
The following percentage scope of visual checks, dimensional checks and functional tests shall be carried out :
Percentage indicated herein is defined as the extent of shop inspection and tests to be performed by Purchaser.
object
Visual check
Dimensional check
Functional test
7.3.1
pressure and Differential Pressure Measuring Instruments
- Pressure gauges - Transmitters
100 % 100 %
10 % 10 %
5% 5%
7.3.2
Level Measuring Instruments
- Transmitters - Float switches
100 % 100 %
100 % 100 %
10 % 5%
7.3.3
Temperature Measuring Instruments
- Thermo wells - Thermometers - Resistance thermometers, thermocouples - Transmitters
100 % 100 % 100 %
100 % 100% 100 %
5% 5%
100 %
5%
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- Transmitters with primary elements and capillaries object
100 %
100 %
10 %
Visual check
Dimensional check
Functional test
7.3.4
Flow Measuring Instruments
- Orifice plates, Restriction orifices - Flow meter - Vol. meter with accessories - Inductive flow meter - Metering stations
100 %
10 %
- %
100 % 100 %
10 % 10 %
10 % 100 %
100 %
100 %
as agreed
100 %
100 %
as agreed
7.3.5
Analysis Systems
100 %
as per manuf. instructions or as agreed
7.3.6
Distributed Digital Control Systems
100 %
100 %
7.3.7
Panel Instruments
- Electric and pneumatic instruments and systems
100 %
10 %
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object
Visual check
Dimensional check
Functional test
7.3.8
Correction Units (control valves)
- Control valve with diaphragm actuator - Control valve with electromotoric / solenoid / hydraulic actuator - Butterfly valve with actuator - Direct acting valve - Solenoid valves in air lines
100 %
100 %
10 %
100 %
100 %
10 %
100 %
100 %
10 %
100 % -
100 % 10 %
10 % 5%
7.3.9
Control Panel,Semigraphic Panel, Local Panel and Desks
100 %
main. dimension connecting dimensions
as agreed
7.3.10
Instrument and System Cubicles
100 %
main. dimension connecting dimensions
as agreed
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object
Visual check
Dimensional check
Functional test
7.3.11
Alarm, Interlocking and shutdown system
100 %
100 %
7.3.12
Installation Material
as agreed
such as electric cables and wires pneum. cable & signal lines impulse lines couplings, fastening materials and sundries cable trays air sets junction boxes & marshaling cabinets special tools
7.3.13
Spare Parts
as agreed
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8.
ELECTRICAL AND COMMUNICATION EQUIPMENT
8.1
General
8.1.1
All inspections and test shall be carried out according to the applicable IEC-Standards - which shall have priority - followed by certain national standards as specified in project specification PTTCHEMSP-E-001.
8.1.2
The equipment and its associated components shall be temporarily set up together to test their functions, simulation of all remote control signals, etc. shall be ensured.
8.2
Inspection / Testing Procedure
8.2.1
In principle, the following inspections/tests shall be carried out: - Completeness check
The quantities as supplied shall be compared with the ordered quantities either by counting, measuring or weighing, and by comparison of the quantities with the specification.
- Inspections/tests for proper workmanship and design
These inspections/tests are to ascertain conformity of workmanship, dimensions, materials, load characteristics, performance and output of the item with the requirements of the specification.
8.2.2
In addition to a check of completeness, the following inspections/tests shall be carried out on the basis of dimension drawings, arrangement drawings and technical specifications :
8.3
Power Transformer : - Visual inspection - of the taps - of accessories - of safety devices
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Physical check of general appearance and finish. Mechanical assembly including good welding, full nuts on bolted parts, undamaged condition and general suitability.
Check of cable termination locations, direction, type of terminals according to the specification.
Correctness of data and diagram on rating plate.
- Check of mains dimensions
- Mechanical inspection
Proper mechanical and electrical operation of auxiliary equipment such as tap changers, breathers, shut-off valves, meters, indicators, relays, etc.
- Electrical tests to check
a) Tapping and tapping range b) Parallel operation (if necessary) c) Impedance voltage d) Secondary rated voltage off load cos phi = 0.85 e) Secondary rated voltage at 4/4 load cos phi = 0.85 f) Excitation current at the rated voltage g) Rated voltage ratio and proof of polarity or vector group h) Primary winding insulation measurement i) Secondary winding insulation measurement j) Primary winding test at 50 Hz k) Secondary winding test at 50 Hz l) Primary winding test induced voltage at increased frequency m) Copper losses measurement n) Iron losses measurement o) Noise level p) Efficiency for load equal to cos phi = 1 and 0.8
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8.4
Generator
- Visual inspection - of nameplate data - of terminal boxes and cable glands - of attached accessories
- Check of dimensions
- Mechanical inspections with respect to - proper mechanical and electrical operation of auxiliary equipment such as anticond. heatings, shut-off valves, meters, indicators, relays, etc.
- Electrical tests No-load characteristic. Short-circuit characteristic. Copper and iron losses measurement. Heat run under no-load conditions at rated voltage. Heat run under overload conditions. Heat run under short-circuit conditions at rated current. Heat run of the bearings. Testing the rotating field. Measurement of cold resistance. Measurement of the sine curve. Shaft voltage. Overspeed test. Winding test. Stator/rotor/excitation high-voltage-test. Noise level. Air gap/ magnetic center. Controller and functional test of excitation. Measurement of the time required for excitation and de-energizing.
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8.5
Switchgear and Controlgear :
- Visual inspection - for proper workmanship - of equipment and terminal designations
- Check of main dimensions
- Mechanical inspections with respect to - easy movement and replaceability of truck-type switchgear and plug-in units - interlocking systems
- Electrical tests inspect racking, closing and trip mechanisms. inspect the alignment of contacts, observe the closing operation. check wiring between all terminations in accordance with the schematic diagrams. Check current transformer ratings and compare with approved drawings.
Primary injection tests shall be made to try current transformer and associated wiring. The resulting secondary circuits shall be measured to check ratio, group and polarity.
Check proper mechanical and electrical operation of all relays and meters. Note as applicable : a) b) Correct type and rating Labeling and phase colors
Selected overload relays should be checked by current injection. The coil should first be heated by passing rated current for 15 minutes, after which time it should be increased by after which time it should be increased by 15 %. checked by current and/or voltage injection. Selected protection relays should be
The relay should operate within its rated time curve.
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Functional test (control loops, automatic, interlocks, alarms) High voltage test. Insulation measurement.
8.6
Motors
- Visual inspection - of nameplate data - of terminal boxes and cable glands - of attached accessories
- Mechanical inspections with respect to - proper mechanical and electrical operation of auxiliary equipment such as anticond. heating, shut-off valves, meters, indicators, relays etc.
- Electrical tests a) Measurement of no-load current. b) Measurement to allow calculation of locked rotor current. c) Measurement of winding resistance. d) Overspeed test. e) High voltage test plus insulation resistance immediately f) Inspection of bearings and mechanical operation of motor at no-load. g) Measurement of shaft and float. h) Measurement of slip at full load. i) Measurement to allow calculation of breakdown torque. j) Measurement to allow calculation of starting torque. k) Measurement to allow calculation of efficiency at full, three quarter and half load. l) Measurement to allow calculation of power factor at full, three quarter and half load. m) Vibration. Peak-to-peak amplitudes. n) Noise measurement.
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o) Full load heat run. p) Inspection of bearings and mechanical operation of motor at full load.
8.7
UPS-Systems, Rectifiers, Inverters, Batteries
- Visual inspection of equipment nameplates
- Electrical tests to check (excluding batteries) - the proper functioning - the insulation of control circuits
The combined equipment shall be given a full load 24 hour run. This shall end in the presence of the Inspector. The temperature rise of all major wound components, main thyristors and diodes shall be measured and recorded throughout the test. Checks shall also be made to establish that other components and any parts of the cubicle are not overheating. The output voltage and frequency shall be recorded throughout the run to give an indication of drift.
During or before the inspection, oscillographs shall be taken of the input voltage waveform to record the effect of the following :
a) when switching from inverter to by-passes b) when switching for by-passes to inverter, c) mains failure, d) inverter failure.
A harmonic analysis of the output voltage waveform shall be carried out before the inspection date, giving the percentage harmonic distortion. These measurement shall be make at no-load, half-load and full load at specified power factor with three levels of input voltage, minimum, nominal and maximum.
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Output voltage shall be checked over the input voltage range at no load and full load at specified power factor. The function of all alarm circuits shall be checked.
Insulation resistance at the input and output terminals shall be checked.
Effect of inverter short-circuit shall be checked.
8.8
Control stations, Switches, Socket Outlets
- Visual inspection of - ratings - cable glands (random checks) - item designations.
- Functional test
8.9
Lighting Fittings
- Visual inspection of - types - built-in components - cable glands
- Electrical tests to check - the proper functioning - the insulation.
8.10
Communication systems, Fire alarm systems:
- Visual inspection of nameplates
- Check of cabinet dimensions
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- Electrical test to check - proper functioning of the central units together with a selected number of apparatus, e.g. call station, loudspeaker, alarm device.
8.11
Cables
- Visual inspection of cable drums to check the quality, rim encasing and marking
- Voltage test (random check)
- Check of outer diameter of each cable type
- Visual inspection of sealing ends fitted for shipment.
8.12
Installation Material ( Cable trays etc. )
- Visual inspection to check proper workmanship.
8.13
Scope of Inspection / Tests
Percentage indicated herein is defined as the extent of shop inspection and tests to be performed by Purchaser. Completeness Check - Power Transformer - visual inspections, dimensions checks, mechanical tests - electrical tests a...f + m...p electrical tests g...l one of each type 100% 100% Inspection / Tests 100%
- Generator : - visual inspection
100% -
100%
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- mechanical test - electrical test noise measurement
50% 100% one of each type
- Switchgear and Controlgear : - visual inspections, dimensions checks, mechanical and functional test - all electrical tests
100% -
100%
100%
- Motors : - high-voltage motors: - visual inspection - mechanical test - electrical tests a...l electrical tests m...p - low voltage motors : - visual inspection 100% 100% 100% 50% 100% one of each type 50%
- UPS-system, Rectifiers, Inverters, Batteries: - visual inspections, dimension checks, mechanical and functional tests - all electrical tests
100%
100%
100%
- Control Stations, Switches Socket Outlets :
100%
15%
- Lighting Fittings :
100%
10%
- Communication and
100%
30%
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Fire Alarm Systems :
- Cable :
100%
10%
- Installation Materials
100%
5%
9.
FIRED PROCESS HEATERS
9.1
General
Each Heater and the materials used in the fabrication thereof shall be tested and inspected for conformance with the requirements of the applicable Codes, of the CONTRACTORs detailed specifications including Project Specifications requirements, and of this specification.
9.2
Materials
All materials shall be inspected and tested in accordance with the relevant specifications of ASME Code, Section II and / or ASTM Standard Specifications for ferrous materials.
Materials equivalent to ASTM/ASME materials and approved by the COMPANY shall be inspected and tested to the Specifications of the relevant ASTM/-ASME material.
Materials that are not covered by an appropriate ASTM / ASME Specification, e.g. high alloy centrifugal and static castings shall be inspected and tested in accordance with the CONTRACTORs relevant material specifications approved by the COMPANY.
The conformity of materials with the relevant specifications shall be confirmed by material certificates. These certificates shall be at least
- for carbon and 0.5% Mo steel : Mill certificates - for higher alloys and all materials that require a mill heat treatment:
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Certificates by a manufacturer holding the relevant ASME approval or Third Party Inspection (TPI) Certificates issued by an approved independent inspection organization such as Lloyds, British Engine, TUV , APAVE , Veritas etc.
9.3
Shop inspection and testing
Shop inspection and testing shall include but not be limited to:
- check of the design for compliance with the relevant Codes and specifications
- review welding procedure qualification and welders performance qualification records and verify compliance with ASME IX
- witness non destructive testing on weld seams: - liquid penetrant examination (PT) - magnetic particle examination (MT) at random, but min 10% at random, but min 10%
- review x-rays (at random , but min. 10%)
- witness pressure and tightness tests of prefabricated pressure parts
- check of dimensions and workmanship of prefabricated parts
- ensure that repairs are welded and tested only to approved and qualified procedures
- carry out final inspection including check of dimensions and workmanship
the nondestructive examination of welds shall consist of : - PT or MT of root passes and top passes of butt and fillet welds - X - ray examination of butt welds
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in accordance with the ASME to the following extent: - Carbon and 0.5% Mo steel for pressures below 70 kg/cm2 (g) - Carbon and 0.5% Mo steel for pressures exceeding 70 kg/cm2 (g) and all alloy materials : 100% 10%
The acceptability of welds shall be judged in accordance with ASME VIII, 1.
10.
COOLING TOWERS
10.1
General
This specification covers the inspection and testing of materials, manufactured and prefabricated parts for cooling towers in the manufacturers workshops to be performed by CONTRACTOR / manufacturer.
10.2
Materials
Ferrous and nonferrous material used for cooling tower parts and accessories shall be inspected and tested for compliance with the relevant ASTM Standard Specifications.
Inspection and test results shall be stated in mill sheets or manufacturers certificates.
10.3
Manufactured and prefabricated parts
Manufactured and prefabricated cooling tower parts shall be inspected and tested for compliance with the relevant Standards and Project Specifications under full responsibility of the CONTRACTOR.
Inspection certificates shall be issued by Purchaser after Vendors certificates and test reports have been checked and accepted by Purchaser.
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11.
STEAM GENERATORS
11.1
General
Each steam generator and the materials used in the fabrication thereof shall be tested and inspected for conformance with the requirements of ASME I, of the CONTRACTORs detailed specifications including Project Specification requirements, and of this specification.
11.2
Additional testing and inspection
Additional inspections by the CONTRACTOR shall include but not be limited to the following :
- witness non destructive testing on weld seams: - Liquid Penetrant Examination (PT) - Magnetic Particle Examination (MT) - Ultrasonic Examination (UT) at random but min. 10% at random but min. 10% at random but min. 10%
- review radiographs
at random, but min. 10%
- ensure that repairs are welded and tested only to approved and qualified of procedures
- carry out final inspection including check of dimensions and quality of workmanship
- audit the performance of the appointed Inspection Authority.
The extent and acceptability of weld examination shall be in accordance with ASME Code, Section I, Part PW with the following additional requirements :
- 5% of circumferential welds of drums, headers, tubes and pipes that are exempted from radiographic examination by Paragraph PW-41 shall be radiographed on full circumference to the standards required in the Code.
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- all circumferential welds of drums, headers, tubes and pipes that are inaccessible after assembly shall be radiographed, even if the number of these welds exceeds the required 5%.
- for each of a.m. 5% circumferential welds or the inaccessible welds that are found defective during examination, two additional welds shall be radiographed.
all welds of P-4 , P-5, or higher alloyed material used for pipes and headers with a wall thickness exceeding 15 mm, shall be 100% radiographed after post-weld heat treatment.
12.
MISCELLANEOUS ITEMS
All equipment, materials and supplies not specifically mentioned in this specification but forming part of the CONTRACTORs Scope of Work / supply shall be tested and inspected as follows :
- equipment, materials and supplies which can be allocated to any of the preceding paras shall be tested and inspected as described therein.
- for equipment, materials and supplies, which cannot be allocated to any of the preceding paras, the type and scope of inspection and testing shall be specified by the CONTRACTOR.
All above mentioned equipment, materials and supplies shall be included in CONTRACTORs Inspection Specification.
13.
PACKING
CONTRACTOR should inspect and release all packages prior to shipment and take full responsibility for proper execution of temporary corrosion protection, packaging and storage on site.
All packages shall not be released without acceptance by Purchaser.

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PTT Maintenance and Engineering CO., LTD.

STANDARD SPECIFICATION FOR

SHOP INSPECTION & TESTING

(INCLUDED THIS PAGE)

SHOP INSPECTION & TESTING

ELECTRICAL AND COMMUNICATION EQUIPMENT

FIRED PROCESS HEATERS

SHOP INSPECTION & TESTING

The CONTRACTOR's Inspection Specification is subject to review by the COMPANY.

Percentage Extent of Inspection and Testing

SHOP INSPECTION & TESTING

The CONTRACTOR shall reject equipment and material which :

SHOP INSPECTION & TESTING

Shop visits by the COMPANY

Testing and Inspection Procedures

Supplements to Purchase Orders and Spare Parts

SHOP INSPECTION & TESTING

General Inspection Activities

The following activities have to be performed by the CONTRACTOR in general :

- Review welding procedure qualification and welders' performance qualification records.

SHOP INSPECTION & TESTING

- Review radiographs (at random, but min. 10 %)

- Review postweld heat treatment records.

- Audit the performance of the appointed Inspection Authority.

SHOP INSPECTION & TESTING

Heavy Duty Pumps acc. to API-610

Section 4 - Inspection and tests.

SHOP INSPECTION & TESTING

General Duty Pumps

Positive displacement Pumps - Reciprocating - acc. to API 674

Section 4 - Inspection and Tests

(clarification and modification)

Paragraph 4.3.3.7 of API 614, Second Ed. Jan. 84 shall apply.

Witnessed and certified performance test acc. to S 4.3.3 or 4.3.4

Certified hydrostatic test in acc. with S 4.3.2

Section 5 - Inspection and Testing

SHOP INSPECTION & TESTING

Hydrostatic test shall be certified.

Performance test shall be witnessed and certified.

Flow repeatability and linearity shall be demonstrated during performance test.

Positive Displacement Pumps - Rotary - acc. to API 676

Section 4 - Inspection and Tests

Hydrostatic test shall be certified.

Witnessed and certified performance test shall be carried out.

Performance data and curve shall be supplied.

Fire Water Pumps acc. to NFPA 20, Edition 1983

Section 2 - 15 Shop Tests

SHOP INSPECTION & TESTING

Diesel Engines acc to DEMA and NFPA

The following witnessed and certified tests shall be performed as a minimum:

Performances test of engines acc. to

ISO 3046/I 1984-10 -01

Hydrostatic pressure test - Certificates of cylinders and cooling-chambers shall be furnished.

SHOP INSPECTION & TESTING

Centrifugal Compressors acc. to API 617

Section 4 - Inspection and Testing

The following Tests shall be witnessed and certified as a minimum:

Hydrostatic test of pressure containing parts acc. to S 4.3.2

Tracer-gas test of casing

Overspeed test of each impeller acc. to S 4.3.3

Performance test of mainrotor.

Complete unit test shall be performed with gears, if applicable.