SIDDHIRGANGJ 335CCPP BANGLADESH
GENERAL INSPECTION AND TEST PLAN
ACCORDING QUALITY MANAGEMENT PLAN
SID-00-YG-QPQ-ISX-001
SUPPLIES.
Receiving materials
- Visual inspection
- Dimensional control
- Documentation review
CIVILWORK / TOPOGRAPHY
Preliminar y topography
- Survey control
Verification of levels
- Survey control
- Check of the phreatic level
Earthmovings and Excavations Works
- Check of the phreatic level
- Evacuation of water
- Slope Checking
- Plate load
- Minimum moisture and density testing for structural fill.
- Field density testing in accordance w i t h AST M D 1557.
Reinforced concrete structure. Materials, preparation and construction.
- Concrete test cylinder according to test plan
- Testing reinforcements steels
- Tensile tests
- Geometric features of the projections, equivalent section and identification marks.
- Split-bend test
Prefabricated reinforced concrete structure.
- Concrete probes test according to test plan
- Testing reinforcements steel s
- Tensile tests
- Geometric features of the projections, equivalent section and identification marks.
- Split-bend test
- Structural welds inspected in accordance with weld quality requirements provided in AW SD1.1.
Selection and identification of padding (material)
- Visual inspection
Compaction of padding in work area
- Proctor Test
Piling
- In process location verifications
- Proof load tests
BOP WELDING / NON DESTRUCTIVE TEST
Welding (prefabricated)
-Qualification as per ANSI/ASME SECTION IX
-NDT as per ANSI/ASME B31.1
Welding (assembly)
-Qualification as per ANSI/ASME SECTION IX
-NDT as per ANSI/ASME B31.1
Execution control of welds
-NDT as per ANSI/ASME B31.1
-Harness P91 100% large bore 20% small bore
Radiography and / or gammagraphy
NDT on lines designed for 400C or above
100 % Visual inspection on all welds
100% X - Ray on NPS >2" Butt welds
100 % DP or MT on NPS < 2 " Butt welds
100% X - Ray on NPS >4" Branch welds
NDT on lines designed for T between 175C and 400C
100 % Visual inspection on all welds
100 % X- Ray on NPS > 2 ", Thickness > 19mm Butt welds
100 % X- Ray on NPS > 4 ", Thickness > 19 mm Branch welds
Dye penetrant tests
END on lines designed for 400C or above
100 % Visual inspection on all welds
100 % DP on N PS < 2 " Butt welds
100 % DP on N PS < 4 " Branch welds
100 % DP on Fillet welds
END on lines designed for T between 175C and 400C
100 % Visual inspection on all welds
100 % DP on Butt welds with Thickness > 19mm
100 % DP on N PS > 4 ", Thickness > 19 mm Branch welds
10% DP on NP S <4", Thickness < 19 mm Branch welds
10% DP on Fillet welds
END on lines designed for T below 175C
20% DP on Fillet welds
PREFABRICATED STRUCTURE AND ASSEMBLY
Prefabricated steel structures
- 100% Visual inspection
- 100% X-Ray on beams and structural columns full penetration butt welds.
- 10% DP on loading resistant elements different than main beams and structural columns fillet welds without full
penetration
Assembled steel structures
- 100% Visual inspection
- 100% X-Ray on beams and structural columns full penetration butt welds.
- 10% DP on loading resistant elements different than main beams and structural columns fillet welds without full
penetration
COATING / PAINTING
Surface Preparation. Sandblast to SA 2
- Visual inspection
- Needle, Surface profile, percentage as per measurement as per specification.
Coating application
- Wheatear conditions measurements and record
- Paying particular attention to drying times between coats.
- Visual inspection
- Dry film thickness
- Pull-Off Test.
Heat insulation material
- Visual inspection
- MTR verification
- Thickness verification
- HC/PP verification during installation
- Correctness of final installation.
MECHANICAL ASSEMBLY
Installation of equipment
- Control of correct assembly as per Project Drawings and material specification
- Welding inspection as per BOP Welding inspection section
Mechanical assembly of a turbine generator
- As General Electric assembly procedure
Assembly of flanged system
- As ASME PCC1
- Gasket inspection
- Bolting material inspection
- Flange alignments
- Torque tightening.
HRSG (Heat Recovery Steam Generator)
- As CMI Erection Manual
- NDT on Boiler internal piping as per ASME SECTION I
- NDT on other piping as per ASME B31.1
- Harness P91 100% large bore 20% small bore
- PMI on alloy piping and welding, on a random basis as verification
- Dimensional control
- Hydro test off all pressure circuits
MECHANICALTESTS
Hydraulic test plant installations- Execution
- Hydraulic tests on piping and pressure retaining equipment.
Pressure testing shall include but not be limited to the following equipment and piping system:
- Pump casings
- HP/IP steam s y stem
- HP feed water system
- Fire protection system (test pressure as per NFPA)
- Fuel gas system
- Chemical feed systems
- SCR ammonia system
- All underground piping.
- Condenser air removal system
- Close d cooling water system
- Potable water system
- Makeup water system
- Condensate system
- Demineralised water
Watertight Test
- Air/Watertight Test (partial and global)
Exhaustive check of pipe in the control of support, free expansion and number of supports
- Visual inspection during erection and final walk down.
Exhaustive check of pipe insulation in terms of sealing and reinforcing sleeve arrangement of the insulation
on the supports.
- Visual inspection during erection and final walk down.
Rotating equipment performance test
- NDT as per ASME Code and specifications.
- Functional test
- Vibration test
- Noise test
- Final cleaning and painting
CATHODIC PROTECTION
Electrical insulation of pipes
- Soil resistivity test
- Electrical test (type, routine and functional)
Control testing cathodic protection facilities
- Electrical test (type, routine and functional)
ELECTRICAL ASSEMBLY / INSTRUMENTS
Installation of conductors
- Verification of sections.
- Check voltage drop by connecting a load on the farthest point of the circuit.
- Identification circuits.
- Identification of the neutral conductor and protective.
- Continuity test of protective conductor and equipotential.
- Insulation resistance between phases and earth.
- Insulation resistance between phases.
Thickness measurement by ultrasound Copper aluminum welding.
- Visual inspection
- Ultrasonic thickness measurement
Survey of earth system
- Visual inspection of welds and compression terminals,
- Verification of bolted connections.
Installation of instruments
- Verification of the correct position of the instruments
- Verification of instrument calibration
ELECTRICAL TEST
Final testing of the electric al system
Checklist of :
- General electricity (medium and low voltage)
- Electrical switchboards
- Tray and conduits
- Cable junction boxes
- Low voltage cables
- Lighting
- Sockets and mechanisms.
- Measures of consumption
- Acoustic and vibration measurements
Low voltakge electrical tests
- Test of step touch voltage
- Measure insulation of conductors.
- Dielectric strength.
- Evidence of continuity and tighten.
- Operation of circuit breakers.
- Measure the level of illumination.
- Power of lighting.
- Check operation of light and power points.
- Test emergency y lighting and proper zoning.
- Check emergency equipment autonomy.
- Checking protective conduct or connection.
Medium voltage electric al tests
- Tests of partial discharge and radio interference.
- Artificial contamination test.
- Short-circuit tests.
- Current pulse testing.
- Measurement of insulation between conductor and strength between conductor and earth.
- Step and touch voltages measurements.
- Testing of interlocks.
TESTS OF CONTROL AND INSTRUMENTATION
Tests of instrumentation and control system
- Review of engineering design of instrumentation and control philosophy
- Control of correct mechanical
assembly of the instruments, according to Hook-ups submit ted by engineering.
- Correct electrical wirings and control
- Control of communications, and correct reading of the signals provided by the instruments.
- Verification of the configuration, calibration and range of the instruments
- Verification of the control loops, according to the proper functioning of the logic presented by engineering , and
according to the proper functioning of the facility
SAT:
- Point-to-point test.
- Cold function al test
- Hot functional test
PRECOMMISSIONING, COMMISSIONING AND START
Precommisining- General .
- Preliminary test s which are tests performed prior to rotation or energizing at normal voltage or admission or
normal water or air pressure to the plan t under test.
- Tests on completion which is tests to progressively prove the correct operation of complete auxiliary systems
and of the main plant items..
- Reliability y run
- As per applicable Procedure.
Precommisioning Gas Turbine and Steam Turbine
- Start-up mechanic a l, running test, adjustment of turbine inlet guide vane control and interlocking, etc. The
measured data such as pressure , temperature, vibration, adjustable speed range, etc. The measured data such as
pressure, temperature, vibration, adjustable speed range etc. shall be observed and recorded.
- Checking of cooling system and lube oil system.
- Checking of over-speed tripping device s , protection and interlocking system, start-up and shut-down sequence of
auxiliary system .
- Noise and vibration level measurement.
- Manual and automatic synchronization.
- Generator Protection relay testing.
- Checking of loading capability.
- Lead rejection and governor tests.
- Preliminary testing of start-up times.
Precommisioning Functional Tests
- Test and Start-up of Auxiliaries
- Tests for Automatic Control System
- Synchronizing Checks
- Tests for Electrical Protective
- Devices to prove operation and stability
- Tests on over speed trip and other Mechanical Protective Devices to prove effectiveness.
- Stability (operation in a stable condition at 25 % of gross rated capacity).
- Full-Load Rejection Test and Step-Load Change Rejection Test (Facility shall also demonstrate the capability of
withstanding sudden loss of demand of 10 % of gross rated output from any load over the rang e of 40% to 100 %).
- Any other tests required to demonstrate compliance with requirements of the Grid System and the Grid Code.
Precommisioning Reliability Run
- Continuous Reliability Test :
168 hours during which time the unit and auxiliaries will operate continuously, uninterrupted without adjustment at all
loads up to and including the maximum loads.
- Cycling Operation, Shutdown and Start-up during the next seven days, after continuous operation.
Commissioning and start
- Start-up and performance Guarantee tests, bearing in account correction curves, metering, fuel analysis, Instrument
Test Measurement Uncertainly, Performance Tolerances,
- Environmental Performance Guarantee Tests (noise level tests in accordance with ISO 619 0:19 99 and method in
accordance with BS 414 2:10 07)
CONFORM TO WORK
Preliminary verification of drawings of work
- Documentation Review
FINAL DOCUMENTATION OF QUALITY
Reception of documents
Documentation Review
