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