YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT

VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

1. QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

General

This Section covers the general requirements for the testing and inspection of
the equipment and material to be supplied under the stipulations of this
Contract. These tests shall be performed for every component as mentioned
below.

A complete quality assurance and control manual and execution plan for
equipment shall be submitted by the Contractor to be approved by 3S EMUAS.

Type and routine tests, checks and measurements at factory shall be planned
and performed under full responsibility of the Contractor. The Contractor shall
also be responsible for damages which may occur in the test field.

In the event that any one test could not be possible at the factory, it shall be
carried out in a recognized laboratory chosen by common consent and again,
charged to the Contractor.

Within 3(three) months after the commencement date of the works, the
Contractor shall submit to 3S EMUAS a comprehensive schedule of workshop
tests indicating scope, kind, purpose, place and probable date of each test. The
standards to be used for the purpose of testing shall also be clearly identified.
3S EMUAS will study this schedule and notify the Contractor which of the
scheduled tests 3S EMUAS shall attend.

These tests which 3S EMUAS intends to participate in, shall be informed to 3S

EMUAS by the Contractor at least 60(sixty) days in advance of the preliminary
date of the test. Such a test can not be started before 3S EMUAS's authorized
representative has arrived at the place of the test, unless the representative has
not arrived within 60(sixty) days after the above mentioned announcement of
the test. All materials which will be coated, shall be tested before being coated.

If the Contractor has, contrary to the agreed test schedule, covered up any
work; it shall, if required by 3S EMUAS's representative, be uncovered for the
examination at the Contractor's expense.

All test reports shall be written in English and shall include date, place, kind,
standards used, permissible values, results and participants of the test. The
test reports shall further include a clear description of the relevant tests and
comments on the test results according to the stipulations of the standards.
One original and three copies of each report shall be submitted to 3S EMUAS
before delivery of the equipment.

The participation of 3S EMUAS representative in the test does not eliminate the
responsibility of the Contractor that it has in accordance with the Contract.

Calibration certificates, according to the latest issue of the relevant standards,

for all test instruments and gauges to be used in tests shall be submitted to 3S
EMUAS before the performance of the relevant test by the Contractor.

The numbers of the relevant standards and codes shall be stated by the

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

contractor depending upon the subject, in detail, within 3(three) months after
the commencement date of the Contract.

Standard, supplier’s method statement and acceptance specification and

reference documents with acceptance criteria as mentioned in the test plan
should be submitted to 3S EMUAS. Standards used in the tests should be
submitted in English.

Before and during manufacturing, the Contractor must take all necessary steps
to avoid changes of material. A material control book shall be kept, which 3S
EMUAS will have access to when so desired.

As far as practicable all parts of the plant are to be assembled provisionally in

the assembly shops of the manufacturer in order to check the correctness of
measurements and to carry out test runs and operating tests. These works and
test procedures for acceptance are to be carried out in accordance with the
latest issues of the relevant standards and the latest acceptance techniques, in
order to confirm the completeness, safe and trouble-free operation of all parts
and to avoid malfunctioning and difficulties when being put into service on the
site.

Test reports shall be prepared in accordance with the conditions of DIN 50049
or other internationally registered equivalent standards.

The equipment to be supplied in fulfillment of the Contract shall be subject to

work inspection and workshop tests. These inspections and tests shall be made
in accordance with the Technical Specifications and shall prove the equipment
fulfills the requirements of the Contract as the safety conditions, and the
equipment corresponds to the relevant

standards and regulations, and the workmanship has been executed

satisfactorily and the equipment is in conformity with the present state of
modern technique.

Material test certificates shall be prepared in accordance with the conditions of

DIN 50049-3 or other internationally registered equivalent standards

2. Visual Inspection and Checking of Dimensions

3S EMUAS may from time to time make visual examination and check
dimensions of the plant and equipment and the conditions under which it is
being manufactured or erected, both in the manufacturer's shops and on the
site, to make sure that the plant and equipment comply with the specifications
and drawings.

3. Material Tests

Test pieces shall be taken from all important forging, castings, pipework, etc.
in accordance with the agreed standard or code to be stated by the Contractor
and to be approved by 3S EMUAS in compliance with the Contract stipulations.
Dimensions shall be adequate. for the purpose intended and the test piece
should accompany the component through all heat treatment. Before cutting or
otherwise removing the test pieces, these shall, together with the forging,

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

castings or components which they represent, be permanently branded in the

presence of 3S EMUAS unless otherwise agreed. All test pieces shall be
machined to the dimensions specified in the agreed standard or code. Casting
and forging supplied in steel shall in all cases be annealed before detaching the
test pieces, chemical analysis of the materials concerned shall also be
submitted.

All cast iron shall be tested for compliance with the standards and shall be
appropriate for the purpose for which the castings are to be employed. A
chemical analysis of the material tested shall be provided by the Contractor. The
results obtained from these material tests shall be evaluated with the values
quoted in the relevant standards and codes and the figures contained within
the relevant sections of the Contract.

Radiographic examination of circumferential welded joints and ultrasonic

examination of nozzle. welded joints, stiffening rings etc. shall be carried out by
the Contractor for compliance with the latest issue of the related standards. All
castings and forging shall be subject to radiographic and/or ultrasonic tests in
accordance with DIN or other internationally registered equivalent standards on
the premises of the casting and forging manufacturers on the rough
workpieces before beginning the machining procedures in order to enable the
Contractor and 3S EMUAS, respectively, to detect defects as early as possible,
and to replace defective pieces in time, thus avoiding undue delays in the
manufacturing and delivery of components. After partial machining in the works
of the Contractor, the tests have to be repeated. The inspection scope for
ultrasonic testing of casting and forging shall be in conformity with DIN or other
internationally registered equivalent standards. For those not covered by DIN,
SEL Regulations shall be used. For all vessels, unavoidable cross welds and all T
seams have to be radiographically tested 100 % and longitudinal and
circumferential seams 10 %.

4. Hydrostatic Tests

All cast or fabricated vessels or inserts and all completed pipes, bends, fittings
and valves which are integral parts of such vessels shall be subjected to
hydrostatic or other tests according to the standards applied.

The test pressure shall be at least 50 % greater than the maximum operating
pressure. Particular attention shall be paid to temperature of water used to be
not below than 20 0C and to the period during which vessel is under test
pressure.

Further tests, after erection, shall be carried out as required by the related
standards and codes.

5. Balance Tests

Each completed rotating unit shall be tested for static and dynamic balance.

6. Performance Tests on Auxiliary Plant Equipment

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

Pumps, compressors and all other individual equipment shall be test run at
workshop and performance tests of those equipment which could be done at
workshop shall be carried out to prove the reliability and correct functioning of
the component and its conformity with the Contract stipulations.

The tests shall be carried out in accordance with the corresponding rules of
acceptance as mentioned in the applied standards, codes and rules. In such
cases, site conditions shall be simulated if possible, otherwise appropriate
correction factors given in the relevant standards, codes and rules shall be
applied.

All of the pumps shall have test runs at workshop. All pumps casing should have
hydrostatic tests and related pressure test. The certificates shall be provided
for each pump.

Valves shall have 100 % functional and hydrostatic tests. Pressure test
certificates shall exist and inspection of external prime coat shall be carried out
at workshop.
The equipment shall also be tested after erection and before energizing the
system according to the related standards and codes.

7. PERFORMANCE TESTS FOR THE PUMPS

Tests shall be performed according to DIN 1944 or other internationally

registered equivalent standards but exclusively using the tolerances specified
under this Article Workshops tests will be carried out with cold water.

For the model pumps, related DIN or other internationally registered equivalent
standards shall be used. But, acceptance shall be made in after performance
tests to be performed in accordance with DIN 1944 or other internationally
registered equivalent standards on the full scale pump.

In case that DIN 1944 is the base standard for the cooling system pumps,
accuracy class type-I shall be valid. Accuracy class type-II shall be valid for the
other pumps.

7.1 Guarantees for Pumps

The Contractor shall guarantee the following:

 Delivery head and rate; power consumption at motor terminals; power
consumption of auxiliary units; required suction head and shape of pump
characteristic, generally in accordance with the curves which shall be provided
by the Supplier,
 Q-H curves stable over the entire range so that irregularities in the operation
of the pumps, in particular when operating in parallel, are impossible,
 Safe operation without excessive vibration under normal operating conditions
the pump sets should not exceed category required according to VDI 2056
Group "G", value stated for "Good".

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

The Contractor shall also guarantee that the equipment supplied under this
contract shall be available for 8000 hours yearly accumulate at any plant load
between 60 % and 100 % of GCC during the guarantee period.

If the 8000 hours yearly cannot be fulfilled accumulative during the guarantee
period due to forced or scheduled outages and forced or scheduled load
reduction caused by any faulty plant or part thereof supplied under this
contract, the Contractor shall make the necessary modifications and the
guarantee period shall start for another 16000 hours period for the improved or
replaced equipment.

The Contractor must be able to prove that the guaranteed values have been
met during trial operations at the test-bench in its works and are in accordance
with the functioning conditions on the site.

If not otherwise specified, the size of the construction tolerance must be limited
as follows:

For pumps with steep or flat curves

Efficiency -0%
Power consumption +0 %

8. Inspections and Acceptance for Corrosion Protection of Concrete Surfaces

All concrete surfaces to be protected shall be inspected for their strength,

moisture and any other surface defects and for their suitability for coating
after post-treatment according to DIN 28052 Part 1 and 2 and AGI Worksheet S10
or other internationally registered equivalent standards.

All coated/lined surfaces shall be inspected and tested acc. to the AGI
worksheet 510 and other relevant norms and test procedures related to the
coating applied on these surfaces (i.e. coating, lining, tiling, etc.)

The quality and condition of coating applied shall be observed till to the end of
guarantee period.

8.1 Inspections and Acceptance for Coating of steel surfaces

All surfaces to be coated shall be checked for their suitability for coating as per
DIN 28053, DIN 28051 and 55928, Part 2 or internationally registered
equivalent standard.

Proof of proper derusting and coating shall be furnished by establishing

reference areas which is governed by the latest issue of German Standard DIN
55 928, Part 7 or internationally registered equivalent standard.

Location, number and size of the reference areas shall be determined by 3S

EMUAŞ, the Contractor and the supplier of the coating material.

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

Protocols covering the execution of the coating work at the reference areas
have to be made up and to be signed by the parties concerned.

After blasting, the surfaces shall be checked for surface roughness, derusting
grade and surface condition.

In addition, the entire coating is subject to checking the film thickness (20
measurements per 10m )and to a visual inspection.

A total of 10% of the measured values may be below the required minimum dry
film thickness but by not more than 10 % of the minimum dry film thickness.

Maximum admissible dry film thickness values shall not be exceeded.

With the coating systems subjected to more than + 80 0C, the minimum dry film
thickness should furthermore not be exceeded by more than 50 %.

About 10 dry film thickness measurements per m 2 have to be performed on the

reference areas.

Outside of the reference areas, the quantity of measurements should be in

reasonable proportion to type, size and importance of the item concerned.

The entire painted surfaces shall be checked visually for uniformity and defects
such as air bubbles, runs and sags or curtains.

Continuity of the coating shall be checked with a nondestructive holiday

detector adjusted to the voltage to be proposed by the coating material
manufacturer.

All results obtained have to be correspondingly recorded.

Among other provisions, those given in German Standard DIN 50 985 or

internationally registered equivalent standard will apply for acceptance.
All non-destructive measuring instruments envisaged for acceptance have to be
correspondingly calibrated and supplied with calibration certificates.

The degree of rusting of anticorrosive coatings shall be evaluated according to

SIS 18 51 11.

The above mentioned inspections and acceptances shall be jointly

performed by representatives of the Contractor, coating material supplier
and 3S EMUAŞ

The Contractor shall always be responsible for advising the items ready for
acceptance in time and has to furnish proof for proper execution of its services.

For the items coated at workshop inspections and acceptances at Site shall be
jointly performed by the Contractor and 3S EMUAŞ after arrival of plant
components on Site, prior to applying the follow-up coating on the prepared
surfaces, and after applying the last finish coat and repairing the erection
damages.

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

9. TESTS FOR ELECTRICAL MOTORS

a) Workshop Tests

Each motor shall be factory tested. Tests shall be performed in accordance

with IEC standards under full responsibility of the Contractor. The
requirements specified in this Section may be required to be substantiated by
actual tests.

Up to 100 kW, motor manufacturer's standard test program shall be applied.

For the motors above 100 kW at least the following tests shall be performed as
described below.
GROUP 1 TESTS
These tests shall be performed on each motor above 100 kW.
- No load test (measurement of no load current and no load losses at rated
voltage),
- Short circuit test (measurement of terminal voltage and output at rated current
and locked rotor),
- Calculation of efficiency by summation of losses,
- Measurement of winding resistance,
- HV test,
- Measurement of insulating resistance,
- Checking of air gap between rotor and stator except for antifriction bearing,
- Vibration measurement,
- Checking of terminal markings and sense of rotation,
- Checking of accessories for correct functioning.

GROUP 2 TESTS
These additional tests shall be performed on one MV motor from each type.
- Plotting of no load characteristics and measurement of iron and friction losses,
- Plotting of short circuit characteristics and measurement of short circuit losses,
- Measurement of starting current and torque,
- Measurement of noise level.

GROUP 3 TESTS
These additional tests shall be performed on one motor above 1 MW from each
type.
- Overspeed test.

GROUP 4 TESTS

These tests shall not be performed if the type test certificates are presented to 3S
EMUAS

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

-Heat test for each type of motor,

-Plotting of partial and full load efficiency curves for each type motors.

GROUP 5 TESTS

These additional tests shall be performed on the motor coupled to the driven
equipment (MV motors only):
- Consecutive starting:
The number of consecutive starts guaranteed shall be executed. After this,
another measurement of vibrations shall be performed and vibration analysis
shall be carried out in accordance in this Section and submitted to 3S EMUAS.
- Power factor:
Determination of the power factor at full load (two wattmeters method) .
Partial loads power factors will also be measured for inverter fed motors. If
these tests are performed at the manufacturers plant test reports shall be
submitted to 3S EMUAS before motor leaves the factory.

These tests shall be performed in the driven equipment manufacturer's plant or

at site.

b) Tests at Site
Such tests as required by 3S EMUAS shall be performed to demonstrate proper
erection, commissioning and functioning of the equipment. At least the
following tests shall be carried out at site:
- Checking for absence of moisture and for proper lubrication.
- Checking of proper alignment, rotation and operation conditions with the
mechanical part.
- Measurement of the space heater and RTD's circuit insulation resistance.
-Measurement of insulation resistance.
-Measurement of winding and RTD resistance.
- Oscillographic measurement of starting current and starting period with
connected load on motors rated 100 kW and higher.
- Calibration of measuring and indicating devices.
- Checking motor vibration (on motors rated 100 kW and higher). Vibration
analysis shall be carried out and submitted if the vibration exceeds the value
specified.
- Check on bearing insulation if applicable start-up tests as specified.

c) Vibration Analysis

Vibration tests shall be performed for the machines and drives which have power of
100 kW and above, with the participation of 3S EMUAS. Test Crew and using
the portable vibration monitoring device provided in workshop

VOLUME IV COOLING WATER SYSTEM

 YILDIZLAR ORTA LIGNITE-FIRED CIRCULATED FLUDIZED BED BOILER PROJECT
VOLUME IV – ANNEX 8
TENDERING SPECIFICATOIN FOR QUALITY ASSURANCE, TESTING AND INSPECTION REQUIREMENTS

equipment .Vibration measurements shall be analyzed on a PC (or on-line

diagnostic system PC) by using a software package to be provided together with
Portable Vibration Monitoring Device (last version of software approved by 3S
EMUAS). In addition, induction motor currents of medium motors shall be
recorded with the Portable Vibration Monitoring Device and analyzed with the
motor test program which has to be provided in the software package.

VOLUME IV COOLING WATER SYSTEM