Book II Section J - Quality Management

Client: SEWA Sharjah Electricity & Water Authority
Tender No. SEWA/HPS/60615

Project: Hamriyah Phase III Power Block Expansion Project
ILF CONSULTING ENGINEERS
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
Book II- Sec J
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LIST OF CONTENT
General ............................................................................................................................................... 5
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
1.5
1.5.1
1.5.2
1.5.3
1.5.4
1.6
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.6.6
1.6.7
Purpose .............................................................................................................................................................. 5
Scope ................................................................................................................................................................. 5
Definitions ........................................................................................................................................................... 5
Contractors Quality Management ...................................................................................................................... 5
Quality systems .................................................................................................................................................. 5
Quality planning .................................................................................................................................................. 6
Quality documentation ........................................................................................................................................ 6
Engineers Quality Control .................................................................................................................................. 7
Evaluation of quality systems ............................................................................................................................. 7
Assessment of effectiveness of quality control ................................................................................................... 7
Surveillance ........................................................................................................................................................ 7
Inspection ........................................................................................................................................................... 7
Procedural Requirements ................................................................................................................................... 8
Quality control plans ........................................................................................................................................... 8
Notification of readiness for inspection/test ........................................................................................................ 8
Right of access ................................................................................................................................................... 9
Contract waivers ................................................................................................................................................. 9
Quality control records ........................................................................................................................................ 9
Quality control certificates ................................................................................................................................... 9
Cost of additional visits ....................................................................................................................................... 9
WORK TESTS .................................................................................................................................... 9
2.1
General Test Requirements ................................................................................................................................ 9
Manufacturers Inspection and Testing Programme ................................................................... 10
3.1
3.1.1
3.1.2
3.2
3.2.1
3.2.2
3.2.3
3.3
3.3.1
3.3.2
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
3.4.10
3.4.11
3.4.12
Materials and Material Tests ............................................................................................................................. 10

General requirements ....................................................................................................................................... 10
Specific requirements ....................................................................................................................................... 11
Welding............................................................................................................................................................. 11
Welding Procedure Tests ................................................................................................................................. 11
Welders Performance Qualifications................................................................................................................. 11
Welding Procedure Approval ............................................................................................................................ 11
Mechanical Plant Tests ..................................................................................................................................... 12
Gas/steam turbine tests .................................................................................................................................... 12
Lubrication and control oil systems ................................................................................................................... 13
Electrical Plant Tests ........................................................................................................................................ 14
Generators & exciters ....................................................................................................................................... 14
Rotating parts ................................................................................................................................................... 16
Excitation, regulator equipment ........................................................................................................................ 18
Generator/exciter auxiliaries ............................................................................................................................. 18
Generator main connections ............................................................................................................................. 19
HV and LV switchgear (including switchgear at generator voltage) switchboards ............................................ 19
Components i.e. Isolators, earthing devices, etc .............................................................................................. 20
Motors ............................................................................................................................................................... 20
Insulating oil and gas ........................................................................................................................................ 22
Surge arresters ................................................................................................................................................. 22
Batteries, chargers and inverters & VFDS ........................................................................................................ 22
Chargers ........................................................................................................................................................... 23
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3.4.13
3.4.14
3.4.15
3.4.16
3.5
3.5.1
3.5.2
VFD units .......................................................................................................................................................... 23

Transformers tanks ........................................................................................................................................... 23
Neutral earthing resistors and associated equipment ....................................................................................... 28
Miscellaneous electrical equipment .................................................................................................................. 29
Control and Instrumentation ............................................................................................................................. 30
Works components tests .................................................................................................................................. 30
Works system tests........................................................................................................................................... 30
SITE INSPECTION, TESTING AND COMMISSIONING TESTS ..................................................... 30
4.1
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.2.3
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
4.4.13
4.4.14
4.4.15
4.5
4.5.1
4.5.2
4.5.3
General ............................................................................................................................................................. 30
Arrangements for testing .................................................................................................................................. 30
Supplementary tests ......................................................................................................................................... 31
General Test Requirements .............................................................................................................................. 31
Procedure ......................................................................................................................................................... 31
Standards and methods .................................................................................................................................... 32
Tests and commissioning inspections .............................................................................................................. 32
Mechanical Plant .............................................................................................................................................. 32
Alignment checks.............................................................................................................................................. 32
Calibration of instrumentation ........................................................................................................................... 32
Setting of regulating and control devices .......................................................................................................... 32
Auxiliary systems .............................................................................................................................................. 33
Orifices ............................................................................................................................................................. 33
Auxiliary pumping systems ............................................................................................................................... 33
Welding and welding tests ................................................................................................................................ 33
Hydraulic and vacuum tests .............................................................................................................................. 33
Pumps .............................................................................................................................................................. 33
Electrical Plant .................................................................................................................................................. 33
General requirements ....................................................................................................................................... 33
Main generator, exciter ..................................................................................................................................... 34
Generator main connections ............................................................................................................................. 34
Motors ............................................................................................................................................................... 34
Switchgear, control panels, earthing resistors .................................................................................................. 34
Transformers .................................................................................................................................................... 35
Batteries and battery charging equipment ........................................................................................................ 36
Inverters & VFDs .............................................................................................................................................. 36
Instruments and instrument transformers ......................................................................................................... 37
Synchronising equipment ................................................................................................................................. 37
High voltage surge arresters ............................................................................................................................. 37
Interlocking ....................................................................................................................................................... 37
Cables and earthing.......................................................................................................................................... 37
Electrical protection equipment ......................................................................................................................... 38
Protection, control, alarms, measurement and indication equipment................................................................ 38
Site Tests - Control and Instrumentation .......................................................................................................... 40
Item tests .......................................................................................................................................................... 40
Loop tests ......................................................................................................................................................... 40
System tests - control and instrumentation ....................................................................................................... 40
TESTS ON COMPLETION ............................................................................................................... 40
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
Gas/Steam Turbine Plant ................................................................................................................................. 40

Cooling water systems...................................................................................................................................... 40
Lubricating oil systems ..................................................................................................................................... 41
Control tests ..................................................................................................................................................... 41
Fire protection test ............................................................................................................................................ 41
Load rejection test ............................................................................................................................................ 41
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5.1.6
The contractor shall demonstrate safe shut down of the unit from full load with A.C. power supply not available.
.......................................................................................................................................................................... 41
GUARANTEE TESTS ....................................................................................................................... 41
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.3
6.4
6.4.1
6.4.2
6.4.3
Test Procedures ............................................................................................................................................... 41

Method of execution ......................................................................................................................................... 41
Instruments ....................................................................................................................................................... 42
Analysis of data ................................................................................................................................................ 42
Test Reports .................................................................................................................................................... 43
Gas/Steam Turbine Tests ................................................................................................................................. 43
General ............................................................................................................................................................. 43
Guarantee tests ................................................................................................................................................ 44
Rated conditions ............................................................................................................................................... 44
Plant operation ................................................................................................................................................. 44
Spare control cards........................................................................................................................................... 44
Plant Reliability Tests ....................................................................................................................................... 44
Combined Cycle Electrical Output .................................................................................................................... 45
The test............................................................................................................................................................. 45
Rated conditions ............................................................................................................................................... 45
Procedure ......................................................................................................................................................... 45
Appendix - Workshop Inspection &Testing ................................................................................. 47
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
Common All Packages .................................................................................................................................. 47

Gas Turbine ...................................................................................................................................................... 50
HRSG ............................................................................................................................................................... 52
Steam Turbine .................................................................................................................................................. 56
Steam Systems................................................................................................................................................. 59
Condensate & Feed water System ................................................................................................................... 59
Fuel Oil System ................................................................................................................................................ 61
Closed Cooling Water System .......................................................................................................................... 62
Instrument and Service Air ............................................................................................................................... 63
Fire Fighting System ......................................................................................................................................... 65
De-mineralized Water Plant and System .......................................................................................................... 66
Cranes and Hoists ............................................................................................................................................ 67
Air Conditioning and Ventilation ........................................................................................................................ 69
Book II- Sec J
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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-contractors 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 Contractors QA or
QC system, together with any additional or revised controls necessary to ensure compliance with the
Contract.
1.4
Contractors 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.
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Wherever the Contractors 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
Contractors 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 subcontractors 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 Manufacturers 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 Manufacturers 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 subcontractors 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.
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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
Engineers 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 Contractors 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 manufacturers 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 manufacturers 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
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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 / SEWAs 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.
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1.6.3
Right of access
ENGINEER / SEWA requires free access to Contractor and manufacturers works to verify full compliance with
specified requirements. Access is also required to records of all the manufacturers 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 Engineers
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
Engineers 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 contractors or his sub-contractors 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.
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.
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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 Contractors 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 Manufacturers 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.
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 Contractors 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.
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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
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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
rd
ultrasonic as appropriate) for sub-surface defects, surface crack detection by an internationally approved 3
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
Contractors 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.
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All auxiliary plant shall be run in the Manufacturers 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 manufacturers 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 manufacturers 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.
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(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 manufacturers 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
manufacturers 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)
3.4.1.3
Bearings, housings etc.
1)
Ultrasonic tests and dye penetrant checks on liner bonding.
2)
Insulation tests where applicable.
3)
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.
6)
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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)
3.4.1.6
Winding copper
1)
Electrical conductivity
2)
Visual and dimensional checks
3.4.1.7
Insulation materials
1)
Dielectric tests.
2)
3.4.1.8
Armature bar formation
1)
Inter-run insulation test (after Roebell setting).
2)
Capacitance and tangent delta tests on all bars.
3)
Dielectric tests.
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)
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.
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5)
Charge/discharge - absorption tests or equivalent.
6)
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.
4)
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.
4)
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.
4)
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)
3.4.2.5
a)
Insulation materials
Dielectric tests.
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3.4.2.6
a)
Bars (through shaft connectors)
Dielectric tests on formed assembly.
3.4.2.9
a)
Radial winding connections studs and assembly
3.4.2.8
a)
Bar formation
Approved inspection of jigging, brazing etc.
3.4.2.7
a)
Rotor windings
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 RTDs, 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)
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(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 times normal pressure for air to water units.
2)
3.4.4.2
1)
Pump
Hydraulic tests.
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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)
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
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(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.
2)
Dielectric tests.
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.
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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.
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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
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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.
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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.
4)
(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
3)
(b) Winding of Turns

1)
Checks during winding of different sections of winding.
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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

1)
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.
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(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 Manufacturers stage test records and
procedures.
(b) Mechanical and electrical checks in the Manufacturers works.
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(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)
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 Manufacturers 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 gasoperated 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.
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(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.
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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
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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.
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.
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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 manufacturers works. In
particular all pressure tests and such temperature tests which have not been made in the manufacturers 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 manufacturers
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 Engineers and witnessing SEWA
Engineers 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.
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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 Contractors test equipment shall be of satisfactory quality and condition and, where necessary, shall be
appropriately calibrated by an approved authority or standard at the Contractors 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 Contractors
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.
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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
1
subjected to test pressures 1 /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.
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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)
4.4.3
Bearing vibration test.

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)
4.4.4
Temperature rise test on full load on completed connections.

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:
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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.
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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.
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.
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4.4.8.1
VFD units:
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
employers 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.
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(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.
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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 CTs 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 manufacturers 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
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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.
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
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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.
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
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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 posttest 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.
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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.
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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:
o
(a) Ambient air temperature 55 C, 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 SEWAs 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:
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03-Aug-2015

(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.
Book II- Sec J
Page 45 of 69
03-Aug-2015

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
Page 46 of 69
03-Aug-2015
Mechanical Test
Control Valves
Body
Bonnet
X
X
X
X
X
X
Disc
X
X
X
X
Yoke
X
X
X
X
Stem
Weld
X
X
X
X
Actuator
Valve assembly
Isolating Valves
Body
Bonnet
Disc
Yoke
Stem
Actuator
Valve assembly
Safety Valves
Book II- Sec J-Rev01

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Ultrasonic Test
X
X
Page 47 of 69
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Assembly Check
X
X
Inspection of Packing
Corrosion Inspection
Visual Chk.
(Pack.P:
Visual/Dimension
Inspection)
Final Insp./ Doc Chk.
Surface Preparation
Tightness / Leakage
Valve Characteristic
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Check of welding work
Welders Qualification
Dye-Penetration Test
Magnetic Part Test
Radiographic Exam
Hardness Test
Material Identification
Weld Preparation
Material Certificate
Eddy Current
Flaring test
Flattening Test
7.1
Heat Treatment
Microscopic Test
Chemical Analysis

APPENDIX - WORKSHOP INSPECTION &TESTING
Common All Packages
X
X
X
X
X
X
X
X
X
03-Aug-2015
Fitting
Butt weld on fitting or on pipe
(longitudinal or circumferential weld)
Weld on branch connection (i.e.
weld between the branch and the
run pipe)
Fillet, socket, attachment and
seal welds
Pump
Casing
Assembly Check
Visual Chk.
(Pack.P:
Visual/Dimension
Inspection)
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
X
X
X
X
X
X
X
X
X
X
Bending
Welding electrode
Metal Piping
Pipe
Magnetic Part Test
Ultrasonic Test
Spring
Welds
Actuator (if applicable)
Valve assembly
Radiographic Exam
X
X
X
X
Hardness Test
X
X
X
X
X
X
X
X
Eddy Current
Bonnet
Disc
Lantern
Stem
Flaring test
Flattening Test
Heat Treatment
Mechanical Test
Microscopic Test
Chemical Analysis
Body
Weld Preparation

X
X
X
X
Page 48 of 69
03-Aug-2015

X
X
X
X
X
X
X
Shell plates
Flanges and covers
X
X
X
X
X
X
X
X
Dividing plate
Heads
X
X
X
X
X
X
X
X
Tube sheets
X
X
X
X
Tube bundle
Weldings
Water box assembly
Shell assembly
Exchanger assembly
X
X
X
X
X
X
X
X
Page 49 of 69
X
X
X
X
X
X
Pump Assembly
X
X
X
X
X
X
X
X
Heat Exchanger
X
X
X
X
X
Assembly Check
X
X
X
X
Visual Chk.
(Pack.P:
Visual/Dimension
Inspection)
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Cover
Shaft
Impeller
Wear rings (if applicable)
Chemical Analysis

X
X
X
X
X
X
03-Aug-2015

Burners
Burner
Fuel Lance
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Performance Test
Control Setpoints
Vibration Test
Final Assembly Test
Flexibility Test
Leakage Test
Hydrostatic Test
X
X
Casing
Shaft
Impeller
Pump assembly
X
X
X
X
X
X
X
X
X
Pump assembly
Auxiliary, emergency, turning oil pp:
X
X
Cylinder / casing bottle

HP/LP steam inlet pipes
IP-LP crossing over
Governors, Gov. characteristics

Overspeed Governor
Impeller
Hydraulic elements
Lube Oil Pumps, Tanks and Piping
Main oil pump casing
Control devices:
X
X
X
X
Vacuum Test
Overspeed Test
Dynamic Balancing
Concentricity Check
Thermal Stability Test
Prelim. Assembly Check
Fuel System
Bearings
Control Oil Pumps
Packing Inspection
X
X
X
Paint/Coat Inspection
X
X
X
Functional Test
X
X
X
Running Check
Exhaust Diffuser
X
X
Check of Clearances
X
X
X
Check of Alignment
Combustion Chamber
Casing Assembly
X
X
X
a) Xb) XX
Bladed Rotor
Casing
Compressor Casing
Turbine Casing
Vane Carriers
Visual Inspection
Dimensional Check
Welding Procedure
NDT Welds
Repair Weld. Procedure
Check of welding
Inclusion Inspection
X
X
Boroscope Inspection
Grain Size Inspection
Surface Crack Inspection
Sulphur Print. Exam
X
X
Etching Examination
X
X
Magnetic Particle
X
X
Ultrasonic Exam.
X
X
Radiograph. Exam.
Coating Inspection
NDT at Mat. Supplier
Eddy Current Test
Hardness Test
Material Verification
Stress Rel. Annealing
Heat Treatment
X
X
Microscopic Test
X
X
Check Anal. at Manuf.
Rotor
Shaft
Blading
Mechanical Test
Gas Turbine
Chemical Analysis
7.2
Page 50 of 69
03-Aug-2015
Oil Piping
Oil Tank
Oil Purifier
Oil Cooler

X
X
Shell
X
X
Water Boxes, covers

X
X
Tube plates
X
X
Tubes
X
X
Cooler assembly
X
X
X
X
Page 51 of 69
X
X
X
X
X
X
X
Pipe work of alloyed material
X
X
03-Aug-2015
Packing Inspection
Performance Test
Control Setpoints
Vibration Test
Functional Test
Running Check
Check of Clearances
Check of Alignment
Final Assembly Test
Flexibility Test
Leakage Test
Vacuum Test
Hydrostatic Test
Overspeed Test
Dynamic Balancing
Concentricity Check
Prelim. Assembly Check
Visual Inspection
Dimensional Check
NDT Welds
Repair Weld. Procedure
Welding Procedure
Check of welding
Surface Crack Inspection
Sulphur Print. Exam
Etching Examination
Magnetic Particle
Ultrasonic Exam.
Radiograph. Exam.
Hardness Test
Coating Inspection
Eddy Current Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
X
X
X
X
X
X
X
X
X

Assembly Check
Visual/Dimension
Check
Final Insp./Doc Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Check of Welding Work
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
HRSG
Chemical Analysis
7.3
Testing of Piping, Valves, Pumps and

Heat exchangers as defined in
Common Systems
Steel Structure
Main Column
Sec. Column
Main Beam
Sec. Beam
Main Bolts
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Pre-assembly
Welding electrode
Carbon Steel Tubes (Low Temp.)
Tube
Butt weld of tube
X
X
X
X
Tube bundle to be dispatched
X
X
Welding electrode
Carbon Steel Headers (Low Temp.)

Header
Nozzle
Page 52 of 69
03-Aug-2015
Butt weld of header

Weld of nozzle/header
Complete pressure part
to be dispatched
Assembly Check
Visual/Dimension
Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
X
X
X
X
X
X
X
Tube bundle to be dispatched

Welding electrodes
Alloy Headers (High Temp.)
Header
Nozzle
Butt weld of header
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
X
X
Welding electrode
Alloy Tubes (High Temp.)
Tube
Butt weld of tube
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
X
X
X
X
X
X
Weld of nozzle/header
Complete pressure part to be
dispatched
X
X
X
Welding electrodes
X
X
X
X
X
Drum
Plate
Head
Nozzle
X
X
X
X
X
X
X
X
X
X
X
X
Page 53 of 69
03-Aug-2015
Drum internals
Manhole
X
X
X
X
X
X
X
X
Assembly Check
Visual/Dimension
Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
Longitudinal weld
Circumferential weld
Weld of nozzle/drum
Complete drum to be dispatched
Welding electrode
X
X
Spray Type Attemperators

Shell
Inner protection tube
Nozzle
Weld of nozzle/shell
X
X
Complete pressure part to be

dispatched
Welding electrodes
Burner Equipment
Front plate
Parallel flow nozzle
Atomizer
Swirler
Lance gas burner
Lighting-up burner
Page 54 of 69
03-Aug-2015

Impeller
X
X
Shaft
X
X
X
Casing
X
X
X
Welds
Lubrication System
Fan Assembly
Page 55 of 69
X
X
Assembled equipment
X
X
X
X
X
X
Bearing
X
X
Coupling
Assembly Check
Visual/Dimension
Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
Forced Draught Fans (if applicable)
X
X
X
X
X
X
X
X
X
X
03-Aug-2015

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
LP rotors only: lashing welds
erosion shields
X X
Blade assembly
Shroud assembly
Disc assembly
Complete rotor assembly
Discs
Casing
HP, IP cylinders
Horizontal Joint finish

machining
Axial Borings finish machining
Radial Borings finish machining
Nozzle chamber, steam inlet

X
X
X
X
X X
X X
X
X
X
X
X
Valve body
Valve stem, cover bolts
Hard metal surface and joint
X X
LP Cylinder
IP-LP crossing over
Steam Bypass Control Valves
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X
X
X
X
X
X X
Page 56 of 69
03-Augs-2015
Chemical Analysis
Packing Inspection
Performance Test
Control Setpoints
Vibration Test
Functional Test
Running Check
Check of Clearances
Check of Alignment
Final Assembly Test
Flexibility Test
Leakage Test
Vacuum Test
Hydrostatic Test
Overspeed Test
Dynamic Balancing
Concentricity Check
Prelim. Assembly
Visual Inspection
Dimensional Check
Repair Weld.
Procedure
NDT Welds
Welding Procedure
Check of welding
Sulphur Print. Exam
Surface Crack
Inspection
Etching Examination
Magnetic Particle
Ultrasonic Exam.
Radiograph. Exam.
Hardness Test
Coating Inspection
Heat Treatment
Microscopic Test
Eddy Current Test
Mechanical Test
Steam Turbine
Chemical Analysis
7.4
Valve actuator
Nozzle chamber
Blades, Diaphragms, Bearings
Rotating blades
Last, last but one stage only:
Static + dynamic frequencies
X
X
X
X
X
X
X
X
X
X
Diaphragms
Borings, horizontal joint
Blade steam passages
Bearing pedestals
Shells and babbits
X X
Erosion shield
Stationery blades
X
X
X X
X X
X X
X X
X
X
X
X
X
X
Chemical Analysis
Packing Inspection
Performance Test
Control Setpoints
Vibration Test
Functional Test
Running Check
Check of Clearances
Check of Alignment
Final Assembly Test
Flexibility Test
Throttle
Leakage Test
Vacuum Test
Hydrostatic Test
Overspeed Test
Dynamic Balancing
Concentricity Check
Prelim. Assembly
Visual Inspection
Dimensional Check
Repair Weld.
Procedure
NDT Welds
Welding Procedure
Check of welding
Surface Crack
Inspection
Sulphur Print. Exam
Etching Examination
Magnetic Particle
Ultrasonic Exam.
Radiograph. Exam.
Hardness Test
Coating Inspection
Eddy Current Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
X
X
X
X
X
X
Shell and babbit bonds

Control Oil Pumps
Control devices:
Governors, Gov. characteristics
Overspeed Governor
X
X
X
X
Hydraulic elements
X
X
X
X
X
X
Lube Oil Pumps, Tanks and Piping

Main oil pump casing
Impeller
Pump assembly
X
X
Auxiliary, emergency, turning oil pp:
Casing
Shaft
Impeller
Pump assembly
X
X
X
X

IP-LP crossing over
Oil Piping
Oil Tank
Oil Cooler
Page 57 of 69
03-Augs-2015

Shell
Water Boxes, covers
Tube plates
Tubes
Cooler assembly

X
X
X
X
X
Page 58 of 69
X
Performance Test
Control Setpoints
Vibration Test
Functional Test
Running Check
Chemical Analysis
Packing Inspection
Check of Clearances
Check of Alignment
Final Assembly Test
Flexibility Test
Leakage Test
Vacuum Test
Hydrostatic Test
Overspeed Test
Dynamic Balancing
Concentricity Check
Prelim. Assembly
Visual Inspection
Dimensional Check
Repair Weld.
Procedure
NDT Welds
Welding Procedure
Check of welding
Surface Crack
Inspection
Sulphur Print. Exam
Etching Examination
Magnetic Particle
Ultrasonic Exam.
Radiograph. Exam.
Hardness Test
Coating Inspection
Eddy Current Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
03-Augs-2015
7.6

Barrel casing
X
X
X
X
X
X
X
X
Casing cover
Nozzle
Shaft
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 59 of 69
Radiographic Exam
Radiographic Exam
Ball Test
Tightness / Leakage
Surface Preparation
Ball Test
Tightness / Leakage
Surface Preparation
Assembly Check
Balancing
Balancing
Vibration Check
Vibration Check
Assembly Check
Function Test
Function Test
Pressure Test
Pressure Test
Visual/Dimension Check
Magnetic Part Test
Magnetic Part Test
Ultrasonic Test
Hardness Test
Hardness Test
Ultrasonic Test
Weld Preparation
Eddy Current
Eddy Current
Weld Preparation
Flaring Test
Flaring Test
Flattening Test
Flattening Test
Heat Treatment
Heat Treatment
Microscopic Test
Condensate & Feed water System
Microscopic Test

Common Systems
Mechanical Test
Chemical Analysis
7.5
Mechanical Test
Chemical Analysis

Steam Systems
Feedwater Pumps
03-Aug-2015
Contact surface
Assembly Check
Balancing disc
Balancing counter disc
Impeller
Impeller and rotor

Nuts
Weld seams
Stud
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
X
X
X
X
X
X
X
X
X
X
X
Pump assembly
Deaerator/ Feedwater Storage

Tank
Plates
Stiffening plates
Covers, heads
Tank internals assembly
X
X
X
X
X
X
X
X
X
X
X
Tower + tank assembly

Clean Drain Flash Vessel and
Tanks
Shell and head
Nozzle
Longitudinal weld
Nozzle / tank weld
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 60 of 69
X
X
X
X
X
X
X
X
X
X
X
X
X
X
03-Aug-2015

Page 61 of 69
X
X
X
X
X
X
X
X
X
X
Assembly Check
Surface Preparation
Condenser assembly
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
X
X
Radiographic Exam
Hardness Test
Welding electrodes
Weld Preparation
Vessel / Tank assembly
Eddy Current
Flaring Test
Flattening Test
X
X
X
Heat Treatment
7.7
X
X
X
Microscopic Test
Gland Steam Condenser

Shell, water box
Tube plate
Tubes
Mechanical Test
Chemical Analysis
Assembly Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

Fuel Oil System

Common Systems
03-Aug-2015

Assembly Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Closed Cooling Water System
Chemical Analysis
7.8

Common Systems
Circulating Water Pump
Guide blade casing
Pump casing
Shaft
Impeller
Wear rings (if applicable)
X
X
X
X
X
X
X
X
X
X
X
X
Shaft sleeve
X
X
X
X
X
X
X
X
Column pipe
Discharge elbow
Pump assembly
X
X
Blade pitch adjustment
Page 62 of 69
03-Aug-2015

Assembly Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Instrument and Service Air
Chemical Analysis
7.9

Common Systems
Air Compressor
Crankshaft
Connecting rod
X
X
X
X
X
X
Piston rod
Piston
X
X
X
X
X
X
Crankcase
Cylinder
Compressor assembly
Cylinder values
Air Drier
Shell plate
Covers
Tubes-stubs-forged
Tank assembled
X
X
X
X
X
X
X
X
X
X
X
Drier assembly
X
X
Air Cooler
Shell plate
Page 63 of 69
03-Aug-2015
Air Receiver
Shell plates
Covers
Stubs-flanges
Welding shell-covers
Receiver assembly
Safety valve

X
X
X
X
X
X
Covers
Tube sheet
Stubs-flanges
X
X
X
X
X
X
X
X
X
Tube bundle
Shell assembled
Tank separator
Unit assembly
X
X
X
Page 64 of 69
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Assembly Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
X
03-Aug-2015

Piping (various)
Drain valves
Butterfly valves
X
X
X
X
X
X
Motorized butter fly valves

Gate valves
X
X
X
X
Check valves
Overflow valves
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Gas detector
Fire alarm control
Bottle (CO2)
Fire water storage tank
X
X
X
X
X
X
Pressure tank
Fire fighting pumps
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 65 of 69
Assembly Check
X
X
X
X
X
Surface Preparation
X
X
X
Manometer
Tightness / Leakage
X
X
X
Solenoid valve
Safety valve
Spray nozzle
Automatic sprinklers
Heat detector
Fire detectors
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Fire Fighting System
Chemical Analysis
7.10
X
X
03-Aug-2015

Testing of Piping, Valves, Pumps
and Heat exchangers as defined in
Common Systems
Mixed Bed Filter
Plate
X
X
X
X
Head
Nozzle
X
X
X
X
X
X
X
X
Page 66 of 69
Assembly Check
X
X
X
X
X
X
X
X
X
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Driver for FF pumps

Jockey pump unit
Fire pump controller
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
7.11
Mechanical Test
Chemical Analysis
Assembly Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
X
De-mineralized Water Plant and System
03-Aug-2015
Gantry Crane
Main girder
Welding preparation
Drum
Drum shaft

X
X
X
X
X
X
X
X
X
X
X
Page 67 of 69
X
X
Cranes and Hoists

Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis
Assembly Check
Assembly Check
Surface Preparation
Complete filter
Tightness / Leakage
Ball Test
Balancing
X
X
Vibration Check
X
X
Function Test
X
X
Pressure Test
X
X
Magnetic Part Test
Ultrasonic Test
Weld of nozzle / vessel
Radiographic Exam
X
X
Hardness Test
Longitudinal weld
Circumferential weld
Weld Preparation
Rubbing
Welding material
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
7.12
Mechanical Test
Chemical Analysis

X
X
X
03-Aug-2015
Rope
Hook
Reduction unit
Trolley frame
Electric motor

X
X
X
X
Main girder
Welding
Drum
Drum shaft
X
X
X
X
X
X
Rope
Hook
X
X
X
X
Trolley frame
X
X
Bolts and nuts
X
X
Bolts and nuts
X
X
X
X
X
Control panel
Assembly crane
Page 68 of 69
Reduction unit
Electric motor
Control panel
Assembly crane
Turbine Hall Crane
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Assembly Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
Mechanical Test
Chemical Analysis

X
X
X
X
X
X
X
X
X
X
X
X
03-Aug-2015
Electric motor
Heat exchange battery
Fans
Electric panels
Refrigerator
Pumps
Piping
Tanks. valves
Insulation
Ducts, dampers, louvers
Single complete plant

X
X
X
X
X
X
Page 69 of 69
X
X
X
E-Heaters
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Assembly Check
Surface Preparation
Tightness / Leakage
Ball Test
Balancing
Vibration Check
Function Test
Pressure Test
Magnetic Part Test
Ultrasonic Test
Radiographic Exam
Hardness Test
Weld Preparation
Eddy Current
Flaring Test
Flattening Test
Heat Treatment
Microscopic Test
7.13
Mechanical Test
Chemical Analysis

Air Conditioning and Ventilation
X
X
X
03-Aug-2015

Book II Section J - Quality Management

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Book II Section J - Quality Management

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Client: SEWA Sharjah Electricity & Water Authority

Tender No. SEWA/HPS/60615

ILF CONSULTING ENGINEERS

UNITED ARAB EMIRATES

SHARJAH ELECTRICITY AND WATER AUTHORITY

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

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

WORK TESTS .................................................................................................................................... 9

General Test Requirements ................................................................................................................................ 9

Manufacturers Inspection and Testing Programme ................................................................... 10

Materials and Material Tests ............................................................................................................................. 10

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

VFD units .......................................................................................................................................................... 23

SITE INSPECTION, TESTING AND COMMISSIONING TESTS ..................................................... 30

TESTS ON COMPLETION ............................................................................................................... 40

Gas/Steam Turbine Plant ................................................................................................................................. 40

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

GUARANTEE TESTS ....................................................................................................................... 41

Test Procedures ............................................................................................................................................... 41

Appendix - Workshop Inspection &Testing ................................................................................. 47

Common All Packages .................................................................................................................................. 47

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

Contractors Quality Management

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

ii. NDT reports.

Performance test reports.

ix. Conformance certificates.

Engineers Quality Control

Evaluation of quality systems

Assessment of effectiveness of quality control

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

Quality control plans

Notification of readiness for inspection/test

Any applicable sub-order reference.

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

Quality control records

Quality control certificates

Cost of additional visits

General Test Requirements

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority

ILF CONSULTING ENGINEERS

MANUFACTURERS INSPECTION AND TESTING PROGRAMME

Materials and Material Tests

Book II- Sec J

Client: SEWA Sharjah Electricity & Water Authority