Section (6)

SECTION (6)
INSPECTION AND TESTING DURING
MANUFACTURE
CONTENT

6.Inspection and test during manufacture .................................................... 167

6.1.General requirements .......................................................................... 167
6.2.Sub-contractors ................................................................................... 167
6.3.Material Test ....................................................................................... 167
6.4.Test at manufacture's works................................................................ 168
6.5.Pump test at maker's works................................................................. 168
6.6.Engine Tests ........................................................................................ 168
6.7.AC Generator Tests ............................................................................ 169
6.8.Transformer Tests ............................................................................... 169
6.9.Switchgear Tests ................................................................................. 169

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 Section (6)

6. Inspection and test during manufacture

6.1. General requirements
The whole of the plant covered by this contract will be subjected to inspection and
test during manufacture, erection and on completion, the cost of all the tests and
inspection shall be borne by the contractor.
Before any plant is packed or dispatched from the main or sub-contractor's works, all
tests called for shall have been successfully carried out full testing documents shall be
submitted to the purchaser engineer for approval.
.

6.2. Sub-contractors
In order to facilitate the inspection of bought-out materials and plant, the contractor
shall be submit for approval three copies of all specifications placed by him.
One copy of any drawing referred to in the sub-order shall be submitted, unless
otherwise agreed by the Purchaser / Engineer.
The drawings and sub-orders submitted to the purchaser / engineer shall cover all
major components which are subject to electrical and mechanical pressure and stress
when the plant is in operation and also all auxiliaries, materials and stores which will
be dispatched to site direct from the sub-contractor's works. For the purpose of this
clause, inter-works orders shall be treated as sub-orders. Sub-orders shall include a
statement advising the sub-contractor that the item being order will be subject to
inspection and test by the purchaser / engineer.
It is important that all copies of sub-orders are clearly marked with the main
contractor's name the following reference:

PUBLIC ELECTRICITY CORPORATION

SADA POWER STATION EXTENSION
CONRACT NO:………………………………

Sub-Contractors shall comply with all the applicable requirements of the

specification and, in particular, with this section, orders issued by a sub-contractor
shall also include the main contractor's name and reference on their sub-order in
addition to the above mentioned heading.
All sub-orders shall also include a statement that work will be subject to inspection
and test by the Purchaser/engineer to the requirements of this specification

6.3. Material Test

The contractor shall provide test sheets as required by the purchaser to enable him to
determine the quality of the material supplied under this contract.
such test sheets shall be prepared and supplied free of charge and any ,cost of the test
shall be borne by the contractor .

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 Section (6)

if any test fail to comply with the appropriate specifications for the material in
question ,the purchaser /Engineer may reject the whole of the material represented by
that test ,the contractors designers and metallurgists will be consulted before any
material is so rejected .
in the event of the purchaser /engineer being furnished with certified particular of the
test which have been carried out for the contractor by the suppliers of material ,the
purchaser engineer may at his own discretion, dispense with previously mentioned
test entirely.

6.4. Test at manufacture's works

Works test shall include electrical, mechanical and hydraulic tests in accordance with
the relevant ISO/DIN standard no type test is required.
The contractor shall include the cost for certification of all equipments supplied under
this contract by an approved company announced by PEC at manufactures works.

6.5. Pump test at maker's works

All motor driven pumps shall be tested at the maker's work .complete performance
tests shall be carried out on each pump to verify its output against total head, power
input and efficiency.
Head /volume, suction head /volume, efficiency and power input curves corrected for
site conditions shall be provided and the whole cost of the tests borne by the
contractor .this also applies to tests carried out at sub-contractor 's work.

6.6. Engine Tests

The completely erected engine shall be directly coupled to a dynamometer or water
brake at the place of manufacture run up from cold in the presence of both
purchaser/engineer and purchaser and loaded to its full B.S rating in the time stated in
the schedule of guarantees.
Using distillate fuel, the engine shall then be run as follows during which time test
records shall be taken including consumption of fuel and lubricating oil:
Duration hours 0.5 0.5 1 6 1

Rating % 25 50 75 100 110

Under the above condition the engine shall be run steadily to the satisfaction of the
purchaser /engineer .all the necessary services ,instruments ,meter ,lubricating oil
,water ,fuel oil….. etc. which are required for the tests shall be provided by the
contractor as part of contract .satisfactory proof of the accuracy of all instruments and
of the calorific value of the fuel used in the tests shall be furnished –to-the .purchaser
/engineer
During these shop tests, the engine shall be run as far as practicable with the auxiliary
to be incorporated in the site installation ,the engine shall be free from all water fuel
or lubricating oil leak .

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 Section (6)

Speed control and govern ring tests to ISO 3046 shall be carried out .tests of all
engine protection devices shall be carried out on this occasion.

6.7. AC Generator Tests

Tests shall be carried out in the presence of purchaser/engineer on the ac generators
including balancing, open and short circuit characteristics, temperature rise on open
short circuit and zero excitation at normal speed and the basic tests laid down in
B.S.4999part 60 or equivalent.
The tests shall be carried out to measure the wave form of the line and phase voltage
and circuit and also the harmonic analysis of the neutral current generator positive
,negative and zero sequence impedances and transient and sub transient reactance's
shall be determined from sudden 3-phase short circuit tests at100%rated voltage.

6.8. Transformer Tests

Routine tests in compliance with I.E.C. and temperature rise tests on transformer shall
be carried out at the makers works.

6.9. Switchgear Tests

Routine test is required to be carried out during manufacture, the certificate must be
produced by the contractor as evidence of such test being conducted.
Tests for all voltage levels of switchgear shall conform to the appropriate IEC
specification.
Tests subject to-other national or international specifications are acceptable in so for
as the level of each test is not less rigorous.

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