Construction of two gas turbine units (GTU)

with a capacity of 27MW each at Tashkent HPP

5.1.13 Inspection and Testing

Scope of Works

The Contractor shall inspect, examine and test all of the equipment and material during fabrication in shop and
at site and after erection at site.

Test procedure shall be submitted to the Employer prior to conduct the test.

All of inspection examine and test reports, shall be submitted to the Employer for review and approval.

Codes and Standards

The Contractor shall comply with the requirements of Section VI Chapter 4.2 “Codes and Standards”.

Definition of Inspection Level

5.1.13.3.1 Spot Witness (SW)

Spot Witness inspection point is an activity during implementation of works where interim measurements,
and/or witness of activity conformation normally take place, prior to the final measurement or inspection being
done.

5.1.13.3.2 Witness (W)

Witness inspection point is an activity during implementation of works where inspection, measurements and/or
testing take place and shall be documented.

Prior to performing the inspections, measurements, or tests the Contractor is required to give written notice to
the Employer. However, in some cases this may not be possible, in such cases the Employer will depend on
the amount of notice given and availability of the Employer, he will endeavor to attend the inspection or test. If
it is not possible and depending on the criticality of the inspection, the Employer may waive his attendance or
ask for the inspection to be deferred until the Employer is available. If the inspection is waived, the Contractor
may proceed with his own inspection witnessing. The result shall be fully documented and submitted to the
Employer for approval without clearing the contractor responsibilities if any incompliance with the technical
requirements or the applicable standards.

5.1.13.3.3 Hold (H)

Hold point is an activity during implementation of works where inspection, measurement, testing must take
place, having mandatory attendance of the Employer. The Contractor cannot proceed with the next work step
activity until the inspection, measurement, or test to be witnessed and approved by all the attending parties.
Again, the Contractor shall give written notification in advance to the Employer for measurement and work
quality inspections.

Inspections conducted under hold point category will not be waived for the Employer attendance.

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5.1.13.3.4 Approval (A)

A document or drawing which is required approval by the Employer prior to proceeding with the activity.

5.1.13.3.5 Review (R)

Documents or drawings, which are submitted for review to the Employer.

The Contractor shall prepare a detailed inspection and test plan indicating inspection level based on definition
herein. The inspection and test plan shall include attendance requirements by the Employer.

Detailed Requirement

5.1.13.4.1 General

All plant and materials shall be subject to inspection and test as required for this plant. Approval of part or the
whole of the plant by the Employer, or the passing of any such inspection or test, will not however prejudice
the Employer’s right to reject the equipment. The costs of all tests and inspections shall be borne by the Con-
tractor. Furthermore, inspecting and expediting by the Employer in no way relieves the Contractor of his re-
sponsibility for quality assurance and delivery commitments.

The Employer shall be given the option of witnessing all tests, and at least 21 days’ notice shall be given before
the equipment or plant is ready for inspection or test to enable the Employer to make necessary arrangements
for witnessing the tests.

The Contractor and his Subcontractor for inspection or test to enable the Employer to make necessary ar-
rangements for witnessing the tests shall provide every facility.

All tests on materials and equipment shall be conducted in accordance with the codes and standards indicated
in this Specification. Any tests on materials or equipment not covered by codes or standards in this Specifica-
tion are to be agreed in advance by the Employer.

The Contractor shall provide test pieces as required by the Employer and shall perform mechanical tests re-
quired by the relevant codes and standards.

If any test piece fails to comply with the requirements of the appropriate Specification, the Employer reserves
the right to reject the material in question and have it replaced.

The Contractor shall provide the Employer with four (4) copies of all sub-orders and inter-works orders at the
time of issue. These shall be in the English Language, suitably endorsed, “Subject to inspection, and expediting
by the Employer”.

One (1) original and five (5) copies of Mill and test certificates, which shall be in English, shall be supplied to
the Employer. The Contractor shall supply at the ex-works stage six (6) bound copies of all certification, suitably
indexed to cover all tests of material and equipment.

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Where type test is specified, in addition to routine tests the Contractor may submit to the Employer type test
certificates in lieu of actual type tests, provided these have been independently witnessed and cover identical
items of plant.

For all non-destructive examination (NDE), the Contractor shall propose the best of Acceptance Criteria Levels
to be used for testing subject to the Employer’s approval, unless otherwise specified.

5.1.13.4.2 Inspection and Tests at Manufacturer’s Works

General

Works inspection shall include mechanical and hydraulic tests, as well, as running and functional tests (under
simulated conditions) on the assembled equipment, prior to shipment to the Site, in accordance with the rele-
vant standards or as otherwise agreed with the Employer.

Non-destructive Testing

Materials requiring non-destructive tests, except where stated otherwise in this Specification, shall be per-
formed in accordance with the following:

ASTM E114 Standard Practice for Ultrasonic Pulse-Echo Straight-Beam

Examination by the Contact Method
ASTM E94 Standard Guide for Radiographic testing
ASTM E142 Controlling Quality of Radiographic Testing
ASTM E709 Standard Guide for Magnetic particle inspection
ASTM E165 Standard Test Method for Liquid penetrant Inspection
Welding

Prior to commencement of any welding of the work, the Contractor shall have all welding procedures, welding
equipment and operators qualified in accordance with ASME Boiler and Pressure Vessel Code Section IX
welding qualifications or other standards as approved by the Employer. All welding procedure and welder
certificates shall be submitted to the Employer for his approval. A list of the qualified operators to be used in
the work must be available for the Employer’s inspection prior to start of any welding.

Strict measures of quality control shall be exercised throughout the work.

The Employer may call for a radiograph of the work of any operator who in his opinion is not maintaining the
standard of workmanship required. Where the interpretation of radiograph proves the welding to be of poor
quality, the Employer reserves the right to re-examine all radiographs on all production welds done by the
operator. Should the welding prove unacceptable, the operator is to be removed from any further production
welding until re-qualified, and all defective or sub-par weld shall be re-worked by other qualified operator.
Uzbekistan welders who are involved in the Project shall have certificates issued by Government of Uzbeki-
stan.

Ultrasonic inspection when called for in the code or in this Specification shall be in accordance with ASTM
E164 Standard Practice for Ultrasonic Contact Examination of Weldments

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Imperfection found by ultrasonic examination shall be judged against the acceptance - rejection standards
outlined in ASME Code Section VIII Div. 1, Appendix 12, and in the case of radiographic examination as out-
lined in paragraph UW 51 or UW 52 as applicable.

Castings

Each pressure retaining casting and each major load-bearing casting shall have an integral test bar, wherever
possible, from which mechanical test specimens to be taken. Test specimens shall be in accordance with
ASTM A370 “Methods and Definitions for Mechanical Testing of Steel Products” and ASTM E8 “Tension Test-
ing of Metallic Materials”. Non-destructive testing when required shall be carried out in accordance with the
standards outlined in Chapter 4.2. The standard as mentioned shall be the latest edition.

Defects in castings, which may be detected by radiography, magnetic particle or liquid penetrant inspection,
are to be assessed against the following standards, which shall be used as a basis for acceptance or rejection
of the casting.

- ASTM E186: Standard Reference Radiographs for Heavy-Walled (51 to 144mm) Steel Cast-

ings

- ASTM E280: Standard Reference Radiographs for Heavy-Walled (114 to 305mm) Steel Cast-

ings

- ASTM E446: Standard Reference Radiographs for Steel Casting Up to 51mm in Thickness

- ASTM E125: Standard Reference Photographs for Magnetic Particle Indications on Ferrous

Casting

For N.D.T acceptance/rejection standards refer to ASME Sect. VIII Div. 1.

Except where stated otherwise the limit of acceptability for all major castings such as boiler and turbine stop
valves, turbine casings, strainer chests and boiler feed pump casings, which have been radiographed, shall
be severity level 1. All parts of castings over 300mm thick shall be ultrasonically examined.

Castings rejected through the application of the above techniques may be repaired by welding, subject to
meeting the requirements states in ASME Section VIII, Division 1 and ASTM A-488 “Recommended Practice
Qualification of Procedures and Personnel for the Welding of Steel Castings”. Repairs not to be allowed to
grey iron castings having injurious defects.

Where a casting forms part of welded assembly, the welds shall be examined in accordance with ASME Sec-
tion VIII, Division 1, and paragraph UW 51.

Rotor Forgings

Rotor for gas turbines, generators, and other equipment, shall be tested and inspected by Ultrasonic in ac-
cordance with ASTM A418 “Ultrasonic Inspection of Turbine and Generator Steel Forgings”. The choice of
rotating, or stationary tests shall be based on the specific design of the rotor to be tested and shall be subject
to the approval of the Employer. The Contractor shall perform thermal stability tests on turbine rotors in ac-
cordance with ASTM A472.

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All generator rotor forgings shall be subject to fracture appearance transition temperature tests, and magnetic
permeability and resistivity tests. An ultrasonic examination shall be carried out in accordance with ASTM A418
after rough machining.

Ultrasonic and magnetic permeability tests shall be carried out for rotor end winding retaining ring forgings.
The retaining ring shall be ultrasonic and dye penetrant checked in the rough machined state and hydraulically
tested followed by dye penetrant inspection after final machining. Ultrasonic inspection shall be in accordance
with ASTM A351 “Ultrasonic Inspection of Turbine Generator Steel Retaining Rings”.

Fabricated Components

All components machined or fabricated from plate, sheet or bar stock shall meet the material requirements of
ASTM or material specification approved by the Employer.

All components shall be subjected to two or more of the following tests, as agreed by the Employer:

 Visual and dimensional

 Dye penetrant
 Magnetic particle
 Ultrasonic
 Radiographic

These tests shall be in accordance with the recommended practices of the ASTM. The terms of reference for
acceptance shall be the applicable ASTM specifications or equivalent standard as applicable.

Alloy Valves

Alloy steel valves, steam chests and fittings shall be supplied complete with forged stub ends of material suit-
able for site welding of the adjoining pipe. Weld preparations shall be subjected to a crack detection test and
be fully radiographed for a distance of 75mm from each end in accordance with ASTM E94 “Recommended
practice for Radiograph Testing” and shall be judged by reference Radiographs for Steel Castings ASTM E186
and E446 as applicable. Acceptance standards for crack detection tests shall be in accordance with ASTM
Section VIII Division 1.

Heat Treatment

All parts subject to heat treatment shall have adequate records kept, giving details of rate of rise and fall of
temperature, holding time, temperature and method of cooling.

HRSG Pressure Parts

All HRSG pressure parts shall be tested in accordance with the requirements of the ASME Boiler and Pressure
Vessel Code unless otherwise specified.

Pipework

All fabricated pipework shall be in accordance with standards as specified by ANSI B31.1 “Power Piping”,
latest edition. Temperature records of hot forming and heat treatment operations shall be made and submitted
to the Employer. The wall thickness of hot formed bends shall be checked by ultrasonic method. Records of

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these tests shall be kept and made available to the Employer. Where random radiography is specified, it shall
refer to the final weld only, and shall be at Employer’s selection and discretion.

All piping not covered by 100% radiography shall be hydraulically tested to 1.5 times the design pressure.

Quantitative Non-destructive Examination Requirement for Piping System. In additional to the NDT require-
ments stated in ANSI B31.1 paragraph 136, percentages given are percentages of the total number of welds
to be examined by radiographic testing for nominal pipe sizes over 50mm and by magnetic particle or liquid
penetrant testing for sizes 50mm and less.

The above requirements are applicable to both site and shop welds.

Magnetic Particle or Dye Penetrant Inspection

All nozzles, branch connections, butt welds and attachment welds in alloy steel pipe shall be subjected to
magnetic particle or dye penetrant inspection.

Magnetic particle inspection shall be carried out in accordance with ASTM E709.

When dye penetrant method is used, it shall be conducted in accordance with ASTM El65 and applied as
directed by the penetrant manufacturer.

Turbine, Generator and Auxiliaries

The Contractor shall perform all tests and inspection necessary to ensure that the material and workmanship
conform to the Contract and design drawings and those tests are adequate to demonstrate that the equipment
will comply with the requirements of these Specifications and meet the guarantees specified.

The generator and the turbine rotors shall be over-speed tested at 20% above rated speed and balanced. The
generator rotor test shall be carried out to demonstrate the absence of shorted turns in the rotor winding. These
tests shall be performed throughout the speed range of the generator. High voltage dielectric tests and insula-
tion resistance measurements shall be carried out on the rotor winding before and after the over-speed test.

All items such as assemblies, sub-assemblies and systems shall be subject to inspection by the Employer.
Such items shall include but not limited to: casing, bedplate, coupling, coolers, bearings, stator core, rotor,
brush gear, terminations, auxiliaries, piping. Systems such as lubrication, seal oil, demineralized water and
shall have both their individual components and the whole system functionally tested.

Where possible functional tests of the systems shall be carried out connected to the generator, and before
shipping to Site.

Where the generator or main parts are not fully assembled in the shop, the items shall be trial fitted together
before shipping.

The build-up tolerances shall be checked and recorded.

The generator stator casing and end shield shall be hydrostatically pressure tested, for 15 minutes to specified
design pressure.

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A ring flux test shall be carried out on the completed stator core to demonstrate absence of local hot spots.

All parts subject to steam or water pressure shall be tested with hydraulic pressure of 50% in excess of the
highest working gauge pressure to which the component will be subjected. All equipment shall be tested under
simulated working conditions, and conducted in accordance with the appropriate ASME Power Test Code.

Heat Exchangers

All materials, welding and non-destructive testing shall meet the requirements outlined in ASME Section VIII
“Pressure Vessel Code” and ASME Section IX “Welding Qualification”.

All parts subject to steam or water pressure shall be tested at a hydraulic pressure 1.3 time of the design
pressure.

All closed cooling water heat exchanger tubes shall be pneumatically tested to 10barg internal pressure and
carefully inspected prior to installation.

Circulating Water Pump & Travelling Band Screen

The Circulating Water pumps shall be tested at the specified minimum submergence and static lift to confirm
pump total head and power requirements between shut-off, maximum rated flow and run-out conditions. On
completion of the tests, the submergence shall be decreased to verify the NPSH requirements at maximum
rated flow.

The Close Circuit Water pumps shall be tested to determine head/capacity, and head/power characteristic
curves and to verify freedom from vibration between shut-off, maximum rated flow and run-out conditions.

The Contractor shall submit detail inspection and test procedure complete with references, codes and stand-
ards, and acceptance criteria to the Employer for review and approval prior to perform the test.

Each travelling band screen shall be completely assembled in the Contractor’s or Subcontractor works to en-
sure correct alignment of mating parts and supports.

All parts subject to pressure shall be hydraulically tested to 1.5 time of the design pressure prior to shipment.

Pumps

All parts subject to pressure shall be tested at a hydraulic pressure 1.5 time of the specified design pressure.

The pumps shall be shop tested in accordance with the Hydraulic Institute Standard for the centrifugal pumps.

Certified pump performance curves and list certificates shall be submitted to the Employer for approval, and
for records.

Pumps shall not be shipped until the Employer has seen and approved the test results.

Where applicable, pumps shall be assembled with their spare inner assemblies and shall be shown to be
interchangeable.

Valves

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Valves shall be hydrostatically tested in accordance with ANSI B16.34 or API 598.

Completed power operated valves and actuators shall be tested under load to determine the following:

 Valve operating time to open and close

 Clutch coil current at rated voltage
 Motor currents at rated voltage for the following condition:
Starting
Full load
Maximum during opening operation
Maximum during closing operation
Pressure Vessels

All pressure vessels shall be inspected and tested in accordance with ASME Section VIII, Division 1 latest
edition. Especially for hydrostatic test, 1.5 times of design pressure shall be applied as a test pressure.

When the vessel is subjected to local regulations, it may have to undergo a second official test following the
first one.

The Contractor shall submit complete manufacturing data records that consisting of list of qualified welders,
welding procedures, welding map, welder certificates, NDE records, hydrostatic test, etc. for each pressure
vessel fabricated at shop or site to the Employer for review and approval.

5.1.13.4.3 Inspection and Tests at the Site

The Contractor shall submit to the Employer for approval a comprehensive quality control plan, covering the
pressure parts of the HRSG, erection of the gas turbine and generator, welding of the associated pipework,
and erection of all ancillary plant and the electrical equipment.

This document shall identify the number of supervisory personnel and degree of inspection and tests expected
to be carried out during erection up to completion. It should be equal to that level of control, which has been
applied at the Works and in compliance with the codes and standards identified in this Specification. In addition,
records of all welders’ qualification are to be submitted to the Employer for approval prior to welding. Records
of all heat treatment and non-destructive tests carried out are also to be submitted to the Employer.

Hydrostatic Testing

The Contractor shall upon completion of erection, subject all the pressure parts to a hydraulic pressure test,
which meets ASME Boiler and Pressure Vessel Code requirements. All pressure parts shall be subjected to
the test prior to any boiler casing installation. The Contractor shall supply and install all equipment, piping and
materials, including the safety valve gauges and pumps, required and necessary for the tests.

Site Pipe work and Hydrostatic Test

Where radiographs of Site butt welds joint root or initial passes are called for, the Contractor, subject to the
minimum weld deposit thickness as given in ANSI Power Piping Code, B.31.1, and Section 131, shall radio-
graph the Contractor hot.

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The Contractor shall perform hydrostatic test on all pipework not covered by 100% radiography to a pressure
not less than 1.5 times design pressure. These tests shall be carried out in the presence of the Employer. For
the purposes of the hydrostatic test, the Contractor shall provide temporary blanking off pieces.

Tanks

Vertical Tanks

All tanks constructed at site, except wherever written in this Specification, shall be subject to inspection and
testing, in accordance with the requirements stated in API 650.

The Contractor before carrying out any welding shall meet the conditions stated in Section VI Chapter 5.1.13
“Inspection and Testing” of this Specification.

Checking of the welded seams shall be by spot radiography. The number and location of radiographs shall be
as specified in API 650, Section 6. The Employer reserves the right to call for additional non-destructive tests,
as he may consider necessary.

On completion, all tanks shall be subjected to the tests prescribed in API 650, Section 5.

Horizontal Tanks

All tanks constructed at site, except where specified otherwise in this Specification shall be subject to inspec-
tion and testing, in accordance with the requirements stated in ANSI/AWWA D100 Standard for Welded Steel
Tanks for Water Storage.

The Contractor before carrying out any welding shall meet the conditions stated in Section VI Chapter 5.1.13
“Inspection and Testing” of this Specification.

Checking of the welded seams shall be by spot radiography except those welds excluded by ANSI/AWWA
D100. The number and location of radiographs shall be as specified in ANSI/AWWA D100 Section 11.

On completion, all tanks shall be subjected to the tests prescribed in ANSI/AWWA D100 Section 11 “Testing”.

Rotating Equipment, Vibration

Rotating Equipment such as pumps shall be subject to a test for checking correct rotation, and verifying vibra-
tion and noise guarantees.

Unless otherwise stated or agreed by the Employer each rotating machine has to comply with the requirements
for vibration magnitude (criterion I) designation as “zone A” stipulated by ISO Specification 10816 for the re-
spective group of machinery. If the vibration magnitude is greater than stipulated as “zone B”, the Employer
has the right to reject the concerned equipment.

Noise emissions shall meet the requirements of Section VI Chapter 6.4.4.5.5 “Noise Limitations”.

Rubber Lining (Piping & Tanks)

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Pin-hole test and visual check of complete lining including any patched portion shall be carried out. The voltage
used shall be 75% of the breakdown voltage of the coating. This breakdown voltage shall be first determined
using test plates coated with the specified rubber lining and thickness, separately. The coating on the test plate
shall also be micro-sectioned, by the applicator to show that it is free from vacuoles and other defects.

If the defects revealed by the above test procedure do not exceed one part per 5m2 of coating surface, the
coating not to be retested after the defects have been repaired. If the defects exceed one part, per 5m2 of
coating surface, the repairs shall be retested, and this procedure shall be repeated until the defects are less
than one part, per 5m2 of coating surface.

Additional Tests

In addition to the tests listed above, the Contractor shall demonstrate the function and capability of all equip-
ment and systems supplied under the Contract, to perform in accordance with the Specification requirement,
and shall be conducted in accordance with the testing procedure.

5.2 Electrical

5.2.1 General

All reasonable precautions shall be taken in the design of equipment and of the works to ensure the safety of
personnel concerned with the operation and maintenance of the works.

All equipment to be supplied shall be new and unused from Original Equipment Manufacturer (OEM), new,
unused and latest (up-to-date). Equipment manufactured under license, overhauled, repaired or refurbished
equipment shall not be accepted.

The works shall be designed to ensure continuity of service under all working conditions obtaining at the site
as the first consideration and to facilitate inspection, cleaning and repairs. Any electrical works such as cable
re-routing for existing facilities which includes disconnection, back pulling, splicing or jointing, testing, re-con-
nection, etc. shall be carried out in an approved manner and with minimum impact to existing plant’s operation.

Outdoor equipment shall be designed so that water cannot collect at any point. The undersides of all tanks
shall be ventilated, in an approved manner to prevent corrosion.

Cast iron shall not be used for the chambers of oil-filled apparatus nor for any parts subject to mechanical
stress.

Mechanisms shall be constructed to prevent sticking due to rust and corrosion, and the bearings of exposed
operating shafts shall be designed so as to prevent moisture seeping along shafts into the interior of equipment.

No welding, plugging or filling of defective parts shall be carried out without the prior sanction in writing, of the
Employer. Any such welding approved by the Employer shall comply with these Bidding documents.

All equipment shall operate without undue vibration and with the least practical amount of noise and shall be
installed on a vibration free base.

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