2.9.0 Inspection and Testing

2.9.0                 Inspection and Testing

 

The bidder shall submit a quality control plan for the approval of the purchaser. The plan shall additionally include the following inspection and testing.

 

                        All material shall be tested as per relevant governing standards.

 

                        UT & DP on shaft material shall be conducted.

 

                        The feed gate housing shall be performance tested under no load condition and cycle test shall be conducted for 10 cycles of ON/OFF operation alongwith the actuating cylinder.

 

                        All actuators cylinders shall be tested as per relevant governing standard.

 

                        Jet pumps shall be visually inspected and checked for dimensional accuracies at manufacturer’s works.

 

                        The performance and guarantee test shall be carried out for all jet pumps at site after erection to verify the rated capacity of jet pumps.  For this purpose the bidder shall supply a set of additional jet pumps, minimum two (2) numbers, with same material of construction, having 25 mm larger throat diameter than the designed throat diameter.  The dimensions (including the nozzle diameter) of other parts of these jet pumps like inlet section, discharge and tail piece shall be the same as the design jet pumps.

 

                        All materials shall be tested/inspected as per governing Code/Standard and test certificates/reports shall be furnished for Owner’s approval.

 

                        Jet pump assemblies shall be subjected to Hydraulic pressure test at shop.

 

                        All materials of valve components shall be tested/inspected as per governing stand­ard/code for its chemical and mechanical properties.

 

                        The valves shall be hydraulically tested for body and seat leakage test at shop.

 

                        All valves shall be subjected to cycle test for 10 cycles  for ON-OFF operation before hydraulic test.

 

                        All pneumatically operated valves shall be tested alongwith the actuators.  However all actuators shall be tested as per relevant standard at manufacturer’s shop

 

2.9.1                 Clinker Grinder

 

                        All raw materials of grinder shall be of tested quality and test certificates shall be furnished for review.

 

                        Clinker grinders shall be visually inspected and checked for dimensional accuracies at manufacturer’s works

 

                        No load run test for 6 hours continuous operation of clinker grinder shall be done to ensure trouble free operation.

 

                        UT/MPI/DP test shall be carried out on shaft material.

 

                        MPI/DP test shall be carried out on welding.

 

                        Welding procedure and welder qualification shall be done prior to welding.

 

2.9.2                 Fluid Coupling

 

                        Static and dynamic balancing shall be carried out for all rotating parts.

 

                        Check for leak tightness of the coupling shall be carried out.

 

                        Functional test on fusible plug for each type of coupling shall be conducted at shop.

 

Check for temperature rise, torque speed, torque slip characteristics and overspeed test on coupling of each size and type during load test (preferably at full load at shop).

 

2.9.3                 Flushing Boxes

 

                        All material of flushing boxes shall be of tested/inspected as per relevant code standard requirements for chemical and mechanical properties.

                        Welding procedure/welder qualification shall be carried out prior to welding.

 

                        MPI/DPI tests as applicable shall be done on weldments to ensure freedom from defects.

 

                        Fill test on assembly shall be carried out.

 

2.9.4                 Gear Boxes

 

                        Gear boxes shall be visually inspected and checked for dimensional accuracy at manufacturer’s works.

 

                        Gear tooth hardness shall be checked and case hardness depth shall be measured.

 

                        UT/MPI/DP test shall be carried out on shaft material

 

                        Non load run test shall be carried out on assembled gear boxes for one (1) hour duration.

 

                        Noise and vibration test shall be conducted at shop and site.         

 

2.9.5                 Expansion Joint for Eco Hopper

 

                        All material shall be tested for chemical, mechanical properties and all other tests as per relevant standards.

 

                        Leak test shall be carried out at 1.1 times design pressure.

 

                        DPT shall be carried out on expanded portion to check cracks.

 

                        Proof of design test/cycle test shall be carried out on one of the expansion joint as per relevant standards. In case the bidder has already carried out the same on the expansion joint of the type and rating being offered, then the test certificate shall be submitted for Engineer’s approval.

 

2.9.6                 Expansion joints for Fly Ash Handling System

 

                        All material shall be tested for chemical, mechanical properties and all other tests as per relevant standards.

 

                        Leak test shall be carried out at 1.1 times design pressure.

 

                        DPT shall be carried out on expanded portion to check cracks.

 

Proof of design test/cycle test shall be carried out on one of the expansion joint as per relevant standards.  In case the bidder has already carried out the same on the expansion joint of the type and rating being offered, then the test certificate shall be submitted for Engineer’s approval.

 

2.9.7                 Vacuum Pumps

 

                        All materials shall be tested for chemical & mechanical properties as per the relevant governing standard.

 

                        Performance test shall be done for capacity & power consumption at rated condition as per pneurop/equivalent standard.

 

               Noise & vibration level shall be measured.

 

2.9.8                 Valves on Fly Ash Branch Segregation

 

                        All material component of valves shall be tested/inspected for its chemical and mechanical properties as per relevant governing standards.

 

                        All valves shall be subjected to cycle test for at least 10 cycles ON-OFF operation to ensure smooth operation.

 

Pneumatic cylinder operated valves shall be tested alongwith pneumatic cylinders.  However, all pneumatic cylinders shall be tested at manufacturer’s works as per relevant standard.

 

2.9.9                 Vacuum Breaker

 

                        All material of vacuum breaker components shall be tested for its chemical and mechanical properties as per relevant governing standard.

 

                        All vacuum breakers shall be subjected to cycle test for atleast 10-cycles ON-OFF operation to ensure smooth operation.

 

Pneumatic cylinder operated vacuum breakers shall be tested alongwith pneumatic cylinders.  However, all pneumatic cylinders shall be tested at manufacturer’s works as per relevant std.

 

2.9.10               Air Intake Valves

 

                        The valves materials shall be tested for chemical and mechanical properties as per relevant governing standard.

 

                        All valves shall be subjected to cycle test for at least 10 cycles ON-OFF operation.

 

2.9.11               Air  Ejector

 

                        Air Ejectors materials shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Hydraulic/pneumatic pressure test at 1.5 times the design pressure or two times the operating pressure, whichever is higher, shall be carried out at manufac­turer’s works.

 

2.9.12               Centrifugal Fans for  Fluidising Pads

 

                        i)          One fan of each type will be type tested as per corresponding IS code.  BS 848 shall supplement the IS code.

 

                        ii)         Acceptance test and routine test shall be carried out as per corresponding IS code.  BS 848 shall supplement the IS code.

 

                        iii)        Dynamic balancing shall be carried out for all fans.

 

                        iv)        Vibration and noise level test shall be carried out for all fans.

 

                        v)         Welding shall be carried out by qualified welders.

 

2.9.13               Air Locks/Pump Tank

 

                        Air locks/pump tanks materials shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Air locks/pump tanks shall be tested hydraulically for 1.5 times the design pressure at manufacturer’s works.

 

                        Welding procedure and welder qualification shall be approved prior to welding.  NDT shall be conducted on welding.

 

                        Inlet and outlet valves shall be tested for its performance to ensure smooth operation.

 

2.9.14               Pneumatic Ash Conveying Pipe Line

 

                        Pipes & fittings shall be tested for chemical, mechanical & dimensional check as per relevant standards.

 

                        Pipes shall be hydraulically tested as per relevant standard.

 

                        Fittings shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

                        In case of cast basalt-lined fittings, basalt-liners shall be tested for chemical and mechanical properties.  Basalt liners shall be examined visually for detection of cracks and defects.

 

Cast Basalt lined fittings shall be hydro tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

2.9.15               Surge/Buffer Hoppers

 

                        Welding procedure/welder qualification shall be done as per ASME Sec-IX.

 

                        DP/MPI test shall be done on weldments suitably.

 

2.9.16               Air Compressors and Receivers

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        All pressure parts shall be subjected to hydraulic testing at a pressure of 200% of working pressure for a period of not less than one (1) hour.

 

                        The Bidder shall include for performance testing of each compressor in accordance with BS:1571 / IS:5456 / ISO:1217.  Each test will be witnessed by the Engineer. The tender must include a testing proposal by the Bidder.

 

                        UT and MPI/DP test shall be carried out all forgings and shafts.

 

                        Rotating elements of compressor components shall be statically and dynamically balanced. 

 

                        Compressor noise and vibration shall be measured at shop and site.

 

                        Type testing as per IS:5456/ISO:1217 shall be carried out in presence of the Owner, if not carried out earlier.  The testing procedure shall be mutually discussed and finalised before commencement of the test.  In case type testing is already carried out, a test certificate with details of test results shall be submitted to the Owner for review and approval.  Also, calculation for volumetric efficiency shall be furnished to Owner.

 

                        Welding procedure and welder qualification shall be carried out as per ASME Sec. IX prior to welding.

 

                        All welding shall be tested as per IS:2825.

 

Air receiver shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher for 30 minutes

 

2.9.17               Air Blowers

 

                        All materials shall be tested for chemical and mechanical properties as per governing Code/Standard.

 

                        NDT shall be conducted on shaft and impeller.

 

                        Rotating elements shall be subjected to static and dynamic balancing.

 

                        Performance testing of blowers shall be carried out as per BS:1571 at manufacturer’s shop.

 

                        Noise and vibration level shall be measured.

 

2.9.18               Instrument Air Compressors

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        UT and MPI/DPT shall be done on all forgings and shafts.

 

                        Rotating elements shall be statically and dynamically balanced.

 

                        Performance/routine test shall be carried out as per BS-1571/IS:5456.

 

2.9.19               Air Receivers

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Welding procedure and welder qualification shall be carried out as per ASME Sec-IX prior to welding. All welding shall be tested as per IS:2825.

 

                        Air receivers shall be tested hydraulically at twice the operating presure or 1.5 times the design pressure whichever is higher for 30 minutes.

 

2.9.20               Air Drying Plant

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Welding procedure and welder qualification shall be carried out as per ASME Sec.IX prior to welding. All welding shall be tested as per IS:2825.

 

                        Pressure vessels shall be tested for hydraulic pressure at twice the working pressure or 1.5 times the design pressure whichever is higher.

 

                        Sequence test shall be carried out.

 

                        Type testing as per IS:5456/ISO:1217 shall be carried out in presence of the Owner, if not carried out earlier.  The testing procedure shall be mutually discussed and finalised before commencement of the test.  In case type testing is already carried out, a test certificate with details of test results shall be submitted to the Owner for review and approval.  Also calculation for volumetric efficiency shall be furnished to Owner.

 

2.9.21               Wetting Head

 

                        Wetting head shall be visually inspected and checked for dimensional accuracies at manufacturer’s works.

                        Hydraulic/pressure test shall be carried out on assem­bled wetting heads.

 

All materials shall be tested for chemical and mechanical properties as per relevant standard.

 

2.9.22               Collector Tanks

 

                        All materials shall be tested/inspected as per govern­ing code/standard for chemical and mechanical proper­ties.

 

                        Welding procedure/welder qualification shall be carried out prior to welding.

 

                        MPI/DP test on welding shall be carried out.

 

                        Fill test on assembled tank shall be carried out.

 

2.9.23               Bag Filters

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Welding procedure and welder qualification shall  be carried out prior to welding.

 

                        NDT shall be done on weldments.

 

                        Leakage test shall be carried out for casing.

 

Pulsing and sequential test on bag filter cases shall be done at shop.

 

2.9.24               Ash Storage Silo

 

                        All material shall be tested for its mechanical and chemical properties as per relevant standard.

 

                        NDT shall be carried out on weldments.

 

                        Welding procedure & welder qualification shall be carried out as per ASME Sec. IX prior to welding.

 

Fit up assembly checks shall be carried out at shop for all despatchable segments of silo.

 

2.9.25               Piping Valves and Fittings

 

                        Pipe & fittings material shall be tested for chemical, Mechanical properties and dimensional check as per relevant governing standard.

 

                        Hydraulic test shall be done on ERW pipes as per relevant standard.

 

Fittings shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

                        Valve materials shall be tested for chemical and mechanical properties as per relevant governing standard.

 

                        All valves shall be tested hydraulically for body and seat as per governing API/BS/IS standards.

 

Air seat test shall also be carried out at 7kg/cm2 pressure in case of air duty valves and wherever applicable as per relevant standard.

 

2.9.26               Inspection and Testing – Ash Slurry Disposal Pipes and Fittings

 

                        Pipes and fittings shall be tested for chemical, mechanical and dimensional check as per relevant std.

 

                        Pipes shall be hydraulically tested as per relevant std.

 

                        Fittings shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

                        In case of Cast Basalt lined fittings, Basalt liners shall be tested for chemical & mechanical properties.  Basalt liners be examined visually for detection of cracks & defects.

 

                        Cast Basalt lined fittings shall be hydro-tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

2.9.27               Horizontal Centrifugal Pumps

 

2.9.27.1            Testing and Inspection at Manufacturer’s Works

 

                        All materials shall be tested for chemical and mechanical properties as per relevant governing standard.

 

                        a)         The pump casing shall be hydraulically tested at 200% of pump rated head or at 150% of shut-off-head, whichever is higher.  The test pressure shall be maintained for at least half an hour.

 

                        b)         For each ash slurry disposal pump the rated pressure corresponds to design pressure.  Rated/Shut off head for each slurry pump shall be taken after adding the rated/shut off head for all the pumps coming in a series. The testing for each pump shall be done corresponding to these pressure and as defined at (a) above.

 

                        The pump rotating parts shall be subjected to static and dynamic balancing tests.

 

                        UT shall be done on shaft forgings and MPI/DP shall be done on shafts and impeller.

 

                        All pumps shall be tested for performance test for capacity head, efficiency and brake horse power at rated speed as per HIS and IS as applicable.

 

                        Noise & Vibration shall be measured during the performance testing at shop.

 

                        Fluid Coupling

 

                        All material shall be tested for chemical & mechanical properties as per relevant standard.

 

                        (i)         Static & dynamic balancing shall be carried out for all rotating parts.

 

                        (ii)        Check for leak tightness of the coupling shall be carried out.

 

                        (iii)       Functional test on fusible plug for each type of coupling shall be conducted at shop.

 

                        (iv)       Check for temperature rise, torque speed, torque slip characteristics and overspeed test on one coupling of each size and type during load test (preferably at full load at shop).

 

                        BS:5353            :           Carbon and Alloy steel plug valves.

 

                        ANSI B:16.10   :           Face to face and end to end dimensions of Ferrous valves.

 

                        API-598            :           Valve inspection and test.

 

2.9.27.2            Slurry Disposal Line Valves

 

                        All materials of valves components shall be tested/inspected as per governing std./code for its chemical & mechanical properties.

 

                        All valves shall be hydraulically tested for body and seat leakage test at shop.

 

 

                        (i)         IS : 1710                       Vertical Turbine pump for clear, cold, fresh water.

 

                        (ii)        IS : 5639                       Pumps handling chemicals and corro­sive liquids.

 

                        (iii)       IS : 5120                       Rotodynamic Special Purpose Pump.

 

                        (iv)       IS : 5659                       Pumps for process water

 

                        (v)        IS : 5600                       Specification for sewage and drainage pumps.

 

                        (vi)       Standards of Hydraulic Institute, U.S.A.

 

2.9.27.3            Vertical Sump Drainage Pumps

 

                        Testing & Inspection at Manufacturer’s Works

 

                        All material shall be tested for chemical & mechanical properties as per relevant governing std. Shaft forgings shall be subjected to UT MPI/DP test shall be carried out on impeller and shaft to ensure freedom from defects.

 

                        The pump casing shall be hydraulically tested at 200% of pump rated head or at 150% of shut-off head, whichever is higher. The test pressure shall be maintained for at least half an hour.

 

                        The pump rotating parts shall be subjected to static and dynamic balancing.

 

                        All pumps shall be tested at the shop for capacity, head, efficiency & brake horse power at rated speed as per HIS/IS as applicable.

 

                        The pump accessories e.g. the thrust bearing, the motor pump shaft coupling etc. will be subjected to tests as per Manufacturer’s standard.

 

 

                        Noise & vibration shall be measured during the performance testing at shop.

 

                        Test reports and certificates of the above mentioned test to ensure satisfactory operation of the system shall be submitted to the owner before despatch.

 

                        Tests at Site

 

                        After erection at site, pumps as detailed under different groups shall be operated to prove satisfactory performance as individual equipment as well as a system.

 

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