RIAU-WV02-G10-QA-0002 - Shop Test and Inspection Plans - Rev0 PDF

Owner
PT MEDCO RATCH POWER RIAU
Contractor
LOTTE ENGINEERING & CONSTRUCTION
Vendor
BOUSTEAD SALCON WATER SOLUTIONS
Vendor Package
WASTE WATER TREATMENT SYSTEM
Project
RIAU GFPP 275MW IPP PROJECT
Title:
Shop Test and Inspection Plans
Contractor Document Number: Rev. No. Page

RIAU-WV02-G10-QA-0002 0 1 of 16
Doc. No :
RIAU GFPP 275MW RIAU-WV02-G10-QA-0002 Rev No.
DOCUMENT TITLE
IPP Project 0
Page 2 of 16
Revision Record :
Prepared Reviewed Checked Approved

Rev. No. Date Purpose
by by by by
0 20Jun2019 Issue for Information KS FZ SS WHY
SHOP INSPECTION AND TEST PLAN
Project: Riau GFPP (275 MW) IPP Project Doc No: RIAU-WV02-G10-QA-0002
Client: LOTTE Vendor: BOUSTEAD SALCON WATER SOLUTIONS PTE LTD
PROCEDURES / INSPECTION BY
No. INSPECTION & TESTS ITEMS INSPECTION ACTIVITIES VERIFYING DOCUMENTS Remarks
ACCEPTANCE CRITERIA BSWS LEC OWNER AI
PRESSURE VESSELS
EN 10204 3.1
Review of Mill Certificates
MATERIAL INSPECTION ASME Sec II or Equivalent Material Inspection Report R R R - certificate for pressure
Material Traceability Report
part only
Material Marking & Identification
ASME Sec IX/

WELDING PROCEDURES Review of WPS, WPQ & PQR ASME Sec IX R R R -
Project Specification
Radiographic Test (Head-Full, Shell-Spot)
ASME Sec V/ PMI and Hardness
NDT Penetrant Test (for SS part) 10% on major joints NDT Reports R R R -
ASME Sec VIII Div 1 Test is Excluded
Magnetic Particle Test 10% on major joints
Nozzle Position and Orientation
Check of Cleanliness (internal, external) Outline Drawing/ Visual & Dimensional Reports/
DIMENSION & VISUAL INSPECTION W R R -
Visual Check of Welding Project Specification As-Built Drawing
Dimensional Check as per Drawing
Check for Pressure Drop
ASME Sec VIII/
HYDROSTATIC TEST Check for Leakage Hydrostatic Test Report H R R -
Endorse Hydrostatic Test Report
AIR LEAK TEST FOR RE-INFORCEMENT PAD Check for any leakage or bubbles Manufacturer's Standard Manufacturer's Standard R R R -
Review of Paint Data Sheets

Check Surface Preparation
Paint Manufacturer's Standard/
PAINTING CHECK Visual Check of Painting Painting Report H R R -
Check of DFT & Color
Cleaning and Passivation Check for SS
Check of Hardness ( For rubber lining only)

Check Thickness Manufacturer's Standard/
RUBBER LINING CHECK / INTERNAL PAINTING Rubber Lining Report H R R -
Check Surface Finishing Project Specification
Holiday Test
TRIAL FIT-UP Fit-up check for ladders & handrails Outline Drawing - R R - -
Visual Check of Complete Product

Check name plate details
Check Packing Conditions Shipping Instruction/ Inspection Checklist/
FINAL INSPECTION H R R -
Check of Packing List & Shipping Marks Project Specification Final Inspection Report
Check for Inspection Release Certificate
Check Complete MDR
Note : R : Record Review H : Hold Point

W : Witness Point S : Surveillance
STEEL TANK
Review of Mill Certificates Manufacturer's Standard/ Material Inspection Report or

MATERIAL INSPECTION R R R -
Material Traceability Report Project Specification Certificate of Conformance
ASME Sec IX/

MPI/PT Manufacturer's Standard/ PMI and Hardness

NDT MPI/PT Reports R R R -
(10% on all major corner joins & nozzles) Project Specification Test is Excluded
Nozzle Position and Orientation

Check for Leakage Manufacturer's Standard/

WATER FILLING LEAK TEST Leak Test Report H R R -
Endorse Leak Test Report Project Specification

Check Surface Preparation
Paint Manufacturer's Standard/
PAINTING CHECK Visual Check of Painting Painting Report R R R -
Cleaning and Passivation Check for SS
Check of Hardness ( For rubber lining only)

Check Thickness Manufacturer's Standard/
RUBBER LINING CHECK / INTERNAL PAINTING Rubber Lining Report H R R -
Check Surface Finishing Project Specification
Holiday Test
TRIAL FIT-UP Fit-up check for ladders & handrails Outline Drawing - R R - -

Check Complete MDR

FRP TANKS
Method of Statement
MATERIAL CHECK Manufacturer's Standard Data Sheets R R R -
Resin Data Sheet
Check visually internal & external

Check of Cleanliness
Check Nozzle Position & Orientation Outline Drawing/ Visual & Dimensional Reports/
VISUAL & DIMENSIONAL INSPECTION H R R -
Check Flange Alignment Project Specification As-Built Drawing
Check Re-enforcement & Stiffener Plates
Check Dimensions as per Drawing
THICKNESS CHECK Check Thickness Randomly Outline Drawing Thickness Check Report W R R -
BARCOL HARDNESS TEST Check Hardness at Various Points Manufacturer's Standard Hardness Check Report W R R -
ACETON WIPE TEST Spot Check Randomly Manufacturer's Standard Inspection Report W R R -
Check for Leakage

LEAK TEST Check of Cleanliness & Draining Manufacturer's Standard Leak Test Report H R R -
Endorse Leak Test Report

Check Complete MDR

PUMPS (CENTRIFUGAL & PRGRESSIVE CAVITY PUMPS)
Check Material Certificate for casing /Shaft & EN 10204 type 2.2
MATERIAL CHECK impeller. ASME Sec II or Equivalent Material Cert or COC R R R - certificate will be
Certificate of Conformance provided for casing

Outline Drawing/ Visual & Dimensional Reports/
VISUAL & DIMENSIONAL INSPECTION Check of Cleanliness W R R -
Project Specification As-Built Drawing
Type test or Certificate

HYDROSTATIC TEST (Pump Casing) Casing Hydrostatic Test Manufacturer's Standard Hydrostatic Test Report R R R -
of conformance
Verify performance against pump data

PERFORMANCE TEST Check for Head & Flow Manufacturer's Standard Pump Test Report R R R -
of conformance
Check Pump Test Curve
Check Noise
MECHANICAL RUN TEST Check Vibration Manufacturer's Standard Pump Test Report R R R -
of conformance
Check Temperature
Visual & Dimensional Inspection

Measurement of Winding Resistance Manufacturer's Standard/ Type test report will be
MOTOR TEST Motor Test Report R R R -
Insulation Resistance Test Project Specification provided..
Noise & Vibration Measurement
Visual Check of Painting Manufacturer's Standard/

PAINTING INSPECTION Painting Report R R R -
Check of Color code & review painting certificate Project Specification
Check of Complete Pump Skid

Check Each components Secured Properly
Shipping Instruction/ Inspection Checklist/
FINAL INSPECTION Check Packing Conditions H R - -
Project Specification Final Inspection Report
Check of Packing List & Shipping Marks
Check Complete MDR

PUMPS (CHEMICAL DOSING & UNLOADING PUMPS)
Material Certificate for metal pump

MATERIAL CHECK ASME Sec II or Equivalent EN 10204 type 2.2 R R R -
Certificate of Conformance for non metallic pumps


HYDROSTATIC TEST (Pump Casing) Casing Hydrostatic Test Manufacturer's Standard Hydrostatic Test Report R R R -
of conformance.
Type Test Certificate will

PERFORMANCE TEST Verify performance against pump data Manufacturer's Standard Pump Test Report W R R -
be submitted.

Measurement of Winding Resistance Manufacturer's Standard/ Type Test Certificate will
Insulation Resistance Test Project Specification be submitted.
Manufacturer's Standard/
PAINTING INSPECTION OF METAL PARTS Check of Painting Color Painting Report R R R -
Check of Complete Pump Skid

Check Complete MDR

BLOWERS/COMPRESSOR
Check Material Certificate for casing.

MATERIAL CHECK ASME Sec II or Equivalent COC R R R -
Certificate of Conformance

Check Noise
MECHANICAL RUN TEST Check Vibration Manufacturer's Standard Test Report R R R -
of Conformance.
Check Temperature

Measurement of Winding Resistance Manufacturer's Standard/ Type test report will be
Insulation Resistance Test Project Specification provided

Check for color code Project Specification
Check of Complete Product

Check Complete MDR
CONTROL PANEL
Check Material Certificate/
MATERIAL CHECK Manufacturer's Standard Material Cert or COC R R R -

HARDWARE CHECK Check all Components in the Panel Outline Drawing FAT Report W R R -
WIRING CHECK Check all Wiring in the Panel Wiring Diagram FAT Report W R R -
Functional test internally done by

INTERNAL FAT FAT Procedure FAT Report R R - -
Manufacturer
FAT Functional Test including sequence test FAT Procedure FAT Report W W R -
Check of Complete Panel

Check Doors Openings & Locks
Check for Protection Against Moisture
FINAL INSPECTION Check name plate details W W - -
Check Packing Conditions
Check Complete MDR

SKID

MATERIAL INSPECTION ASME Sec II or Equivalent Mill Cert or COC R R R -
ASME Sec IX/

WELDING PROCEDURES Review of WPS, WPQ & PQR ASME Sec IX R R R - For Metal Piping Only
Fit-up Inspection
Check of Cleanliness Outline Drawing/ Visual & Dimensional Reports/
DIMENSION & VISUAL INSPECTION H R R -

Check Surface Preparation Manufacturer's Standard/
PAINTING CHECK Painting Report W R R -
Visual Check of Painting Project Specification
Visual Check of Complete Skid

Check Complete MDR

VALVES / STRAINER
MATERIAL INSPECTION Review of Material Certificates Manufacturer's Standard COC R R R -
Dimensional Check as per Drawing Project Specification As-Built Drawing

Certificate of
HYDROSTATIC TEST (Valve/Strainer Body) Check for Leakage Manufacturer's Standard Hydrostatic Test Report R R R -
Conformance.
Check of Cleanliness & Draining

Certificate of
SEAT TIGHTNESS TEST Check for Leakage Manufacturer's Standard Seat Tightness Test Report R R R -
Conformance.
Check of Cleanliness & Draining

PAINTING CHECK Painting Report R R R -
Check of Color Project Specification
Check On/Off Condition

Check ON/Off Timing 10 % Random
FUNCTIONAL TEST (for Automatic Valves) Manufacturer's Standard Functional Test Report H R R -
Check Position Indicator inspection
Check Limit Switch
CALIBRATION CERTIFICATES NIST Standard/

Review Calibration Certificates Calibration Certificates R R R -
(for PRV) Project Specification

Check Complete MDR

INSTRUMENTS
MATERIAL INSPECTION Review of Material Certificates Manufacturer's Standard COC R R R -
DIMENSION & VISUAL INSPECTION R R R -
Dimensional Check as per Drawing Project Specification As-Built Drawing
Visual Check of Painting

PAINTING CHECK Manufacturer's Standard Painting Report R R R -
Check of Color
NIST Standard/
CALIBRATION CERTIFICATES Review Calibration Certificates Calibration Certificates R R R -

FINAL INSPECTION Check of Packing List & Shipping Marks H R R -
Check Complete MDR

PIPING (Pre-Fabricated Spools)
For Metal Piping Only .

MATERIAL INSPECTION ASME Sec II or Equivalent EN 10204 3.1 R R R - For GRP/ CPVC pipes
COC will be provided.
ASME Sec IX/

WELDING PROCEDURES Review of WPS, WPQ & PQR ASME Sec IX R R R - For Metal Piping Only
Radiographic Test 10% On major joints

ASME Sec V/
NDT Penetrant Test (for SS part) NDT Reports R R R - chose randomly. For
Magnetic Particle Test Metal Piping Only
Fit-up Inspection

Check for Leakage ASME Sec VIII/ Only for flanged pipe
HYDROSTATIC TEST Hydrostatic Test Report H R R -
Check of Cleanliness & Draining Project Specification spools
Endorse Hydrostatic Test Report

Check Surface Preparation Manufacturer's Standard/
PAINTING CHECK Painting Report H R R - For Metal Piping Only
Check of Hardness
Check Thickness Manufacturer's Standard/ For Lined Metal Piping
RUBBER / PPE LINING CHECK Rubber Lining Report H R R -
Check Surface Finishing Project Specification Only
Holiday Test
Visual Check of Complete Spools

Check of Tagging
Check Complete MDR

MIXER

MATERIAL CHECK Manufacturer's Standard COC R R R -
Check of visual appearance


Manufacturer's Standard/ Type test report will be
MOTOR TEST Measurement of Winding Resistance Motor Test Report R R R -
Project Specification submitted.
Insulation Resistance Test

Check of Color Project Specification
Check of Complete Product

FINAL INSPECTION H R - -
Check Complete MDR

CLARIFIER

Manufacturer's Standard/
MATERIAL INSPECTION Material Traceability Report Mill Cert or COC R R R -
ASME Sec IX/



Check Surface Preparation Paint Manufacturer's Standard/

Check Complete MDR

CENTRIFUGE

MATERIAL CHECK Manufacturer's Standard Material Cert or COC R R R -


Check Surface Preparation Paint Manufacturer's Standard/

Check Complete MDR


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Owner

PT MEDCO RATCH POWER RIAU

BOUSTEAD SALCON WATER SOLUTIONS

Shop Test and Inspection Plans

Contractor Document Number: Rev. No. Page

Prepared Reviewed Checked Approved

ASME Sec IX/

Review of Paint Data Sheets

Check of Hardness ( For rubber lining only)

Visual Check of Complete Product

Note : R : Record Review H : Hold Point

Review of Mill Certificates Manufacturer's Standard/ Material Inspection Report or

ASME Sec IX/

MPI/PT Manufacturer's Standard/ PMI and Hardness

Nozzle Position and Orientation

Check for Leakage Manufacturer's Standard/

Review of Paint Data Sheets

Check of Hardness ( For rubber lining only)

Visual Check of Complete Product

Note : R : Record Review H : Hold Point

Check visually internal & external

Check for Leakage

Visual Check of Complete Product

Note : R : Record Review H : Hold Point

PUMPS (CENTRIFUGAL & PRGRESSIVE CAVITY PUMPS)

Check visually internal & external

Type test or Certificate

Verify performance against pump data

Visual & Dimensional Inspection

Visual Check of Painting Manufacturer's Standard/

Check of Complete Pump Skid

Note : R : Record Review H : Hold Point

PUMPS (CHEMICAL DOSING & UNLOADING PUMPS)

Material Certificate for metal pump

Check visually internal & external

Type test or Certificate

Type Test Certificate will

Visual & Dimensional Inspection

Check of Complete Pump Skid

Note : R : Record Review H : Hold Point

Check Material Certificate for casing.

Check visually internal & external

Visual & Dimensional Inspection

Visual Check of Painting Manufacturer's Standard/

Check of Complete Product

Check visually internal & external

Functional test internally done by

Check of Complete Panel

Note : R : Record Review H : Hold Point

Review of Mill Certificates

ASME Sec IX/

Review of Paint Data Sheets

Visual Check of Complete Skid

Note : R : Record Review H : Hold Point

MATERIAL INSPECTION Review of Material Certificates Manufacturer's Standard COC R R R -

Check for Pressure Drop

Check for Pressure Drop

Visual Check of Painting Manufacturer's Standard/

Check On/Off Condition