31003 - Quality Assurance, Inspection, Testing and Commissioning_MECH

QUALITY ASSURANCE, INSPECTION AND TESTING (MECH)SECTION 31003

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1.0 GENERAL

1.1 DESCRIPTION

1.1.1 The quality assurance, inspection and testing procedure shall be complied with in every respect unless otherwise stated agreed by the E.R.

1.2 WORK INCLUDED

1.2.1 Provide quality assurance manual (QAM), works quality assurance programme (WQAP), field quality assurance programme (FQAP) and quality plan.

1.2.2 Tests at manufacturer's works.

1.2.3 Provide assistance and testing equipment for witnessed site inspection and tests.

1.2.4 Perform site tests and commissioning for all mechanical and electrical equipment.

1.3 SUBMITTALS

1.3.1 After Contract Award, submit the following :-

(1) Quality Assurance Manual (QAM)

(2) Works Quality Assurance Programme (WQAP)

(3) Field Quality Assurance Programme (FQAP)

(4) Quality Plan

1.3.2 For Inspection and testing, submit inspection and testing procedures, programme and record sheets.

1.3.3 After completion of testing, submit test records, packaging, transportation and storage instructions and methods.

1.3.4 For site installation and commissioning, submit installation methods or procedures, notification and procedures for pre-commission and commissioning.

1.3.5 After commissioning, submit site test records, as-built drawings.

1.4 QUALITY ASSURANCE

The Contract shall refer to the appropriate parts of ISO 9000 series as guidelines for the implementation of the quality programmes.

2.0 PRODUCTS - NOT USED

3.0 EXECUTION

3.1 QUALITY ASSURANCE CONCEPT AND CONTROL

3.1.1 Minimum requirements for establishing and implementing a quality assurance programme shall be applied to all aspects of the work necessary for carrying out the Contract. Quality assurance shall extend to material parts, components, systems and

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services as a means of obtaining and sustaining the reliability of critical items, operating performance, maintenance and safety.

3.1.2 Acceptance of the Contractor's quality assurance programme does not relieve the Contractor's obligation to comply with the requirement of the Contract document. If the programme is found to be ineffective or inadequate in providing for quality assurance or control, then the Employer's Representative reserves the right to request for necessary revisions of the programme.

3.1.3 The Contractor is required to produce readily identifiable documentary evidence covering the extent and details of both his own and his Contracts' quality assurance system.

3.1.4 The documentary evidence should take the following form :

(1) Quality Assurance Manual (QAM)

(2) Works Quality Assurance Programme (WQAP)

(3) Filed Quality Assurance Programme (FQAP)

(4) Quality Plan

3.1.5 These documents shall be prepared by the Contractor for all items and services to be supplied, after the Contract has been placed, but before commencement of fabrication, and shall be subject to evaluation and acceptance by the Employer's Representative before start of works.

3.1.5.1 Quality Assurance Manual (QAM)

The QAM shall be a general comprehensive document outlining the Contractor's basic organization, policies and procedures. The information to be given in the QAM shall include but not limited to :

(1) Quality policy

(2) Quality assurance programme

(3) Organisation structure showing inter-relationships

(4) Functional responsibilities and levels of authority

(5) Lines of communication

(6) Customer relations

(7) Laboratory facilities

3.1.5.2 Works Quality Assurance Programme (WQAP)

The WQAP shall detail the Contractor's quality assurance programme at works applicable throughout all phases of Contract performance including design, procurement, manufacture, inspection and testing. It shall identify each of the programme elements to be designed, developed, executed and maintained by the Contractor for the purpose of ensuring that all supplies and services comply with this Specification.



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The information to be given in the WQAP shall include but not limited to :

(1) Organization and Responsibility

(2) Contract Review

(3) Design and Document Control

(4) Procurement Control

(5) Production Control

(6) Control on Contracts

(7) In-process Quality Control and Traceability

(8) Inspection and Testing

(9) Control of Non-conformances

(10) Corrective Action

(11) Control of Inspection, Measuring and Test Equipment

(12) Handling, Storage, Packaging and Delivery

(13) Records

(14) Quality Audits

(15) After-Sales Servicing

3.1.5.3 Field Quality Assurance Programme (FQAP)

The FQAP shall detail the Contractor's Quality Assurance Programme at Site applicable throughout site construction, erection and commissioning. It is the underlying philosophy that the quality built into the product at works shall be maintained throughout the construction and commissioning stages.

While, in principle, the FQAP shall include the items discussed in WQAP, it shall, however, be approached differently to take into account site conditions.

The FQAP shall include, but not limited to the following information :

(1) Organization and Responsibility

(2) Control of Drawings and Documentation

(3) Product Checklist

(4) Control and Traceability of Purchased Materials and Services

(5) Receipt Inspection of Materials at Site

(6) Material Storage Control



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(7) Inspection and Examination Procedures

(8) Control of Painting and Insulation Works

(9) Pre-commissioning

(10) Commissioning

(11) Control of Non-conformances

(12) Corrective Action

(13) Control of Inspection, Measuring and Test Equipment

(14) Records

(15) Quality Audit

(16) Personnel Training

(17) Servicing during Defects Liability Period

3.1.5.4 Quality Plan

The Contractor shall be required to prepare manufacturing and construction/erection quality plans for all equipment items and services. The quality plan shall also define the involvement of the Employer's Representative in the inspection and test programmes.

The Quality Plan shall incorporate as appropriate :

(1) Charts indicating flow of materials, parts and components through manufacturing quality control, inspection and test to delivery and erection.

(2) The charts shall indicate the requirement for quality control, inspection and test beyond which manufacture shall not continue until the action required by the requirement is met, and the documentation required is generated.

(3) The control documents associated with each hold point, i.e. drawings, material specification, Works Process Schedule (WPS), Process Quality Records (PQR), quality control methods and procedures and acceptance Standards.

(4) These control documents should also include Process Contract document Sheets, Inspection Procedure Sheets, Site Fabrication Specification, Cleaning and Protection Application Sheets and Purchase Specifications.

(5) These documents shall detail the procedures and approvals with which the process complies.

(6) An indication of the organization responsible for the quality activities covered.

(7) Reference to quality assurance procedures, and non-conformance procedures.

(8) The Contractor shall submit his contractor's quality plans. The Contractor shall determine and agree with the Employer's Representative the control to be



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exercised over the Contracts and the degree of surveillance that will take place.

(9) Provision for the Employer's Representative to insert hold points at which quality activities are to be witnessed.

(10) The Contractor shall prepare education and training programmes as required for the indoctrination of his quality assurance and quality control personnel. Where personnel are required to be certified by this Contract document, e.g. skilled wiremen, the Contractor shall keep an up-to-date register which will be subject to examination by the Employer's Representative.

3.2 REPAIR PROCEDURES

3.2.1 The Contractor shall prepare a Repair Procedure for Works and site based on the specification requirements and approved Standards for mechanical equipment and finishing and painting. The procedure shall take into account Site conditions, and be detail enough to include, for example, equipment to be used, methods of repair, acceptance/rejection criteria, inspections required, etc. The repair procedure shall cover welding, painting, etc.

3.3 OTHER DOCUMENTS

3.3.1 The Contractor shall submit to the Employer's Representative one copy of other relevant documents, such as manufacturer's instructions, technical papers, etc., where such documents are being referred to in the documents.

3.4 SITE QUALITY CONTROL SECTION

3.4.1 The Contractor's Quality Control (Q.C.) Section shall be headed by an experienced Quality Control Engineer. He shall be assisted by other supervisors. The Section shall be an independent one, reporting to the Contractor's Site Manager only on administrative matters, but otherwise under full control by the Contractor's Corporate Quality System Management.

3.4.2 The Contractor's Q.C. Section shall liaise closely with the Employer's Representative in charge of Quality Assurance/Quality Control, and to whom it shall fullest cooperation. It is the underlying principle of this Contract document that while the Contractor's Q.C. Engineer implements the Contractor's quality programme, the adequacy and effectiveness of that implementation shall be audited by the Employer's Representative at Site whose recommendations on improving or maintaining quality shall be acted upon promptly by the Contractor's Q.C. Section.

3.5 WELDING QUALITY ASSURANCE

3.5.1 WELDING MANUAL

3.5.1.1 It is a specific requirement of this Specification that the Contractor shall produce a separate Welding Manual covering all aspects of welding and welding controls at works and Site. This Manual shall be submitted to the Employer's Representative for evaluation and acceptance after the Contract has been placed, but before start of any welding.

3.5.1.2 The Manual shall cover in detail all the welding processes to be employed in this project, their normal and special requirements and the quality controls to be implemented.



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3.5.1.3 Furthermore, the part on Site welding shall incorporate as a minimum , all items discussed in the Site Welding Documents and Site Welding Control.

3.5.2 SITE WELDING DOCUMENTS

3.5.2.1 Before commencement of Site Welding, the Contractor shall prepare the following documents and submit to the Employer's Representative at Site for approval. In cases where the Contractor employs Contracts to carry out certain Site Works, eg. non-destructive testings (NDT), it is still the Contractor's responsibility to prepare such quality control documents relating to that Site Works. Furthermore, it is specifically required in this Specification that such documents shall be, after the Contractor obtains the necessary approval from the Employer's Representative, forwarded to the Contracts for their compliance. It is the Contractor's responsibility to retrain, if necessary, his Contracts's personnel and/or procure additional equipment in order to meet the requirements of the approved quality control documents.

3.5.3 WELDING PROCEDURE SPECIFICATIONS (WPS) AND PRO CEDURE QUALIFICATION RECORDS (PQR)

3.5.3.1 All welding, on pressure parts or non-pressure parts, shall be done to approved qualified Welding Procedure Specification (WPS). The Contractor shall compile all the WPS, and their respective Procedure Qualification Records (PQR), to be used for Site welding in one single volume and submit for approval to the Employer's Representative at Site before commencement of work. The E.R. shall accept any or all the WPS without prejudice to his rights to call for re-qualifications of any or all of the WPS at Site, should he deems it necessary. If such a re-qualification is required, the WPS test shall be conducted, at no extra cost to the Employer, based on agreed National or International Standards, but in any case shall incorporate, as a minimum, the requirements of relevant Clauses of the Contract Document.

3.05.4 FABRICATION

3.5.4.1 Weld procedures shall be designed to give a weld reinforcement height of 1.5 mm. minimum to 3 mm. maximum.

3.5.4.1.1 The weld procedure documents shall be fully detailed and shall indicate clearly which item it is intended to cover. The following information shall be included on each weld procedure document:-

(1) The general arrangement drawing no, and identification of the weld

(2) Range of plate thickness or tube diameters covered by the procedure.

(3) Dimensioned details of weld preparation, the roof gap and the permitted misalignment.

(4) Welding process for the roof run and for the filter material.

(5) The weld deposition procedure and the number of runs, including angle of welding i.e. vertical, downhand overhead etc.

(6) Type of electrodes or wires and fluxes together with the maker's name, type number and reference.

(7) Chemical composition and physical properties of the parent material to be jointed.



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(8) Chemical composition and physical properties of the deposited weld metal.

(9) Gauge of electrodes or wire to be used with the appropriate voltage and current settings.

(10) Preheat temperature if applicable, together with the minimum temperature at which welding may be carried without preheat.

(11) Postheat temperature if applicable.

(12) Weld dressing or finish required.

(13) Inspection and tests to be carried out on the complete weld.

(14) The approved standards relevant to the set up, procedure and inspection.

3.05.4.3 In the event of the Contractor wishing to make an alternation to any point of the procedure, he is first to submit the Employer’s Representative a copy of the revised procedure showing the amendment proposed and to await confirmation on its acceptance or non-acceptance.

3.5.4.4 Approval of the welding procedure, etc., shall not relieve the Contractor of his responsibility of quality work as per specification.

3.5.5 WELDERS' QUALIFICATION TEST PROCEDURES

3.5.5.1 The Contractor shall prepare a Welders' Qualification Tests Procedures summarizing the different types of Welders' tests need to be done at Site. Such test procedures shall be based on approved Standard. The numbers and types of tests required shall be determined by the essential parameters such as :(1) Welding process

(2) Materials

(3) Filler materials

(4) Pipe or plate

(5) Size - diameter and/or thickness

(6) Positions

(7) Type of joints - butt and/or fillet joints

3.5.5.2 Each test procedure shall be specific in its details as to include, but not limited to, information on specimen size, methods of tests : non-destructive and/or destructive, assessment of test results, rejection and acceptance criteria.

3.5.5.3 The Contractor shall prepare weld maps of all the joints to be welded at Site. The weld map shall show diagrammatically the location of each joint, the identification numbers of the joints (each joint will have its own unique number), the dimensions and edge preparation of each joint and the WPS applicable. The weld maps shall be submitted to the Employer's Representative at Site for his comments and approval.



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3.5.6 WELD APPLICATION TABLE

3.5.6.1 It is mandatory that the Contractor prepares a Weld Application Table before commencement of work. A Weld Application Table is a summary of the requirements of each individual joint to be welded. An example of the format of a Weld Application Table is shown on the next page.

WELD APPLICATION TABLE (EXAMPLE)

System :

Joint No :

Item Description Specification

1. Base metals SA 335 P22, SA 217 WC 9

2. Tube size (diameter x thickness)

(mm x mm)

406.4 x 67

3. Welding procedure specification (WPS) no.

55TA-SR1

4. Procedure qualification records (PQR) no.

P-55TA-1

5. Filler metal (specification no.) AWS 5.28, AWS 5.5

6. Root run ER 905-G (DA4)

7. Subsequent runs E90166-B3 (CMA 106)

8. Preheat temperature ( º C) 150

9. PWHT procedure no. PWHT-003

10. Soaking temperature ( º C) 720 ± 20

11. Soaking time (minute) 168

12. Heating rate ( º C/min) 93

13. Cooling rate ( º C/min) 50

14. Visual weld inspection 100%

15. Non-destructive examination :

Radiographic (x-ray) techniques

10% and/or specified values

16. Pressure testing of weld Yes

17. Remarks :

3.5.7 NDT PROCEDURES

3.5.7.1 All NDT to be carried out at Site shall be approved procedures. Such procedures shall not be just a reference to or a reproduction of agreed Standard, but shall be tailor-made to take into account the actual works to be done at Site, the availability and type of equipment at Site and the shall of NDT operators employed. The NDT equipment shall be of well-known make and complies with the requirement of approved Standards further all equipment should carry a calibration certificate.

3.5.7.2 The NDT operators shall be certified to an approved Certification Scheme such as the one operated by the National Industrial Training and Trade Certification Board



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(NITTCB), Ministry of Labour, Malaysia. Other Certification Schemes shall be approved solely at the discretion of the Employer's Representative.

3.5.7.3 Not with standing any approval given to NDT operators of any Certification Scheme, the Employer's Representative at Site has the right to conduct practical tests involving actual construction items and/or test specimen as deemed fit by him. Such tests shall be carried out by the Contractor at no extra cost to the client.

3.5.8 HEAT TREATMENT PROCEDURES

3.5.8.1 For the purpose of this Clause, heat treatment includes post-fabrication heat treatment of welds and post-heat treatment of welds. The Contractor shall prepare the Heat Treatment Procedures based on agreed Codes and Standard and/or Manufacturer's proven practice. The procedures shall not be just a reference to or a reproduction of the agreed Standard, but shall be tailor-made to suit the Site conditions : type of joints, accessibility, type and availability of equipment at Site, and shall be suitable for the Heat treatment operation employed.

3.5.8.2 The procedures shall, additionally, discuss the following items :-

(1) Method(s) of heating

(2) Calibration of temperature recorders and thermocouple wires; frequency of calibration

(3) Calibration centre, methods of calibration

(4) Number of joints to be heated at the same time

(5) Number of thermocouples per joint

(6) Methods of attachment of thermocouples to joints

(7) Locations of thermocouples on the joints

(8) Number of heating elements per joint

(9) Size of heating elements

(10) Methods of securing heating elements to joints

(11) Methods of prevention of direct heating (shorting) of the thermocouples underneath the heating elements: the use of high temperature putty

(12) Type of insulation blankets

(13) Size of insulation blankets : width x length x thickness

(14) Coverage of insulation blankets over heating elements

(15) Methods of securing blankets over joints

(16) Emergency procedures : what to do if there is a temporary power cut or a permanent power cut or shorting of the thermocouple wires?



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Additional precautions to take during rainy weather : water chilling of joints while heating/soaking/cooling

(17) Restressing of a joint : how many times can it be done?

(18) The use of portable hardness-tester to check efficacy of heat treatment.

(19) Confirmation of the efficacy of the heat treatment procedures by in-situ metallography.

(20) Stamping/recording of the heat treatment recorders' charts : information needed and format.

3.5.9 REPAIRS

3.5.10 SITE WELDING CONTROL

3.5.10.1 In order to monitor and maintain welding quality on Site, the Contractor shall establish within his Site Organization an independent Quality Control Section, whose function would solely to enforce the Contractor's field quality assurance programme and Site Quality plans. Among areas where the Contractor shall exercise greater controls, in order to achieve the desired quality, are control of welders and control of welding activities, control of welding consumables and control or NDT.

3.5.10.2 The Contractor shall prepare repair procedures, methods of repair, acceptance/rejection criteria, and inspection requirements, etc for approval.

3.5.11 CONTROL OF WELDERS

3.5.11.1 The Contractor shall employ only experienced welders. However, all welders, with or without previous qualifications, shall be tested to the approved Test Procedures. Holders of current welding certificates from the Factories and Machinery Department, Malaysia, shall not be exempted from sitting the test. However, the Employer's Representative at Site may, at his discretion, allow these welders to work if they can demonstrate their skill on five production joints, the sizes and locations of them shall be selected by the Employer's Representative, without any defects as revealed by visual inspection and radiography. The same rule shall apply to bonafide welders from the Contractor's manufacturing works.

3.5.11.2 All welders qualification test shall be conducted, at Contractor's expense, and witnessed by the Employer's Representative and from whom final decision as to the suitability of the welders shall be obtained.

3.5.11.3 In cases where the statutory requirement requires the welders to be registered with the Factories and Machinery Department, Malaysia, and if it deems necessary by the Inspectors of the Department that the welder's qualification test be conducted in their pressure, then it is the responsibility of the Contractor to arrange for the Inspector's attendance.

3.5.11.4 The Contractor shall monitor the performance of his welders throughout the project. The Employer's Representative may require a welder to be re-qualified if he deems the all of the welder has deteriorated, and the Contractor shall promptly remove the said welder from the job.



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3.5.11.5 At the discretion of the Employer's Representative, the re-qualification test may be in the manner of the original test or in a different form that more resemble the actual production joints condition for example, if a welder consistently procedures bad welds in the furnace region, the re-qualification test may not be just welding a single test piece of appropriate size in 6G positions, but may be welding five parallel tubes and in the vertical position at a pitch distance. All costs of re-qualification tests shall be borne by the Contractor.

3.5.11.6 It is a specific requirement of this Specification, that welders welding on attachments, such as thermocouple pads, tube-fins, lugs, etc., on pressure parts shall be qualified pressure part welders. In addition such welders shall be required to do a mock-up welding of the attachments to the pressure parts in order for the Employer's Representative to assess that such welding can be successfully done by the said welders.

3.5.12 CONTROL OF WELDING ACTIVITIES

3.5.12.1 The Contractor shall at all times control its welding activities in a manner whereby the quality requirement of its FQAP is never compromised, but at the same time no delay to the welding progress is experienced. The Contractor shall draw up a working procedure to accommodate the Employer's Representative at Site participation in accordance with Table 1.

3.5.12.2 In all cases, the Contractor's scope shall be 100%. In cases where the Employer's Representative participation is also 100%, such inspection may be done jointly at the same time when the Contractor does his inspection. However, the Employer's Representative may insist that the Contractor does his inspection initially and correct whatever defects found before calling for the Employer's Representative participation.

3.5.12.3 The Contractor shall liaise closely with the Employer's Representative and keep him inform of the status of welding on hand. The Contractor shall submit a daily return of welding works undicating the distribution of welders, the number and identification of joints welded, the number and identifications of joints needed to be NDT and PWHT.

3.5.12.4 The Contractor shall prepare all check sheets for the inspections, the format of them shall be agreed with the Employer's Representative at Site. Such check sheets must be signed by the relevant parties immediately at the end of each inspection. The Contractor shall compile these check sheets and hand them in bound volumes, appropriately titled, to the Employer's Representative at the end of Site construction.

3.5.12.5 The radiographic (x-ray) films, after review by the Employer's Representative at Site, shall be returned to the Contractor who shall then compile, catalogue and store them in appropriately labeled boxes in clean, dry, pest-free air-conditioned room. The Contractor shall keep the films in such good conditions for at least five years after end of construction period. The Employer's Representative shall have access to these films at any time during the storage period.



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Table 1

Item Activities Employer's Representative Scope

1. Material receiving checks 100% checking

2. Cleaning of components Spot checking

3. Alignment of components 100% checking

4. Fit-up checks 100% checking. The Contractor shall not proceed to weld the joints until Employer's Representative approval is obtained.

5. Issue of electrodes/filler material

Spot checking

6. Inspection during welding Spot checking, but the Employer's Representative approval is obtained.

7. Visual inspection after welding 100% checking. The Contractor shall not proceed to NDT or other work until the Employer's Representative has given approval.

8. NDT before PWHT All NDT shall be witnessed by the Employer's Representative. For radiography, the E.R.'s may not be present at all times. However, joints shall be selected by the Employer's Representative, and the radiographs together with their Interpretation Reports shall be submitted to him not later than 1500 hrs (3pm) the following day. The Employer's Representative decision on the acceptability or otherwise, as per the agreed Standard, of the radiographs and/or the joints shall be final and binding on the Contractor.

9. PWHT Spot checking during PWHT. The Contractor shall submit to the Employer's Representative each joint PWHT Chart within 23 hours following the completion of the PWHT of the joint.

10. NDT after PWHT All NDT after PWHT shall be witnessed by the Employer's Representative in the similar manner as item 8 above.

11. Hydrostatic Test 100% checking. Where it is required by the Statutory Requirements that the hydrostatic test shall be witnessed by the Inspector from the Factories and Machinery Department, Malaysia, the Contractor shall arrange for the said Inspector's attendance. All costs and fees payable in respect to such an attendance shall be borne by the Contractor.

3.5.13 CONTROL OF WELDING CONSUMABLES

3.5.13.1 Contractor shall follow the manufacturers' recommendations in storing and handling of all welding consumables.

3.5.13.2 It is the Contractor's responsibility to ascertain with the manufacturers the purity of welding gases, e.g. argon, supplied. The Contractor shall have in his possession at the time of welding works accurate instruments for measurement of gas flow and oxygen concentration.

3.5.13.3 The Contractor shall only bring to Site approved (as per the approved WPS) welding electrodes and other filler materials.



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3.5.13.4 Each consignment of these welding consumables to Site shall be accompanied by the manufacturer's Mill Certificates. The Contractor shall not change the brands of the welding consumables without prior approval from the Employer's Representative.

3.5.13.5 The Contractor shall provide electric ovens with suitable timers and temperature indicators for the purpose of preheating the welding electrodes before issuing to the welders. The quantity of electrodes issued shall only be sufficient for four hours' use. The Contractors shall provide his welders with electrically heated quivers to carry the electrodes to working areas. Furthermore, in order to ensure compliance with the requirement that only four-hour use of electrodes are issued at one time, the Contractor is required to provide two colour-coded quivers to each welder, such that, for example, only red quivers are used in the morning and blue ones in the afternoon (after lunch). It is strict requirement of this Specification that the Contractor ensures that his welders return unused welding electrodes to store after every four shift and fresh electrodes for use in the next four hours be issued in different quivers.

3.5.13.6 The Contractor shall establish and follow diligently an Electrode Record Procedure whereby the amount and type of electrodes issued to each welder at every issue are recorded in either a Record Book or Card. Such record shall be made available to the Employer's Representative at Site for scrutiny whenever requested for.

3.5.13.7 For filler materials to be used in TIG welding process, the Contractor shall ensure that the filler materials are clean, dry and rust-free. They shall also be positively identified either by using tags, colour codings, or both. Alternatively, their specification numbers shall be stamped on the rods at regular intervals in such a manner that when cut in shorter lengths, such stamps will still be visible. For rods that are identified by flags or colours, the Contractor shall also ensure that the flags or coloursare also present in all lengths, when cut in shorter pieces. The filler materials shall be carried to work-areas in suitable containers.

3.5.14 CONTROL OF NDT

3.5.14.1 The Contractor shall be responsible to control shall NDT activities under this Contract, even when he Sub-Let-Contracts the job to a NDT specialist company.

3.5.14.2 He shall ensure that his NDT equipments are reliable, modern, calibrated and comply with all relevant requirements of the agreed Standards.

3.5.14.3 The Contractor shall only employ mature and experienced NDT operators. He shall ensure that the NDT operators hold current and relevant certificates from approved Certification bodies such as National Industrial Training and Trade Certification Board, Ministry of Labour, Malaysia. Not with standing such a certificate, he shall promptly arrange for the demonstration of the skill of his NDT operator to the Employer's Representative, should the Employer's Representative may so request.

3.5.14.4 In the case of radiography, the Contractor shall comply with all the requirements of the Act 304 of the Government of Malaysia - Atomic Energy Licensing Act 1984. Radiographic (x-ray) works shall only be carried out after normal working hours, from 7p.m. to 7a.m. the next day. However, the Employer his Representative may delay permission to start radiography or suspend it for any duration during the



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permitted hours if urgent construction works and/or plant operational activities need to proceed without interference.

3.5.14.5 If the Contractor desires to Sub-Let-Contract part or the whole of the NDT works under his scope, he shall first obtain the approval from the Employer's Representative at Site. He need to prove to the satisfaction of the Employer's Representative that his quality of inspection will not be compromised even though he Sub-Let-Contracts the inspection work.

3.5.14.6 The Contractor shall arrange for NDT works to be done promptly after completion of welding, but in any case not later than 72 hours. Where welds require PWHT, the NDT shall be done after the PWHT.

3.06 INSPECTION AND TESTING

3.06.1 General

3.06.1.1 All equipment and components supplied shall be subjected to inspection and tests by the Employer’s Representative during manufacture, erection/installation and after completion. The inspection and test shall include but not be limited by the requirements of this Contract document. Prior to inspection and testing, the equipment shall undergo pre-service cleaning and protection.

3.06.2 Third Party Certification

3.06.2.1 The Contractor shall arrange for an independent third party certification to certify the design, materials and construction of the equipment in his scope to comply with design and statutory requirements and for insurance purposes. The certification shall include all trade in the Contract Works and shall cover both fabrication at the manufacturer’s works and at the Site.

3.06.2.2 The certification organisation shall be approved by, and registered with, the Malaysian Factories and Machinery Department or relevant authorities and shall be approved by the Employer. All costs associated with the third party certification shall be borne by the Contractor.

3.06.3 Guarantees

3.6.3.1 Contractor shall state and guarantee the technical particular listed in the Schedule of Technical Data. These guarantees and particulars shall be binding and shall not be varied without the written permission of the Employer’s Representative.

3.6.3.2 No tolerances shall be allowed other than the tolerances specified or permitted in the relevant approved Standards shall apply unless otherwise stated.

3.06.4 Rejection

3.6.4.1 If the guaranteed performance of any item of equipment is not met and/or if any item fails to comply with the specification requirement in any respect whatsoever at any stage of manufacture, test or erection, the Employer’s Representative may reject the item, or defective component thereof, whichever he considers necessary, and after adjustment or modification as directed by the Employer’s Representative, the Contractor shall submit the item for further inspection and/or test.



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3.6.4.2 All repair procedures shall not be performed without the prior approval of the Employer’s Representative. In the event of a defect on any item being of such a nature that the specification requirements cannot be fulfilled by adjustment or modification, such item shall be replaced by the Contractor, at his own expense to the entire satisfaction of the Employer’s Representative. Any item repaired to an approved procedure shall not be accepted as a part of the Works as a permanent solution or replacement unless the Contractor guarantees in writing that the repaired component shall have the same service life and efficiency as the component originally manufactured.

3.6.4.3 The approval of the Employer’s Representative of inspection and/or test results will not prejudice the right of the Employer’s Representative to reject an item of equipment if it does not comply with the Contract document when erected or prove completely satisfactory in service.

3.06.5 Contracts

3.6.5.1 The Contractor shall be responsible for the timely transmission of the relevant and appropriate sections of the Contract document to Contracts and other manufacturers and the proper execution of all tests on work materials carried out or supplied by Contracts, wherever such tests may be carried out, to the same extent as if the tests on work, materials were carried out or supplied by the Contractor himself.

3.07 CASTINGS AND FORGINGS

3.7.1 Steel Castings

3.7.1.1 The Contractor shall prepare materials purchasing specifications for all important castings. Each document shall indicate fully the quality and inspection requirements for the component casting covered. Copied of this Specification shall be issued to the Employer’s Representative for his use. Wherever possible castings shall be selected from the range of materials covered in the ANSI, ASME or ASTM Standards and the inspection and quality requirements together with the other provisions of this Specification shall be regarded as the minimum acceptable Standard.

3.7.1.2 All surfaces shall be satisfactorily prepared for inspection purposes. On medium and large size castings the test blocks for mechanical test shall be cast integrally with the casting and shall not be removed until all heat treatment has been completed or otherwise authorised by the Employer’s Representative.

3.7.1.3 Magnetic particle inspection shall be applied to all castings after acid cleaning and shot blasting. All defect cut outs shall be inspected by magnetic particle inspection after grinding and before repairs are commenced.

3.7.1.4 Castings may be repaired by welding provided the approval of the Employer’s Representative is first obtained. The Contractor shall submit drawings, sketches or photographs showing the location and principal dimensions of the defect together with the proposed weld repair procedure.

3.7.1.5 The Employer’s Representative’s approval in writing must be obtained prior to the repair of defects which penetrate more than 50% of the wall thickness.



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3.7.1.6 Only welders who have passed an appropriate qualification tests shall be employed on the repair of castings. All repairs shall be carried out by the metal arc process.

3.7.1.7 Selected areas for future butt welds shall be subjected to radiographic (x-ray) examination. The defects revealed by this examination shall be compared with the acceptance criteria given within the agreed standard. Wherever possible the acceptance criteria shall be related to an agreed set of reference radiographs. The reference radiographs to be used for this purpose together with the selection of the standard films for shrinkage, subsurface linear discontinuities, porosity, voids, sand and slag shall be to the Employer’s Representative’s approval.

3.7.1.8 On completion of repair, welded areas shall be ground smooth and carefully blended into the parent material. After final heat treatment the total internal and external surface shall be subjected to magnetic particle inspection.

3.7.1.9 Quadruplicate copies of all records and test certificates covering Chemical Analysis, Mechanical Properties, Heat Treatment History, Location and Size of Defect Reported, Radiographic (x-ray) Report, and Dimensional Inspection, shall be forwarded to the Employer’s Representative.

3.7.1.10 All castings shall be identified by hard stamped, or cast on reference marks which shall be entered on all relevant documents and test certificates.

3.07.2 Cast Iron Castings

3.7.2.1 No weld interlocking, plugging or filling of defective part is to be performed without the prior approval of the Employer’s Representative in writing. Full details of the proposed method of repair shall submitted approval.

3.7.2.2 Test blocks are to be integrally cast on all medium and large castings.

3.7.2.3 The Employer’s Representative may require that certain castings shall be checked using radiographic (x-ray) techniques. The Contractor shall include for this eventually and shall comply with the Employer’s Representative’s instruction when issued.

3.07.3 Aluminium Bronze Castings

3.7.3.1 The Contractor shall prepare material purchasing specification for all important aluminium bronze castings. Each document shall indicate fully the quality and inspection requirements for the component casting covered. Copies of the specification shall be issued to the Employer’s Representative for his use. The inspection and quality requirements shall include chemical analysis of each cast, mechanical testing of tests bars for each cast, pressure testing, penetrant flow detection and radiographic (x-ray) examination of selected critical areas.

3.7.3.2 Weldable grades of aluminium bronze may be repaired by welding provided the approval of the Employer’s Representative is first obtained. The Contractor shall submit full detail of the proposed weld repair procedure and weld procedure qualification test prior to making any weld repairs. On completion of repairs, weld areas shall be ground smooth and carefully blended into the parent material. The repaired areas shall be examined for defects using penetrant flow detection and radiography. Crack-line linear defect shall not be permitted.



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3.07.4 Steel Forgings

3.07.4.1 The Contractor shall draw up material purchase specifications for all important forgings, and supply copies of these specifications to the Employer’s Representative for his use. Specifications shall be produced for, but not limited to compressor shafts, motor shafts and precision forge compressor blades, etc. In each case the quality and inspection requirements shall be clearly stated.

3.7.4.2 Sulphur prints shall be taken from all large forgings and other forgings as directed by the Employer’s Representative, the prints shall indicate the absence of significant segregation.

3.7.4.3 Test blocks from which the mechanical test pieces will be machined shall be cut from the forgings at positions to be agreed by the Employer’s Representative. On large and important forgings several test pieces shall be taken from radial and longitudinal directions.

3.7.4.4 Solid shaft forgings will be acceptable provided that ultrasonic examination confirms the absence of centre line defects. The Employer’s Representative will reserve the right to insist that shaft or rotor forgings with centre line defects shall be bored to remove such defects.

3.7.4.5 Shaft and rotor bores where provided, shall be smooth machined to a standard suitable for intrascope examination. Trepanned sections of the cores shall be subjected to mechanical test for information purposes only. Local chamfering or remachining of bores to a larger diameter shall only be carried out with the approval of the Employer’s Representative.

3.7.4.6 Bores, where provided, shall be inspected visually and with magnetic particle inspection. Magnetisation shall be in accordance with the ANSI, ASME or ASTM Standards. The inspection shall be made with a suitable intrascope having an acceptable level of illumination and magnification.

3.7.4.7 Bearing journals of large shafts and rotors shall be subjected to dye penetrant examination on completion of final machining.

3.7.4.8 Repairs by welding or other means shall not be undertaken on forgings at any stage of the production cycle.

3.7.4.9 Quadruplicate copies of test certificates shall be provided to the Employer’s Representative including the following records :- Chemical Analyses, Mechanical Properties, Electrical Properties (when supplied), Heat Treatment Records, Top and Bottom Percentage Ingot Discards, Dimensional and Concentricity Records.

3.7.4.11 Each forging shall be suitably branded with an identification number which shall be transferred throughout all final machining stages. The identification number shall be marked on all documents and test certificates relative to the forging.

3.7.4.12 Copies of thermal stability tests conducted on compressor rotors shall be forwarded to the Employer’s Representative in quadruplicate.



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3.8 TESTS AT MANUFACTURER’S WORKS

3.8.1 GENERAL

3.8.1.1 Where no specific test is specified then the various items of materials and equipment shall be tested in accordance with the specifications. Where no appropriate Standard is available, tests shall be carried out in accordance with the manufacturer’s Standard practice, subject to the prior approval of the Employer’s Representative. In all cases, works tests shall include electrical, mechanical and hydraulic tests in addition to any test called for by the Employer’s Representative to ensure that the equipment being supplied fulfils the requirements of the Contract document. Where applicable, tests must comply with the requirements of the Factories and Machinery Regulations 1970, of the Government of Malaysia.

3.8.1.2 If considered necessary by the Employer’s Representative, any multi-part assemblies shall be fully erected in the works prior to packing and despatch to Site.

3.8.1.3 All tests to be performed during manufacture, fabrication and inspection shall be agreed with the Employer’s Representative prior to commencement of the work. The Contractor shall prepare the details of the schedule and submit these to the Employer’s Representative for approval. It must be ensured that adequate relevant information on the design code/Standard employed, the manufacture/fabrication/assembly procedure and the attendant quality control steps proposed are made available to the Employer’s Representative. The Employer’s Representative will mark in the appropriate spaces his intention to attend or waive the invited tests, or inspections.

3.8.1.4 A minimum of twenty-one days’ notice of the readiness of equipment for test or inspection shall be provided to the Employer’s Representative by the Contractor (whether the test be held at the Contractor’s or Contracts’s works). The subject items should remain available for Employer’s Representative inspection and test up to a minimum of 10 days beyond the agreed dates of witnessing the test. Every facility in respect of access, drawings, instruments and manpower will be provided by the Contractor and his Contracts to enable the Employer’s Representative to carry out the necessary inspection and testing of the equipment.

3.8.1.5 No. plant shall be packed, prepared for shipment, or dismantled for the purpose of packing for shipment, unless it has been satisfactorily inspected, all tests called for have been successfully carried out in the presence of the Employer’s Representative or approved for shipment, or alternatively inspection has been waived.

3.8.1.6 Functional electrical, mechanical and hydraulic tests shall be carried out on completed assemblies in the works. The extent of these tests and method of recording the results shall be submitted to, and agreed by, the Employer’s Representative in sufficient time to enable the tests to be satisfactory witnessed, or if necessary for any changes required to the proposed programme of tests to be agreed.

3.8.1.7 All instruments and apparatus used in the performance of the tests shall be supplied by the Contractor, to the approval of the Employer’s Representative and shall be calibrated to an agreed Standard at SIRIM (Malaysia), or equivalent centres approved by the Employer’s Representative. Calibration Tests Certificates shall be submitted in respect of each and every instrument and apparatus. All calibration shall be conducted within 6 months before the date of the actual tests and the corresponding tests certificates shall be issued and submitted to the Employer’s Representative at least 1 month before commencement of the test. Calibration done and Certificates issued outside the period aforementioned shall not be valid and the Contractor shall arrange



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for the recalibration of the instrument or apparatus at no extra cost to the Employer’s Representative.

3.8.1.8 The Employer’s Representative reserves the right to visit the Manufacturer’s Works at any reasonable time during fabrication of equipment and to familiarize himself with the progress made and the quality of the work to date.

3.8.2 MATERIAL TESTS

3.8.2.1 Representative samples of all plates, bars and pipe, etc., which form components of the equipment shall be tested as required by the relevant approved Standard. All test precious shall be prepared and supplied by the Contractor at his own cost. If any test piece fails to comply with the requirements of the specifications for the material in question, the Employer’s Representative may reject the whole of the material represented by that test piece.

3.8.3 TEST CERTIFICATES

3.8.3.1 Within 30 days of the completion of any test, triplicate sets of all principal test records, test certificates and correction and performance curves shall be supplied to the Employer’s Representative.

3.8.3.2 These test records, certificates and performance curves shall be supplied for all tests, whether or not they have been witnessed by the Employer’s Representative or not. The information given on such test certificates and curves shall be sufficient to identify the material or equipment to which the certificate refers and should also bear the Contract reference title.

3.8.3.3 When all equipment has been tested, the test certificates from all works and site tests shall be complied by the Contractor into volumes and bound in an approved form complete with index and four copies of each volume shall be supplied to the Employer’s Representative.

3.9 TYPE TESTS

3.9.1 Type tests are required on all equipment whether specifically noted or not to prove the general design the equipment in accordance with the relevant approved Standards and the Contractor may submit test certificates of tests which have been carried out on identical equipment. Notwithstanding any provision in a Standard, the employer’s Representative shall have the right to accept or reject such certificates in lieu of the specified type tests.

3.9.2 The type tests prescribed shall be carried out at the Contractor’s cost in all cases where such certificates are not available or are rejected.

3.9.3 Notwithstanding the above one type of each rating of equipment shall be type tested under this Contract, to the relevant approved Standard, and test certificates submitted to the Employer’s Representative.

3.10 ROUTINE TESTS

3.10.1 All items of system shall be subjected to visual, dimensional, material, non-destructive, hydraulic, functional and performance tests at the manufacturer’s works. The tests to be carried out shall be strictly in accordance with the appropriate National Standards approved by the Employer’s Representative. All relevant material and works



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certificates shall be available at the time of test and the tests shall be carried out against approved drawings.

3.11 HYDROSTATIC TESTS

3.11.1 All cast, forged of fabricated pressure vessels or enclosures and all completed pipes, bends and fittings which are to be subjected to an internal pressure or vacuum during operation shall be subjected in the maker’s works to a hydrostatic test. The test pressure shall be maintained for a minimum of 30 minutes or longer at the discretion of the Employer’s Representative to permit complete examination by the Inspector.

3.11.2 All hydrostatic tests shall be carried out prior to surface coating or painting and cast iron enclosures may be subjected to hammering as required by the Employer’s Representative.

3.11.3 Hydrostatic test of equipment manufactured from austenitic steels should be carried out using water having chloride content less than 30 ppm.

3.11.4 The manufacturer shall supply labour and appliances for such testing as may be carried out on his premises. Failing facilities at his own works the manufacturer shall make arrangements for carrying out the tests elsewhere.

3.11.5 The testing shall include, but not be limited to, the following system :-

3.11.5.1 Each sections of the compressor casing, control valves and emergency stop valves shall be tested as defined in the relevant Standard for a minimum of 2 hours duration.

3.11.5.2 Pipework shall be hydrostatically tested in accordance with the relevant Standard. The test pressure shall not be less than one and one half times the normal working pressure. Any expansion bellow shall be tested together with an adjacent section of pie. Satisfactory arrangements must be made to protect the bellows from damage during the test.

3.11.5.3 The body of each valve of fitting shall be tested to not less than one and on half times its design pressure. In the particular case of safety valves the seats shall be blanked and the hydrostatic pressure applied only the part of the body at the inlet valve.

3.11.5.4 With the exception of the following items and items which may suffer internal damage e.g. bellows operated instruments, etc., each assembled fitting shall be tested to not less than one and one half times its design pressure.

1) Assembled safety valves

2) Tubular glasses for water gauges

3) Sub-assemblies containing the glasses of water gauges of the through vision or reflex glass type.

3.11.5.5 Pressure gauges shall be tested in accordance with the relevant approved Standard.

3.11.5.6 All prefabricated tanks operating at atmospheric pressure shall be tested by filling to maximum level and being subjected to an additional superimposed hydrostatic pressure of 15 mbar. All tanks shall be tested in accordance with approved Standard.

3.11.5.7 Pumps casings shall be hydrostatically tested in accordance with an approved Standard.



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3.12 PERFORMANCE TEST AT MANUFACTURER’S WORKS

3.12.1 All equipment shall be subjected to routine performance tests at the Manufacturer’s Works in accordance with the relevant ANSI, ASME or ASTM Standard including operating of complete assemblies to ensure correct operation of apparatus and components. A strip-down internal inspection of pumps, compressors, motors as required by the Employer’s Representative shall be carried out.

3.12.2 Each equipment shall be subjected to a performance test to prove that reliability and operation and performance conform to the requirements of this Specification. Equipment shall be fully assembled and complete in every respect prior to the commencement of Works performance tests. The Contractor, at his own expenses, he will arrange for one representative each from the Employer Representative, the Employer's organization and the design consultant to witness this performance test.

3.12.3 Pumps, fans compressors and other rotating equipment shall be given full load tests, and run to 15% over speed for 5 minutes to check vibration. Main and auxiliary gear boxes shall be subjected to shock load test and a six-hour endurance run at rated speed and maximum torque.

3.12.4 The Contractor shall submit single line diagrams including the location of test instrumentation and the principal dimensions of the layout. All calculations to device performance data shall be made strictly in accordance with formulae given in the approved Standards. Any alterations or deviations from the approved test layout or formulae shall be subjected to the prior approval of the Employer’s Representative.

3.12.5 The formulae used for correcting test results to Site conditions shall be subjected to the Employer’s approval and be given with the test results together with calibration details of any measuring instruments.

3.12.6 All pressure gauges, flow meters, venturi tubes or ducts, office plates and other instruments to be used for works tests shall be subjects to routine calibration against Standard instruments. Calibration records shall be available for inspection by the Employer’s Representative.

3.12.7 Wherever possible, equipment shall be tested with the driving motor specifically purchased for the respective item. Where such an arrangement is not practical then it will be permissible to utilize a test motor providing fully technical performance details are available for scrutiny by the Employer’s Representative.

3.12.8 The Contractor shall demonstrate that the system under this Contract is of a satisfactory proven type in commercial operation. In such a case, at his own expense, he will arrange for one representative each from both the Employer’s Representative and the Employer’s organization to visit such units and to meet with responsible representative of the respective owners/operators.

3.12.9 Each completed rotating units shall be subjected to a dynamic balance test. A check balance test shall be carried out after the item has been subjected to any overspeed or performance test. The Standards for dynamic balance shall be specified by the manufacturer and agreed by the Employer’s Representative.

3.12.10 All pumps shall be tested – in accordance with BS 5316 Class B or equivalent approved ANSI and ASTM Standards. Prior to any test taking place, the Contractor shall submit for the Employer’s Representative approval, a test procedure showing the layout of the testing equipment with the position of pressure measurement points, flow measuring device and relevant datum lines for measuring fluid heads. In addition,



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details of the calibration of the flow measuring device, the motor power vs. efficiency cure, a specimen of the test records sheet and details of the performance calculations shall be provided.

3.12.11 The performance test shall be conducted over the fully operating range of the pump to a closed valve condition and a minimum of five measurement points covering the full range shall be taken. Curves indicating Quantity vs. Head, Quantity vs. Power absorbed, and Quantity vs. Pump efficiency shall be provided. In addition a curve of the NPSH required vs. Quantity shall be provided except when the suction conditions do not require this test. Any proposal for the omission of this test shall be to the approval of the Employer’s Representative.

3.12.12 On completion of tests the Contractor shall submit a report showing the rest results obtained together with the curves corrected to the Site operating conditions.

3.12.13 The Contractor is to state his normal practice with regard to the testing of turbine components, the trial erection of the turbine, and the steaming of the turbine assembly in works to prove the satisfactory mechanical operation prior to despatch to Site.

3.12.14 Air compressors shall be tested in accordance with the requirements of the relevant Standard and the particular test procedure to be applied to each compressor shall be agreed with the Employer’s Representative.

3.12.15 All inspection, testing, marking and certification for Air Receivers shall be performed to the appropriate ANSI, ASTM and ASME Standards.

3.12.16 The vessels shall be constructed and tested under the supervision of a third party inspector approved by the Employer’s Representative.

Safety valves, bursting discs and other fittings shall be tested in accordance with the requirements of the appropriate ANSI, ASTM, ASME Standards.

3.12.17 The Contractor shall carry out at this Works, tests as required by the ANSI, ASTM and ASME Standards, to prove the capacities of the lifting equipment Test Certificates shall be provided and shall include the material of fabrication, welding and non-destructive testing, electrical equipment, wire ropes, hooks, chain blocks, shackles, runway beam, eye bolts and any other related items which are provided.

3.12.18 All tests shall be carried out in the presence of the Employer’s Representative and the nominated third party inspector. Upon completion of the tests, the equipment shall be clearly marked with the equipment’s safe working load (SWL) and any making that the Employer’s Representative may require. A permanent nameplate shall be attached containing the following information :-

Date of manufactureDate of testLoad applied

3.12.19 The testing of storage tanks shall conform to the appropriate ASME and ANSI Standard.

3.13 ACCEPTANCE TESTS OF ELECTRICAL EQUIPMENT

3.13.1 Acceptance tests shall be carried out by random sampling of manufactured equipment in accordance with IEC. The results of tests shall be recorded and verified by the Employer’s Representative. Three copies of the test result shall be submitted to



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the Employer’s Representative. The same set of test results shall be included in the Operation and Maintenance documentation.

3.14 ERECTION AND INSTALLATION

3.14.1 During the course of erection, the Employer’s Representative shall have full access for inspecting the progress of the work and checking its accuracy by witnessing such checks as may be required by him.

3.14.2 The Contractor shall provide all temporary scaffolding, platforms with adequate and safe flooring and handrails essential for proper access of the Employer’s Representative to carry out inspection.

3.14.3 The Contractor shall provide all labour, materials and instruments and other resources necessary for the use of the Employer’s Representative for checking, setting out of the Works, for the periodic measurement of the works executed and for the aforementioned Site inspections and tests.

3.14.4 On completion of erection, tests on all equipment shall be carried out by the Contractor and witnessed by the Employer’s Representative to demonstrate adequately that the equipment as erected on Site, is entirely suitable for operation.

3.14.5 The Contractor shall provide all erection check lists for the works, copies of which are to be provided to the Employer’s Representative after signing at each stage of inspection.

3.14.6 The Contractor shall record the results of the tests clearly, on an approved form and with clear reference to the equipment and items to which they refer, so that record can be used as the basis for maintenance tests by the Purchaser during the working life of the equipment. The required number of site test result records shall be provided by the Contractor to the Engineer as soon as possible after completion of the tests. This information is required by E.R. before the system will be accepted for initial energizing.

3.14.7 No tests as agreed under the programme of tests shall be waived except upon the instruction or agreement of the Employer’s Representative in writing.

3.14.8 The Contractor shall submit to the Employer’s Representative for his approval a list of recommended settings for all protection and other types of automatic equipment, not less then three (3) months before such equipment is required in service. Where the settings involve discrimination with settings of TNB’s network, the relevant information shall be supplied to the Contractor.

3.14.9 The Contractor’s test equipment shall be of satisfactory quality and condition and shall be appropriately calibrated by and approved authority or standard at the Contractor’s expense. 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.

3.15 TESTS AT SITE

3.15.1 GENERAL

3.15.1.1 All equipment and assemblies shall pass site tests to prove compliance with the Contract document independently of any tests which may have already been carried out at the Manufacturer’s Works.



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3.15.1.2 The Contractor shall check electrical and mechanical connections to all equipment and assemblies supplied under the Contract before they are brought into commission and shall be responsible for the correctness of such connections in accordance with the Contract document.

3.15.1.3 In particular all functional and pressure tests on fully assembled and complete items of equipment and assemblies which have not been carried out at the manufacturer’s works, shall be carried out at Site.

3.15.1.4 All instruments and apparatus used in the performance of the tests shall be supplied by the Contractor and shall be to the approval of the Employer’s Representative and shall be calibrated to an approved Standard at SIRIM (Malaysia) or equivalent centres approved by the Employer’s Representative. Calibration Tests Certificates shall be submitted in respect of each and every instrument and apparatus. All calibration shall be conducted within 6 months before the date of the actual tests and the corresponding tests certificates shall be issued and submitted to the Employer’s Representative at least 1 month before commencement of the test. Calibration done and Certificates issued outside the period aforementioned shall not be valid and the Contractor shall arrange for the recalibration of the instrument or apparatus at no extra costs to the Employer’s Representative.

3.15.1.5 The Contractor will be responsible for the submission to the Employer’s Representative for Site inspection and tests of all equipment in his supply.

3.15.1.6 The Contractor shall submit a written programme of tests and checks for the approval of the Employer’s Representative.

3.15.1.7 The Contractor shall provide experienced test personnel subject to the approval by the Employer’s Representative (CV’s shall be submitted) and conditions imposed by the Electrical Supply Regulations issued by the Department of Electricity Supply, Ministry of Energy, Telecommunication and Post Malaysia, and any regulations ruling at that time on such practice

3.15.1.8 The testing shall be carried out during normal working hours as far as is practicable.

3.15.1.9 The Contractor shall advise the Employer’s Representative 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.

3.15.2 HYDROSTATIC TESTS

3.15.3 After erection a hydraulic test shall be carried out on each heat exchanger with all mountings, fittings and associated piping in compliance with the relevant Standard approved by the Employer’s Representative and with the Malaysian Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970, with all fittings and mountings in position. No control valve shall be used as a block valve for the purpose of this or any other test.

3.15.4 PIPEWORK TESTING

3.15.5 PRELIMINARIES

3.15.5.1 The Contractor shall be responsible for conducting pressure tests but these shall be witnessed by the Employer’s Representative to his satisfaction and approval.



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3.15.5.2 On completion of erection, the interior of all pipes, valves, fittings and other associated equipment shall be flushed and free from loose mill scale, welding slag, temporary protective coating and other foreign matter.

3.15.5.3 Mechanical equipment and pressure relieving devices shall be blanked off or removed from the line during pressure testing.

3.15.5.4 Where in testing, parts of the piping system shall be subjected to a pressure exceeding that corresponding to 90% of the specified minimum yield stress of the material, these parts shall be isolated until testing is completed.

3.15.5.5 Instruments, filters and similar equipment for which the maximum permissible cold test pressure is lower than the test pressure applied to the system, shall be removed or blanked off or removed from the line before testing. Such equipment shall be inspected during commissioning.

3.15.5.6 Provision shall be made for the automatic relief of excess pressure caused by thermal expansion.

3.15.6 HYDROSTATIC TESTING

3.15.6.1 The completed piping system shall be tested to a pressure of at least one and one half times the design pressure.

3.15.6.2 The test pressure shall be maintained for a period of at least 24 hours. After correction for variation caused by temperature changes, the initial and final test readings shall not differ by more than 5%. Four reading shall be recorded.

3.15.6.3 Temporary vents shall be located at high points in the system or section thereof to be tested, in order to ensure complete displacement of air.

3.15.6.4 All testing equipment such as temporary pumps, strainers, pipework, valves, instrumentation etc. shall be included under this Contract.

3.15.7 REPEAT TESTING

3.15.7.1 Upon failure of the pressure test results to meet the above requirements the Contractor shall check the installation for leaks and other defects and carry out rectification work accordingly to the satisfaction of the Employer’s Representative. He shall fully inform the Employer'’ Representative of all reticulation works. The pressure test shall then be repeated. This procedure shall be repeated until satisfactory results are obtained. The Employer’s Representative may, at his discretion, review the test requirements in accordance with Site conditions.

3.15.8 WELDED PIPEWORK

3.15.8.1 All chilled water service pipe for both above and below grade shall have all their welds inspected using ultrasonic tested or dye-penetration. In addition, 10% of the total welds shall be radiographed to ASME B31.1 standards to ensure weld integrity, visually inspected and signed off by ER. When one or more failures occur in a sampling examination, for example in 10% radiography, than the failure(s) shall be repaired and re-radiographed, and a further 10% radiography sampling is to be taken. If there is further failure(s), the new failure(s) shall be repaired and re-radiographed, and additionally now, all the remaining unexamined welds shall be radiographed and repaired, if necessary, and re-radiographed until all the welds are confirmed to be without defects. All below grade piping shall be visually inspected using a camera which can be routed through the pipeline.



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3.15.8.2 TESTING REQUIREMENTS

3.15.8.3 All chilled water service pipe for both above and below grade shall have all their welds inspected using ultrasonic tested or dye-penetration. In addition, 10% of the total welds shall be radiographed to ASME B31.1 standards to ensure weld integrity, visually inspected and signed off by ER. When one or more failures occur in a sampling examination, for example in 10% radiography, than the failure(s) shall be repaired and re-radiographed, and a further 10% radiography sampling is to be taken. If there is further failure(s), the new failure(s) shall be repaired and re-radiographed, and additionally now, all the remaining unexamined welds shall be radiographed and repaired, if necessary, and re-radiographed until all the welds are confirmed to be without defects. All below grade piping shall be visually inspected using a camera which can be routed through the pipeline.

3.15.9 AIR PIPING

3.15.9.1 All air piping before being concealed and before acceptance of the work shall be subjected to an air tests of one and half times its design pressure but not less than 4.5 bar g and all joints shall be checked for leaks using a soap solution test. Tests shall be made for a period of two hours.

3.15.9.2 All compressed lines shall be blown though with compressed air before connection is made to instruments and other equipment.

3.16 PAINTING INSPECTION METHODS

3.19.1 GENERAL

A short description of the various inspection methods is included in this specification to provide a reference base for both the Contractor and the Inspector in order to ensure that all coating related activities and the final coating film conform to the requirements as laid in this specification.

These inspection procedures shall be used singly or in conjunction with each other – as circumstances may warrant – to resolve disputes relative to application conditions, film, thickness, degree of cure, adhesion to the substrate or between coats, determination of the correct time between coats etc. and to determine whether individual coating films or the total coating system meet the acceptance criteria specified.

3.19.2 DESCRIPTION OF INSPECTION METHODS

3.19.2.1 SURFACE PROFILE MEASUREMENTS

One or the other of the following methods shall be used to measure the surface profile of abrasive blasted steel surfaces :-



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3.19.2.1.1 Surface Profile Comparator Method

The comparator unit (Keane-Tator comparator 372, or its approved equivalent) consists of a reference disc made of high purity nickel, which is an electro – formed duplicate of a master disc and 5-X illuminated magnifier with magnetic disc holder. The disc has surface profiles ranging from 10 to 100 microns. The blast cleaned surface shall be compared with the reference disc through the illuminated magnifier.

3.19.2.1.2 Press-O-Film Method

The appropriate grade of Press-O-Film tape shall be selected. The dial of the spring micrometer shall be adjusted to read minus 50 microns. The thickness of the selected tape shall then be measured by realizing the snap gauge GENTLY. The film shall be then applied to the surface being inspected and shall be rubbed with burnishing tool until the entire surface has uniformly darkened. The replica shall then the removed and its thickness re-measured with the spring micrometer. The reading thus obtained is the maximum peak to valley heights of the blasted surface.

3.19.2.1.3 Criteria For Acceptance shall be :

If the measured values of the surface profile exceed the specified limits by more than 25% over an area that exceeds 25% of total surface area, it shall be deemed unacceptable and shall be reblasted.

3.19.2.2 WET FILM THICKNESS (WFT MEASUREMENT)

The combined gauge shall be used. The surface selected for measurement should be smooth. The WFT necessary to give the specified dry film thickness should be known. The measurements should be made at frequent intervals during or within 5-10 minutes of the actual application, but in any case, before the coating has set or lost an appreciable proportion of its solvent.

3.19.2.3 DRY FILM THICKNESS (DEE) MEASUREMENTS

A magnetic or electro-magnetic gauge shall be used which shall be calibrated daily. The average measurement of the DFT at 3 points of close proximity to each other shall constitute a spot measurement.

Five separate spot measurements, spaced evenly over each 2m2 section constitute of 1 area of the structure shall be taken. No combination of other area section in order to meet the 2m2 section is allowed. The average of five spot measurements for each section shall be not less than the specified minimum DFT. No single spot measurement in any section shall be less than 90% of the specified minimum DFT. Single gauge readings constituting the spot measurement may underrun by a greater amount but shall not be less than 75% of the specified minimum DFT. No single spot measurement in any section shall be 25% more than the specified manufacturer maximum DFT.

3.19.2.4 HARDNESS TESTING

3.19.2.4.1 The Barcol Hardness Gauge No. 935 or similar shall be used to determine the degree of cure of Ultra High Build (UHB) coatings. The measurements shall be carried out by placing the gauge on an area of smooth coating surface (free of overspray or orange peel), pressing the needle into the surface and noting the highest value reached on the dial.

To determine whether the curing process is progressing satisfactorily all areas of freshly applied coating shall be tested for hardness 6 to 24 hours after application



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depending on the type of coating being inspected. The frequency of measurements shall be 5 evenly spaced readings per area that is coated during each hour of the working day. If the hardness value then indicated is less than :

i) 60% of the cured hardness in the case of epoxies, and

ii) 80% of the cured hardness in the case of polyesters.

The coating shall be checked for hardness over next 72 hours to clearly established a hardening trend. Coating not showing a satisfactory trend shall be rejected and replaced.

The coating shall be considered fully cured when the Barcol rating is in the range of:-

i) 70-75 for epoxies 7 days after application (@ 24°C and 30-60%RH); and

ii) 80-90 for polyesters, 7 days after application (@ 8-25% and 50-80% RH)

3.19.2.4.2 The Dur-O-Test Hardness Tester shall be used to determine the degree of cure mainly of inorganic zinc silicate films but may also be used in the case of thin film catalyzed coatings. The procedure for use is as follows :-

In the pretensioned state, the scratch needle extends slightly out of the jacket. The tip of the DUR-O-TEST shall be placed on the coating surface (ensuring that it is square on the surface) and a line shall be drawn approximately 25 mm long within three seconds, maintaining sufficient pressure to keep the needle against the rod stop. If the tension has been too high, the surface will be clearly marked if too low, there will be no mark. The correct pretension will result in a barely visible mark - this is the pretension that should be reported as value “P”. In the case of inorganic zinc silicates, the “P” value to be reported will be the one at which, when the line is drawn, then will be no accumulation of zinc dust at the end of the line. The interchangeable springs of varying strengths correspond to test ranges engraved as scales on the jacket of the instrument.

No. 1:0 – 300P (Division = 10P, Plain Spring)No. 2:0 – 1000P (Division = 50P, Red Spring)No. 3:0 – 2000P (Division = 100P, Blue Spring)

Inorganic zinc silicate coatings, should have a minimum hardness of 250 P, before they may be top coated. Depending on the prevailing conditions, this value of hardness can be attained within four to 24 hours after application with both the he solvent and water home inorganic zinc silicate coatings. A hardness of 200 to 240 P shall be accepted but only if a trend of hardening has been clearly established over a period of not less than 72 hours after application.

Note : The manufacturer shall be required to supply details (in the form of curves) showing the curing rates, under specific conditions, for each type of coating used in the project.

3.19.2.5 ADHESION TESTS

The test may be used to determine the bond of single coating films (including inorganic zinc silicates) to the substrate as well as the adhesive and cohesive stretch of multicoat systems.

3.19.2.5.1 Pull-off Method



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Using the Elcometer 106 or similar instrument. This method is used to measure the adhesive/cohesive strength of coating systems of any thickness up to 5mm.

This method of bond test is required to obtain a specific value for the strength of adhesion to the substrate or between coats. Using suitable Araldite epoxy adhesive, aluminum dollies shall be cemented to the fully cured coating surface. After overnight cure of the epoxy adhesive, the dollies shall be pulled off the surface using the Elcometer 106 Adhension Tester in accordance with the recommendations of the instrument suppliers. The force required to remove the dollies shall be recorded and reported as an average of at least three pull-offs. The site and mode of failure shall also be reported.

Criteria for acceptance shall be :

i) 20 kg/cm2 minimum in the case of inorganic zinc silicate / epoxy topcoat systems.

3.20 CLEANING PROTECTION OF EQUIPMENT

3.20.1 GENERAL

This section covers mechanical and chemical pre-service cleaning and protection of the equipment that are not subsequently to be painted.

Cleaning of fabricated component items shall be carried out after fabrication and final heat treatment or welding at manufacturer’s works or at site as appropriate.

Mechanical cleaning as opposed to alternative chemical cleaning is the preferred method for works cleaning except where this is precluded by design or access considerations.

Mechanical cleaning is preferred for items constructed from materials other than stainless steels. Stainless steel items shall be chemically cleaned with mixed nitric – hydrofluoric acid formulation to the Employer’s Representative approval. Alternatively approved proprietary paste formulations may be used for this purpose.Machined surfaces shall be protected during the cleaning operations.

In event of the surfaces not being cleaned to the Employer’s Representative satisfaction, such parts of the cleaning procedures or agreed alternatives as are deemed necessary to overcome the deficiencies shall be carried out at the Contractor’s sole expense.

For recleaning small areas, hand cleaning by wire brushing may be permitted. Wire brushes used on austenitic materials shall have austenitic steel bristles.

Austenitic stainless steels, copper and aluminium alloys, cast iron, bimetallic and metallic/plastic items, and components fabricated by spot welding or riveting shall not be chemically cleaned.

All weld areas shall be suitably stress relieved before chemical cleaning.

The date and place at which works cleaning will be carried out shall be notified to the Employer’s Representative at least two weeks in advance for witnessing and inspection.

At an appropriate time, but not less than six months prior to commencement of any Site cleaning, the Contractor shall submit a detailed programme covering all



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procedures, and supporting calculations giving velocities, chemical solutions, silencing, draft factors, pipework forces and movements imposed during Site cleaning operations.

3.20.2 Mechanical Cleaning at Manufacturer’s Works

Mechanical cleaning shall preferably be carried out by abrasive blasting. The Employer’s Representative is prepared to consider alternative methods provided they achieve the necessary surface condition.

3.20.2.1 Surface Condition

The metal surfaces shall be clean and free of mill scale, rust, dirt, grease and any other deleterious matter.

Where metal surfaces are to be painted the surface profiles shall conform with the painting specification requirements.

Where this does not apply, surfaces shall have a surface texture not coarser than Grade 80 abrasive paper.

3.20.2.2 Abrasives

Abrasives containing silica, silicates or slag residues shall not be used for water /steam side surfaces of plant except for cleaning sand castings where hydro-blasting with sand may be used.For austenitic materials only abrasives containing 98% or more of alumina A12 03 shall be used.

3.20.2.3 Removal of Abrasive and Debris

After cleaning, abrasive and debris shall be thoroughly removed from components.

3.20.2.4 Chemical Cleaning at Manufacturer’s Works

3.20.2.5 General

The procedure shall comprise pre-treatment, acid treatment, neutralization, rinsing and drying to achieve cleanliness equivalent to that specified for mechanical cleaning. The procedure to be adopted shall be to the Employer’s Representative approval.

4.0 EXECUTION

1.1 TESTING

.1 GENERAL

.1 Perform all tests required by Codes, Ordinances, and as specified herein, as well as demonstrations of operation for all equipment. Each final test to be



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witnessed by the Engineer Give a minimum of seven (7) days written notice before performing tests.

.2 Install all temporary and permanent equipment and instruments required for tests, as well as additional thermometer wells, gauge and instrument connections, as no additional cost to the Owner.

.3 Perform preliminary tests and repair all leaks before notifying the Engineer of final tests.

.4 Repair leaks, damage, or defects discovered during or resulting from tests or replace to a like-new condition. Remove leak pipe joints, ductwork, etc., and replace with acceptance materials. Retest systems repaired.

.5 Maintain a log book of all tests, preliminary and final, showing dates, personnel, observes’ initials, description of test, and test status. Provide updated log to Engineer each month throughout the construction period. Initial log submitted to include listing of all anticipated tests.

.6 Testing, balancing, and adjusting will not relieve the Nominated Sub-Contractor of the warranty requirements.

.7 Furnish all fuel, water, and electricity required in performing the testing, balancing and adjustment of mechanical systems.

.8 Clean all piping and before testing.

.9 Use calibrated test gauges with at least 100mm diameter. Gauge range not to be more than three (3) times test pressure.

.10 Provide and demonstrate operation of all test equipment and apparatus required for the complete testing and inspection of all systems at such time and locations as may be directed by the Engineer and/ or by the authorities having jurisdiction.

All tests shall be successfully completed and approved prior to the application of insulation and prior to the concealment of any portion of the system being tested.

3.20.3 Protection at Manufacturer’s Works

As soon as all items have been cleaned and within four hours of the subsequent drying they shall be given suitable anti-corrosion protection.

All water, air and steam side surfaces shall be protected by the application of approved water soluble corrosion inhibitors, or vapour phase inhibitors that on be subsequently removed by site water washing or steam blowing, or by initial operation.

The gas side of steam generating plant items shall be protected by the application of temporary protective that do not require to be removed before commissioning, but which are removed during initial firing.

The Contractor shall submit to the Employer’s Representative the rate of application of volatile corrosion inhibitor accompanying with results of other power plant which have been experienced by the Contractor.

The rate of application of volatile corrosion inhibitors shall be at least 10 grams per square metre or 35 grams per cubic metre, whichever is the greater, except for pipes



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up to 300 mm diameter for which the minimum application rates shall be 5 grams per square metre.

Immediately after the protective treatment has been applied, all vessels and pipes shall be suitably sealed off by discs or approved alternatives or prevent ingress from the surroundings. Cylindrical plugs shall not be driven into the ends of pipes. These protective covers shall not be removed until immediately before final connection is made to its associated equipment.

3.20.3.1 Site Cleaning Procedure

3.20.3.2 General

In interpreting the following requirements, no items incorporating copper or aluminium or their alloys, or zinc coatings shall undergo any chemical cleaning other than flushing or manual cleaning as agreed with the Employer’s Representative.The Contractor shall take all necessary precautions to ensure that the internal surfaces of all site are kept clean and free from injurious matter during erection.

When the site has been erected and lagged or at such other time as may be agreed with the Employer’s Representative for sub-assemblies, the installation shall undergo a procedure for Site cleaning in accordance with the requirements and associated Schedules as specified herein.

All switchboards, panel boards, wireways, enclosures, etc. to be thoroughly vacuum cleaned prior to energizing equipment and at the completion of the project. Equipment shall be opened for observation by the Employer's Representative as required.

3.20.3.3 Piping and Vessels

All piping and vessels shall be flushed with air or oil, or steam or deionised, distilled, potable, or sea water, as deemed appropriate by the Employer’s Representative to remove loose debris.

3.20.3.4 Cleaning and Flushing of Oil System

Before any machine is run on Site, the oil shall have been thoroughly cleaned and flushed. The complete system shall be flushed, excluding such items as bearings and control valves etc. Temporary strainers shall be incorporated in the flushing arrangements to collect foreign matter and debris, and to indicate when a satisfactory state of cleanliness has been achieved.

All unalloyed ferrous lubricating oil pipes shall be pickled and passivated prior to oil flushing.

The Site flushing procedure shall be submitted to the Employer’s Representative for approval. The oil shall be circulated in the flushing procedure at a temperature satisfactory in excess of any emergency operating conditions likely to occur.

Once the strainer have appeared free from debris the circulation of flushing oil shall continue for a further three hours, and the strainers again checked to confirm satisfactory cleanliness of the system. All flushing oil, temporary pipework, strainers, and any other materials required for the Site flushing procedure shall be supplied under this Contract. Both hot and cold flushing shall be carried out.



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3.20.4 INSPECTION

At the end of the cleaning operations, the Site shall be made available for inspection.

In event that the surfaces are not cleaned to the Employer’s Representative satisfaction such parts of the cleaning procedure or agreed alternatives as are deemed necessary to overcome the deficiencies shall be carried out at the Contractor’s sole expense.

3.20.5 PROGRAMME FOR SITE CLEANING

At an appropriate time not less than six months prior to commencement of any Site cleaning, the Contractor shall submit a detailed site cleaning specifications and programme including procedure details, supporting calculations giving cleaning times, velocities, chemical solutions, silencing, drag factors, pipework forces and moments imposed during site cleaning operations.

3.20.6 DISPOSAL OF WASTE EFFLUENTS AT SITE

The Contractor will be responsible for satisfactorily disposing of all waste effluent liquors and materials and treating them to render them suitable for discharge to waste in accordance with regulations prevailing at Site regarding disposal of waste effluents.

~END OF SECTION 31003~
