0 Jun. 22, 2010 For Approval W.H.LEE S.W.PYUN I.G.

SON
REV. DATE DESCRIPTION DSGN CHKD APPD

FOR APPROVAL
OWNER :

PROJECT TITLE :
Engineering, Procurement, Construction, Operation and Maintenance of
Combined Cycle Gas Turbine Project at
Sabiya Power Station
CONTRACT NO : MEW/C/4010-2009/2010
CONTRACTOR : SUBCONTRACTOR FOR POWER :

JEONGWOO INDUSTRIAL
MACHINE CO., LTD.
DESIGNED BY DATE
W.H.LEE Jun. 22, 2010
CHECKED BY DATE Inspection and Test Procedure
S.W.PYUN Jun. 22, 2010 (Strainer)
APPROVED BY DATE
I.G.SON Jun. 22, 2010
SCALE NONE DOCUMENT NUMBER REV.
G/SM/PPLT-PIP/805 0
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PROJECT Sabiya CCGT Project

1.1. SCOPE
This procedure describes the requirements of inspection and tests for STRAINER of
Sabiya CCGT Project

1.2. APPLICABLE CODE AND STANDARDS, SPECIFICATION

1.2.1. American Society of Mechanical Engineers (ASME)

- SEC.Ⅱ Material
- SEC Ⅴ Non-destructive examination
- SEC Ⅸ Welding & Brazing (for qualification)
- ASME B36.10 : Welded and Seamless Wrought Steel Pipe
- ASME B16.11 : Forged Steel Fitting
- ASME B16.47 : Large Diameter Steel Flange
- ASME B31.1 : Power Piping
- ASME B16.25 : Butt Welding Ends
- ASME B16.5 : Pipe Flanges and Flanged Fittings
- ASME B31.3 : Process Piping

1.2.2. American Society for Testing And Materials (ASTM)

1.2.3. American Welding Society (AWS)

1.2.4. American Iron and Steel Institute (AISI)

1.2.5. Steel Structures Painting Council (SSPC)

1.3. INSPECTION AND TESTS

1.3.1. INSPECTION OF MATERIALS

- Visual.& Dimensional Inspection
- Mill Sheets

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1.3.2. INSPECTION OF WELDING

- Edge Preparation & Fit-Up Inspection
- Final Inspection

1.3.3. NONDESTRUCTIVE EXAMINATION

- R. T : 100% (Butt weld only)
- R.T or U.T : Casting & Forging
- M.T or P. T : Fillet weld

1.3.4. DIMENSION & VISUAL INSPECTION

1.3.5. PRESSURE TEST

1.3.6. CLEANING & PAINTING INSPECTION

1.3.7. PACKING INSPECTION

1.4. TEST PROCEDURE AND REQUIREMENTS

1.4.1. INSPECTION OF MATERIAL

(1) The inspector shall examine the material test report or certificate of compliance and shall
determine that it represents the material and meets shall sign on it.

(2) Materials shall be inspected for the purpose of detecting imperfections, surface cracks,
requirement of specification and approved drawings.

(3) Material identification shall be performed in accordance with ASME B16.5 and material
control chart. Mark transferring shall be carried out by marking method such as only
stamping, painting, tagging, and other suitable methods.

(4) JIMC will check the following items of mill sheet for pressure retaining parts in
accordance with applicable specification or standards, prior to fabrication of the strainer.
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PROJECT Sabiya CCGT Project

① Chemical composition
② Mechanical properties
③ Heat No. (or Charge No.)
④ Other items specified in the applicable codes and standards

1.4.2. INSPECTION OF WELDING

(1) GENERAL

① Qualification of WPS and welders shall be performed in accordance with ASME

SEC. IX
② Welding shall be done by qualified welders.
③ The required weld rods shall be dried before welding and each welder shall be
keeping the dried weld rods in the portable container.
④ Preheating and inter pass temperature shall be applied to the WPS.
⑤ Surface inspection of welding parts shall be performed visually by the inspector.

(2) EDGE PREPARATION & FIT-UP INSPECTION

① The edges of surface of parts to be jointed by welding shall be uniformed, smoothed

and cleaned of all foreign materials such as moisture, slag, oil, grease, paint, scale or
rust for distance of at least 13mm(1/2”) from the welding joint preparation for ferrous
materials.
② Alignment tolerances of plate edges.

Joint Categories
Section Thickness, in.
A B, C, & D
Up 1/2 to inch. 1/4t 1/4t
Over 1/2 to 3/4 inch. 1/3in. 1/4t
Over 3/4 to 1 1/2 inch. 1/8in. 3/16t
Over 1 1/2 to 2 inch. 1/8in. 1/8t
Over 2 Lesser of 1/16t or 3/8in. Lesser of 1/8t or 3/4in.

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③ Welding groove dimensions shall be checked by gauge in accordance with

fabrication drawings under tack welded condition prior to welding.
④ Alignment of sections to be welded shall be provided within the allowable tolerance
and shall be preserved during welding.
When the misalignment exceeds 2.0 mm. It’s preferred that the component with the
wall extending internally be trimmed as bellow :
Trimming shall result in a piping thickness not less than the minimum design
thickness and the change in counter shall not exceed 30 degree.
⑤ The tack weld for alignment shall be removed by grinding.

(3) FINAL INSPECTION

① Butt welded joints shall have complete penetration and full fusion. The surface of
welds shall be sufficiently free from coarse ripples, grooves, overlaps, and abrupt
ridges and valleys.
② Reduction in thickness due to the welding process is acceptable provided all of the
following conditions are met.
a. The reduction in thickness shall not reduce the minimum required thickness.
b. The reduction in thickness shall not exceed 0.8mm or 10% of the nominal
thickness of the adjoining surface, which is less.
③ The weld grooves are completely filled so that the surface of the weld metal at any
point does not fall below the surface of the adjoining base material.
Weld metal may be added as reinforcement on each face of the weld, the thickness
of the weld reinforcement on each face shall not exceed the fellows.

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Max. Reinforcement (mm)

Material Nominal
Circumferential Joints in
Thickness (mm) Other Welds
Pipe and Tubing

Less than 2.38 2.38 0.79

2.38 to 4.76, mm 3.18 1.59
Over 4.76 to 12.7, mm 3.97 2.38
Over 12.7 to 25.4, mm 4.76 2.38
Over 25.4 to 50.8 mm 6.35 3.18

1.4.3. NON-DESTRUCTIVE EXAMINATION

(1) VISUAL INSPECTION

① Surface preparation of items

a. The surface to be examined shall be free of foreign matters that could mask
surface defects or otherwise interfere with the examination.
b. Solid matters shall be removed by suitable hand tool or electrical tool.
c. Liquid matters such as oil, grease, etc. shall be cleaned with cloth or paper towel.

(2) RADIOGRAPHIC EXAMINATION or ULTRASONIC TEST

① Radiography test shall be performed with 100% for welded butt joint only.
Welded joints shall be radiography in accordance with the approved procedure. If any
defect was found on the welded joint, the Radiography test shall be performed again
after repair welding is completed using a acceptable methods to the inspector.
② All of casting and forging shall be testing R.T or U.T

(3) LIQUID PENETRANT or MAGNETIC PARTICLE EXAMINATION

① Fillet welded joints shall be Liquid Penetrant or Magnetic particle Examination in

accordance with the approved procedure.

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② PT or MT shall be performed by ASME SEC.V, Non-destructive examination

1.4.4 DIMENSION CHECK & VISUAL INSPECTION

(1) DIMENSION CHECK

① Dimension check shall be performed in accordance with the manufacturing drawings

before hydrostatic testing.
② Allowable tolerance to the completed components shall be adopted as following
except drawings tolerance.

ALLOW
DIMENSION REMARK
TOLERANCE
30 mm under ± 1.0 mm
30 mm over 120 mm under ± 2.0 mm
120 mm over 315 mm under ± 3.0 mm
315 mm over 1000 mm under ± 5.0 mm
1000 mm over 2000 mm under ± 5.0 mm

1.4.5 VISUAL INSPECTION

(1) The following items shall be inspected visually :

① Deformation
② Material surface
③ Marking & Name plate description
④ Internal cleaning
⑤ All surface and cutting edge shall be smooth and free from oil, grease, scale and
weld spatter

(2) ACCEPTANCE CRITERIA

① Any leakage is not permitted.

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② After the successful completion of the hydrostatic test, the bolting used during testing
shall be replaced. Service bolts, nuts and gaskets furnished by the vendor shall not
be used for testing.

1.4.6 PRESSURE TEST

The hydrostatic test pressure shall be as shown on the fabrication drawing approved by
purchasers.

(1) GENERAL

① Hydrostatic shall be performed before painting.

② Surface to be tested shall be dried and free oil, grease and paint all obstacles shall
be removed for inspector to read a gauge.
③ Two of calibrated test gauges shall be used.

(2) HYDROSTATIC TEST

① Hydrostatic test shall normally be carried out by use of water.

② The pressure in the vessel shall be gradually increased to minimize the shock during
testing, the temperature of the vessel and test water shall not be lower than 5℃ nor
more than 48℃.
③ The water used for hydrostatic testing shall not contain toxic or corrosive substances,
bacteria, colloidal suspensions or emulsions or any harmful matter which may affect
the strainers. For austenitic stainless steel strainer shell not have a chloride contend
exceeding 30ppm.
④ During testing the inspector shall take a care to examine the deformation of the
strainer. Any leakage on the strainer or temporary gasket or seal shall not be
permitted.
⑤ The test pressure shall be as specified in the approved drawing, and it shall be held
for at least 30 Minutes.

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(3) ACCEPTANCE CRITERIA

① Any leakage is not permitted.

② After the successful completion of the hydrostatic test, the bolting used during testing
shall be replaced. Service bolts, nuts and gaskets furnished by the vendor shall not
be used for testing.

No. Item Description Design Pressure Hydro. Test Pressure Holding Time Remark

1 00GHC31/32/33/34/35/36/37/10AA301 11 bar 16.5 bar At least 30 minutes.

2 00GHE31/32/33AA301 11 bar 16.5 bar At least 30 minutes.

3 10/20/30PGB50AA301,00PGB10AA301 11 bar 16.5 bar At least 30 minutes.

4 11/12/21/22/31/32/GMB21/22AA301 11 bar 16.5 bar At least 30 minutes.

5 11/12/21/22/31/32/LAE20AA301 77 bar 115.5 bar At least 30 minutes.

6 11/12/21/22/31/32/GMB11/12AA301 11 bar 16.5 bar At least 30 minutes.

7 10/20/30LCE40AA301 40 bar 60 bar At least 30 minutes.

8 00GKC31/32AA301 11 bar 16.5 bar At least 30 minutes.

9 11/12/21/22/31/32LAF20AA301 40 bar 60 bar At least 30 minutes.

10 00GHC81/82/61/62/63AA301 11 bar 16.5 bar At least 30 minutes.

11 10/20/30GHE11AA301 11 bar 16.5 bar At least 30 minutes.

12 11/12/21/22/31/32HAC30AA301/302 40 bar 60 bar At least 30 minutes.

13 11/12/21/22/31/32LAB11/12AA301 12 bar 18 bar At least 30 minutes.

14 10/20/30LCA11/12/13AA301 11 bar 16.5 bar At least 30 minutes.

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No. Item Description Design Pressure Hydro. Test Pressure Holding Time Remark

15 10/20/30LCE50AA302, 40 bar 60 bar At least 30 minutes

16 10/20/30LCE30AA301 40 bar 60 bar At least 30 minutes

17 10/20/30MAW10AA302 11 bar 16.5 bar At least 30 minutes

18 00MAV41/42AA301 11 bar 16.5 bar At least 30 minutes

19 11/12/21/22/31/32LCE10AA301 40 bar 60 bar At least 30 minutes

20 10/20/30LCE20AA301 40 bar 60 bar At least 30 minutes

21 11/12/21/22/31/32LAF50AA301 77 bar 115.5 bar At least 30 minutes

22 11/12/21/22/31/32LAE70AA301 219 bar 328.5 bar At least 30 minutes

23 10/20/30END41/42AA302 15 bar 22.5 bar At least 30 minutes

24 00END40AA303/304/305 15 bar 22.5 bar At least 30 minutes

1.4.7 CLEANNING INSPECTION

(1) Applicable code and standard : - SSPC - STEEL STRUCTURE PAINTING COUNCIL

(2) SURFACE PREPARATION

① Surface preparation is very important for effective painting and shall be done as
followings :
a. According to SSPC SP-1, oil grease, crayon and etc shall be cleaned
b. Scale weld spatter, excess weld metal, sharp points and edge shall be removed
c. Cleaning
(a) Blast shall be done according to SSPC SP-10
(b) Acid Cleaning shall be done according to SSPC SP-8(Stainless Steel)
(c) After blast cleaning the surface shall be cleaned by air
② Painting condition
a. Humidity is sensitive to dryness of painting. When the humidity is high,
evaporation of solvent is delayed. The most effective humidity for painting is
40% ~ 80%.

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③ Painting procedure
a. Preparation
When the painting material is multi-mixture, it must be mixed well enough
according to maker's instruction such as mixture rate. If it needs a solvent,
only designated solvent shall be used. Mixture rate of paint and solvent will be
controlled by painting condition. Mixing of paint shall be done before painting
and if mixed with hardening material it shall be used within effective time.
b. Painting method
(a) All painting shall be performed by standard painting system.
(b) Paint shall be sprayed or brushed uniformity on the surface, and sage and
drip is not acceptable.
(c) Spray-gun shall be operated at a adopt distance with the surface and
vertical.
(d) To obtain a equal thickness on all surface, stripe coat on weld seam and
edge is needed
(e) Bolting area and areas to be welded shall be protected before painting.
(f) Additional painting shall be done after pre-painted surface was dried well.
(g) Dry-film thickness shall be checked by coating thickness gauge and the
area under specified thickness shall be painted additionally.
c. Repair and touchup paint
Damaged surface shall be repaired by proper method and touch-up painted.
After repair painting the final painting shall be done.
d. Inspection
(a) The inspector shall witness and inspect the painting work, and use the
following equipment.
-Air Temperature Gauge
-Steel Surface Temperature Gauge
-Dry Film Thickness Gauge
(b) All surface and cutting edge shall be smooth and free from oil, weld spatter.
(c) Surface condition painting material any dry-film thickness are as follows :
-Surface Preparation : AS PER DWG. or painting procedure

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1.4.8 PACKING INSPECTION

(1) The requirements for packaging of products protection against corrosion, physical
Damage, contamination, or any effect that would lower the quality or cause the product
to deteriorate during the time they are shipped, handled, and stored.

(2) The product shall be protected from physical and mechanical damage. The product just
before packaging, shall have been inspected for cleanness, dirt, oil residue, metal
chip, or other forms of contamination shall have been removed.

(3) Box markings shall appear on a minimum of two sides of a box, markings shall be
included the following information :
- Contract Number or p.o no.
- Package Number & Weights
- Manufacturer Name
- Size (length X width X high = volume)

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