INSPECTION TEST PLAN No.

REVISION :

DESCRIPTION INSPECTION TEST PLAN FOR THE FABRICATION OF FISH PASSING FACILITIES

CONTRACT: PROJECT TITLE: WSB JOB NO: CLIENT:

PACKAGE 2 - HYDROMECHANICAL EQUIPMENT XAYABURI HYDROELECTRIC POWER PLANT PROJECT, LAO PDR. CH KARNCHANG (LAO) COMPANY LIMITED

DESCRIPTION OF ITEMS: DESIGN, FABRICATION & INSTALLATION OF FISH PASSING FACILITIES

PREPARED BY:

APPROVED BY:

DATE:

DATE:

LEGEND:
A1 = A2 = W1 = W2 = R1 = R2 = S = H = AP = IN =

APPROVAL STAMPS: 100% ACTUAL INSPECTION / TEST SAMPLE INSPECTION / TEST 100% WITNESS INSPECTION / TEST SAMPLE WITNESS INSPECTION / TEST 100% REVIEW OF DOCUMENTS SAMPLE REVIEW OF DOCUMENTS OPERATION SURVIELLANCE MANDATORY HOLD POINT SUBMIT FOR APPROVAL SUBMIT FOR INFORMATION Flux Cored Arc Welding Sheilded Metal Arc Welding Submerged Arc Welding Radiogarphic Test Magnetic Particle Inspection Dye Penetrent Inspection Non Destructive Test Dry Film Thickness

FCAW =
SMAW = SAW = RT = MPI = DPI = NDT =

DFT =

Page 2 of 4

Xayaburi HydroElectric Power Plant.

INSPECTION TEST PLAN ( ITP ) Discipline : Fabrication of Fish Passing Facilities.

Reference : PTS Exibit IV- Fish Passing Facilities (Pump, Motor,Embedded Part)
Activity No. A A1 DESCRIPTION OF ACTIVITY REQUIRED INSPECTIONS ACCEPTANCE CRITERIA QUALITY RECORDS
WHESSOE

ITP No: Revision : 0

INSPECTION RESPONSIBILITY CLIENT OWNER

DOCUMENTS
Issue Design Calculation & Detail Dwgs To Review & Approve Client Submission of Technical Documents for approval Review & Approve Client spec Approved Design Calculation & Drawings. Approved Control Procedures & Method Statement AP R1/AP

A2

Client Spec

AP

R1/AP

A3

Qualify WPS / PQR for Selected material/welding process. Welder Qualification Test (WQT)

NDT & Mechanical tests

ASME IX / Client Spec(GTS Approved WPS Sub-Clause 2.1.1) ASME IX / Client Spec(GTS WQT certificates Sub-Clause 2.1.1)

W1 / AP

W1 /AP

A4

NDT & Mechanical tests

W1 / R1

W1 / AP

B B1

MATERIAL
Material Receiving inspection & Storage Visual check for defects, Qty check Check plate marking / Heat no. EN 10204/DIN 50049 : Cert Categories (EN10024:3.1) PTS- Section 4.1.1, American Welding Society (AWS) Material receiving report. Material Deficiency report . Mill certificates. Material receiving report. Material Deficiency report . Electrode batch certificates. A1 / R1 A2 / R1

B2

Welding consumables receiving inspection Visual check for damages, & storage Qty check Check batch no.

A1 / R1

A2 / R1

C C1

FABRICATION (Pump)
Design of Pump follow required parameter Check the pump Specification Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.2 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.3 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.4 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.5 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.6

R1
-

R2

C2

Hydraulic condition of pump

Check the pump range operation

Manual for Pump system

A1 / R1

A2 / R2

C3

Pump specified condition

Check the reliable of pump for minimum duration (40 years)

Manual for Pump system

A1 / R1

A2 / R2

C4

Mode of conditiion for pump

Check to ensure all the mode is working smoothly

Manual for Pump system

A1 / R1

A2 / R2

C5

Motor charateristic

check either follow the given specification

Manual for Pump system

A1 / R1

A2 / R2

C6

Transient behaviour data for pump

check the speed & pressure variation Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.7 Check to ensure system is stable under load condition Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.8 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.9 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.10 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.11 Client spec: PTS- Section 4.1.1, Sub-Clause 1.3.12 Client spec: PTS- Section 4.1.1, Sub-Clause 1.8

Manual for Pump system

A1 / R1

A2 / R2

C7

Stability of system

Manual for Pump system

A1 / R1

A2 / R2

C8

Noise range for pump

Check the noise level ,<90 dB(A)

Manual for Pump system

A1 / R1

A2 / R2

C9

Vibration range for pump

Check the vibration level, > zone condition

Manual for Pump system

A1 / R1

A2 / R2

C10

Sand erosion consideration

Check to meet the necessary precautions

Manual for Pump system

A1 / R1

A2 / R2

C11

Safety requirement for pump

Ensure the pump is safe for user

Manual for Pump system

A1 / R1

A2 / R2

C12

Shop assembly and test

Check the pressure test, roughness of bearing and runout measurement of shaft

Shop test certificate

A1 / R1

A2 / R2

C13

Site installation & commisioning test

Verified the allignment, pre-stressing, Client spec: NDT & corrosion potection PTS- Section 4.1.1, Sub-Clause 1.9 Check completeness of each reports. / Client spec.

Site Commisioning report

A1 / R1

A2 / R2

C14

Compile all reports and inspection data into Review all documents document package for each section.

Final Document Package

R1

R1

D D1

FABRICATION (Motor)
Design of motor follow a parameter Check the pump Specification Client spec: PTS- Section 4.1.2, Sub-Clause 1.2 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.2

R1
Manual for Motor system

R2

D2

Stator for motor

Check the consist of non-ageingjointless and overlapped layer of singal segmental

A1 / R1

A2 / R2

Page 3 of 4

Xayaburi HydroElectric Power Plant.

INSPECTION TEST PLAN ( ITP ) Discipline : Fabrication of Fish Passing Facilities.

Reference : PTS Exibit IV- Fish Passing Facilities (Pump, Motor,Embedded Part)
Activity No. D3 Rotor DESCRIPTION OF ACTIVITY REQUIRED INSPECTIONS ACCEPTANCE CRITERIA QUALITY RECORDS Manual for Motor system
WHESSOE

ITP No: Revision : 0

INSPECTION RESPONSIBILITY CLIENT OWNER

DOCUMENTS

Check the material of rotor(magnetic Client spec: steel-copper/alluminium) PTS- Section 4.1.2, Sub-Clause 3.2.3 Check the life cycle of motor for minimum duration (40 years) Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.4 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.5 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.6 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.7 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.8 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.9 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.10

A1 / R1

A2 / R2

D4

Operation and start-up characteristic

Manual for Motor system

A1 / R1

A2 / R2

D5

Motor protection

Check the thermal sensor and vibration monitoring system

Manual for Motor system

A1 / R1

A2 / R2

D6

Combined thrust guide bearing for lower bracket

Check that any forces transferred to the pump

Manual for Motor system

A1 / R1

A2 / R2

D7

Alignment for motor

Check the final allignment of the motor shaft

Manual for Motor system

A1 / R1

A2 / R2

D8

Cooling system for motor

Check the air circuit of cooling system

Manual for Motor system

A1 / R1

A2 / R2

D9

Noise/Vibration range for motor

Check the noise level ,<80 dB Check the vibration level, > zone condition Ensure the ingress protection of motor

Manual for Motor system

A1 / R1

A2 / R2

D10

Enclosure of motor

Manual for Motor system

A1 / R1

A2 / R2

D11

Common start-up equipment for motor

Check the constituted of transformer Client spec: and on-load switches PTS- Section 4.1.2, Sub-Clause 3.2.11 Check the limitation of motor under frequency converter Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.12 Client spec: PTS- Section 4.1.2, Sub-Clause 3.2.13 Client spec: PTS- Section 4.1.2, Sub-Clause 4.2 Client spec: PTS- Section 4.1.2, Sub-Clause 4.4 Check completeness of each reports. / Client spec.

Manual for Motor system

A1 / R1

A2 / R2

D12

Operation with frequency converter for motor

Manual for Motor system

A1 / R1

A2 / R2

D13

Gearbox(optional) for motor

Check to conform no oil leakage & follow requirement of the pump and motor Check the temperature rise, short circuit withstand, noise level & load test Verified the erection, connection, cabling & bolted connection

Manual for Motor system

A1 / R1

A2 / R2

D13

Shop assembly and test

Shop test certificate

A1 / R1

A2 / R2

D14

Site installation & commisioning test

Site Commisioning report

A1 / R1

A2 / R2

D15

Compile all reports and inspection data into Review all documents document package for each section.

Final Document Package

R1

R1

C C1

FABRICATION (Crane & Auxilary Hoist)

Mark-out Steel material. Check marking dimensions prior cutting,Edge prep. Record plate Heat No.for Material traceability. Record post-cutting dimension. Check edge prep. Visual- free of surface defects Fit-Up Inspection Check misalignment,root gap Visual Inspection GTS- Volume 2,Sub-Clause 1.7 Approved Drawings Pre-cutting record

A1

A2

C2

Steel material cutting / bevelling

Approved Drawings

Pre-cutting record

A1

A2

C3

Fit-up all main part crane structure & attachment Welding all main part crane structure & attachment

Approved Drawings & WPS Fit-Up Inspection Report

A1 / R1

A2 / R2

C4

Approved Drawings & WPS Visual Inspection Report

A1 / R1

A2 / R2

C5

Carry out NDT activity of the completed Structure.

Major Butt Weld (Catagories A) =100% UT + 10% MT Secondary Part GTS-Volume 2 SubClause 1.7.1 Final Dimensional Inspection

WPS & UT Procedure & MT Procedure

UT & MT Reports

A1 / R1

A2 / R2

C6

Carry out Dimensional survey of the completed Structure.

Approved Drawing & Dimensional Report PTS- Volume 2,Sub-Clause 1.7 Approved Drawings OSHA & ASME PTS- Section 4.1.3.1,SubClause 5.2.7 Load Test Certificate

A1 / R1

A2 / R2

C7

Load Test Of Hoist

load tested to 125% of its safe working load limit.

A1/R1

A2/R2

Page 4 of 4

Xayaburi HydroElectric Power Plant.

INSPECTION TEST PLAN ( ITP ) Discipline : Fabrication of Fish Passing Facilities.

Reference : PTS Exibit IV- Fish Passing Facilities (Pump, Motor,Embedded Part)
Activity No. C8 DESCRIPTION OF ACTIVITY Blasting & Painting Of completed Section DOCUMENTS REQUIRED INSPECTIONS ACCEPTANCE CRITERIA QUALITY RECORDS Blasting & Painting Report
WHESSOE

ITP No: Revision : 0

INSPECTION RESPONSIBILITY CLIENT OWNER

Check profile, DFT,Cleanliness of the Client spec: surface & Quality Of Coating. PTS- Section 1.3.2,SubPaint System: Clause 8.2.2 A=Steel above water,contact with oil B=All Steel under water C=Control,panel board & cubicles Test the ability of Crane to operate Client spec: PTS- Section 4.1.3.2,SubClause 7.3 Check completeness of each reports. / Client spec.

A1 / R1

A2 / R2

C9

Commissioning Test at Site

Commissioning Test Report

A1

A2

C10

Compile all reports and inspection data into Review all documents document package for each section.

Final Document Package

R1

R1

D D1

FABRICATION (Embedded Part)

Mark-out Steel material. Stiffener. Check marking dimensions prior cutting,Edge prep. Record plate Heat No.for Material traceability. Record post-cutting dimension. Check edge prep. Visual- free of surface defects Fit-Up Inspection Check misalignment,root gap Approved Drawings Pre-cutting record

A1

A2

D2

Steel material cutting / bevelling

Approved Drawings

Pre-cutting record

A1

A2

D3

Fit-up Stiffener Segment to main part

Approved Drawings & WPS Fit-Up Inspection Report

A1 / R1

A2 / R2

D4

Welding all main part and Stiffener Segment to main part. Carry out NDT activity of the completed Structure.

Visual Inspection PTS- Section 3.2, Sub-Clause 6.2.2 (d) Major Butt Weld (Catagories A) =100% UT + 10% MT Secondary part PTS-Section 4.2 SubClause 6.2.2 (c) Final Dimensional Inspection Tolerance as per: (PTS- Section 4.2, Sub-Clause 4.5)

Approved Drawings & WPS Visual Inspection Report

A1 / R1

A2 / R2

D5

WPS & UT Procedure & MT Procedure

UT & MT Reports

A1 / R1

A2 / R2

D6

Carry out Dimensional survey of the completed Structure.

Approved Drawings

Dimensional Report

A1 / R1

A2 / R2

D7

Machine work for Complete Structure

All working surfaces shall be Approved Drawings machined and free of twists or warps. PTS-Section 4.2 Sub-Clause 4.6.1 Correctness Of Gap & Operation Inspection Approved Drawings & Client spec: PTS- Section 3.2,SubClause 6.3.1

Dimensional Reports

A1 / R1

A2 / R2

D8

Carry out Preliminary Test (Dry Tests)

Dry Test Report

A1 / R1

A1 / R1

D9

Blasting & Painting Of completed Section

Check profile, DFT & weather checks Client spec: during painting activity. PTS- Section 3.2,SubPaint System Clause 4.4 Check completeness of each reports. / Client spec.

Blasting & Painting Report

A1 / R1

A2 / R2

D10

Compile all reports and inspection data into Review all documents document package for each section.

Final Document Package

R1

R1