Equipment / Part / Description WP no. Place of Intervention
Acoustic panels # Doboj, BIH
Quality Control Plan / I&TP Intervention Date
Report Date
Supplier quality plan 72121-9110, rev - # 28.11.2017 28.11.2017
Equipment Specification Purchase Order Number
GT acoustic enclosure 4101381997
Additional Relevant Project Information
#
Type of Intervention
☐ Expediting ☒ Quality Inspection
☒ Acceptance Test
☐ Other ☐ Other
Attendees supplier or representing Attendees General Electric or representing
Stefan Ristic, project engineer Limex Marius Popescu
Jelenko Jokic, project manager Limex
Nikola Ristic, project engineer Limex
Milan Milotic, technical director Limex
Roland De Sousa, project manager Isolite
SUMMARY
Limex is a suitable contractor for acoustic panels. Limex meets all requirements to successfully produce acoustic panels. Limex is certified according ISO 2001:2015. The 3D model produced in Solidworks in Limex was sent back to Isolite for overlaying (put the 3D solidworks model over the original 3D Autocad model), checking and production release. Limex has dedicated and suitable areas for -powder paint application and handling of panels respectively curing the panels in convection oven -assembly areas for panels -cutting, punching and bending of the metal sheets
INSPECTION DETAILS
Engineering/manufacturing drawings Isolite has produced the 3 D model in Autocad for GT enclosure and generator. The 3D model was sent electronically to Limex as step file together with the pdf 2D drawings and part list. Limex is using Solidworks for 3D drawings and Autocad for 2D drawings. The original 3D model was rebuilt in Limex using Solidworks software to include all manufacturing details like dimensions, bending and cutting details, assembly rivet locations.
Furthermore, all 2D manufacturing drawings were also produced in Solidworks from the 3D model. Only the 2D cutting drawings from Solidworks were converted to Autocad dwg because the CNC cutting machine is recognizing Autocad dwg format. The 3D model produced in Solidworks in Limex was sent back to Isolite for overlaying (put the 3D solidworks model over the original 3D Autocad model), checking and production release. Design of acoustic panels There are 2 types of panels: roof panels and wall panels. Each wall panel includes a built-in sealing rubber along the length of the panel and is already assembled in the work shop. That means there is no need to send the rubber loose to the site for this connection of the wall panels. A connection / joint between 2 panels was tested in Fraunhofer Institute Stuttgart for acoustic measurements. The connection / joint for the roof panels is different from the wall panels. The roof panels are just lying side by side without need to be riveted. For the roof panels, the rubber between 2 panels is put on site. Assembly of the panels (valid for both wall and roof panels): Outside: Al-HDG galvanized metal sheet (carbon steel): AZ185 (185 g / m^2) with a thickness of 22 microns. On this metal sheet a 3 layers powder coated paint was applied (thickness 200 microns): 2 x layers (DFT 80 microns + 80 microns) of primer (Polyflex EP-20-Korroflexprimer NT-GU). Before applying the primer the surface was degreased and slightly abraded using sand paper. The final layer is a top coat DFT 40 microns (Polyflex PES-135) BS386 (leigt bej) – light and weathering resistant. The application of both primer and top coat was done manually (dry electrostatic manual application followed by backing/curing in convection oven at 180 grad C for 15 min - top coat and 160 grad C and 15 min for primer coat). Internal metal sheet of the panel is a perforated meatal sheet Aluminium alloy Al Mg3 (EN 5754 H22). This internal metal sheet is not painted. The connection/joint between the perforated metal sheet and the outer metal sheet is done by using rivets. Between the perforated sheet and metal sheet there is layer of mineral wool (Knauf DPF-40). Between the mineral wool and perforated sheet there is a thin layer of protection to stop mineral wool coming out of the panel. The rivets are made of aluminium steel zinc plated (3 microns).
Quality control All panels have been 100% dimensionally inspected in Limex. The results are recorded on the control lists. The powder coating DFT has also been 100% inspected and measured. The results are recorded in control lists. After dimensional check, the panels are packed on the wooden pallets (according IPPC standard for the treated wood) and send to Isolite for container packing. Each panel is marked with the drawing and position number. The preliminary packing list is done in Limex and send to Isolite together with the packed panels. Production area Limex has dedicated and suitable areas for -powder paint application and handling of panels respectively curing the panels in convection oven -assembly areas for panels -cutting, punching and bending of the metal sheets Limex has adequate and suitable machines for cutting and punching (3x machines: 1.5 width, length up 11m, 1x 2 m width and 11 m length: thickness up 5 mm) and bending (2x machines up to 6m respectively up to 4m). The perforated sheets are punched in Limex out of metal sheets. Other production machines: Steel beams cutting machine 1x: up to 600 mm height and 1x machine for drilling, tapping and milling and can also place marking on the piece. Welding table for pre-assembly the parts before welding. Trial Assembly During the visit, a trial assembly of the enclosure removable panels has been carried out with satisfactory results. Cross-cut test During the visit a cross-cut test was carried out on a sample coated metal sheet with satisfactory results. Material Test Certificates The mill certificates were checked for following items: panel metal sheet, panel perforated metal sheet, rivets, powder paint, mineral wool and treated wood. Acoustic measurement values were shown as checked in the FI.
