Inspection & Test Procedure

8/18/2019 Inspection & Test Procedure

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A IFA 2012-08-17 For Approval C.H.Jang J.S.Jeon H.J.Jo

Rev Purpose Issue Date DescriptionPrepared

by:Reviewed

by: Approved

by:

Owner:

HAJR Electricity Production Company

Contractor:

Sub Contractor:

NK TECH CO. LTD.

Project:

Qurayyah Independent Power Project

Document Title:

Inspection and Test Procedure

Document No.: QIPP-MPN025-G00-3003

Owner’s Document No.: QIPP-MPN025-G00-3003

For Approval


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Ⅰ GAS CYLINDER

Ⅱ CYLINDER RACK

Ⅲ PRESSURE REDUCING SKID

Ⅳ MANIFOLD AND PIPE SPOOL

TABLE OF CONTENTS

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QIPP-MPN025-G00-3003

INSPECTION TEST PROCEDURE

NK TECH CO.,LTD.NK TECH CO.,LTD.


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1.0 SCOPE

This procedure applies to during the process test of high pressure gas cylinder

for Service Gas Supply System.

2.0 PURPOSE

This procedure is to estabilish the methods and requirments for manufacturing

of high pressure gas cylinder's to be used in Qurayyah IPP Project Service

Gas System

3.0 RESPONSIBILITY

3.1 The NK QM inspection personnel is responsible for witness or review the

manufactuing process test and preparing the test reports if required.

3.2 The NK QM Manager is responsible for reviewing & approval for the test reports

4.0 PROCEDURE

4.1. Material Control

4.1.1 The NK and Independent Inspector will verify that the CMTRS(Certified

Material Test Report) issued for the raw material are proper and

I. CYLINDER

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NK TECH CO.,LTD.

that the chemical contents specified are as required.

A. For Intermediate Manganese steel, carbon 0.38max, manganese

1.35/1.75, Phosphorus 0.02max, sulpur 0.02max, silicon 0.10/0.35,

B. For Chromium Molybdenum steel, such as 4130X, carbon 0.30/0.37,

manganese 0.15/0.30, Phosphorus 0.02max, sulpur 0.01max, silicon

0.10/0.40, chromium 0.90/1.20, Molybdenum 0.15/0.30.

C. A heat of steel made under the above specifications, check chemical

analysis of which is slightly out of the specified range, is accetable.

If satisfactory in all other respects, provided the tolerance

allowed in ISO 9809 cylinder specification.

4.1.2 Manufacturer will separate raw materials by heat numbers and/or

coded number and store raw materials in the designated area in yard.

4.1.3 NK will mark the coded number on each raw materials.

A. The NK and Independent Inspector will verify that the heat number

or manufacturing coded numbers, if used, are proper and recored.

NK TECH CO.,LTD.


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4.1.4 Wall thickness is measured by using an ultrasonic instrument.

A. The Independent Inspector will review the calculations for wall

thickness. The NK and Independent Inspector will verify that

each wall thickness meets or exceeds the minimum will thickness

as approved drawing.

B. The results of the ultrasonic thickness test are recorded on

the Receiving Inspection Report and filed in NK QC Sect after

review by the Independent Inspector.

4.1.5 All accepted rew materials are held until further processing is

performed.

4.2 Each raw materials is cut to required lengths, or

circular blanks.

4.2.1 Prior to cutting raw materials, the coded number is transferred to


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and Independent Inspector will verify the correctness of the

transfer.

4.2.2 Each raw materials is cut to the specified or circular blank

required for manufacturing.

4.3 Cleaning Zinc Phosphating / Soaping

4.3.1 Each tube and circular blank is cleaned by shot blasting and / or

chemical means to remove scale, etc., if necessary, before

further process.

4.3.2 Each circular blank and cup is lubricated by Zinc Phosphating and

Soaping treatment prior to the drawing operations by CUP press &

DDI (Deep Drawing Ironing) press.

NK TECH CO.,LTD.


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4.4 Spin Forming

4.4.1 One end is preheated to the required temperature.

A. The preheating furnace operator will check the temperature of

each tube during the preheating and NK inspector will verify

that the temperature is proper compared with the applicable

preheating procedure.

B. Temperatures are measured during the preheating by use of a

contact thermometer or pyrometer.

4.4.2 A tube is mounted in the automatic controlled spinning machine for closing.

4.4.3 Tubes are spun closed while continuing to be heated.

A. The spinning operator will check the tube's temperature by use of a

contact thermometer or pyrometer.

4.4.4 The spinning operator will watch for and determine if folding has

occurred duriug the spinning process.

4.4.5 The formed tube is removed from the automatic controlled machine and


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pressed to the required bottom shape by a hydraulic press and then cooled.

4.4.6 Shotting and Inspection

upon cooling, the inside area of formed tube shall be

cleaned by shotting.

4.4.7 After shotting, the formed tube will be inspected by

the NK and Independent Inspector.

A. The NK Inspector will inspect whether the thickness

tube's inside for any discontinuities that may have occurred during spinning process.

B. The NK Inspector will inspect whether the thickness

of the bottom of the cylinder is, under no condition,

to be less than two times the minimum wall thickness of

the cylinderical shell, such bottom thickness to be

measured within an area bounded by a line representing

the point of contact between the cylinder and

NK TECH CO.,LTD.


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REV. A

floor when the cylinder is in a vertical position,

the Independent Inspector shall verify this have

been performed.

4.4.8 Stamping

After inspection, heat numbers and / or manufacturing coded numbers

will be stamped on the formed area of the accepted tube as follows.

A. Each cylinder will be marked the representative

suitable number of heat numbers and / or manufacturing coded numbers by direction of raw tubes from section 4.1

B. The quantity of each lot for one heat numbers and / or

manufacturing corded numbers shall be selected as per

lot control procedure.

4.4.9 After stamping, the opposite end is fotmed / closed through

the same process as stated above.

4.4.10 Forming the opposite end, surface treatment of the cylinder will be

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performed by use of a mechanical method for a smooth and uniform

surface, if any, and inspected by NK inspector.

4.5 Heat Treating

4.5.1 Intermediate manganese steel cylinders will be quenched by oil,

or other suitable medium and tempered.

A. The steel temperature on quenching shall be that recommended

for the steel anaiysis, but in no case shall exceed 1750℉. B. The steel will be tempered at temperatures not less than 1150℉.

and after heat treating, each cylinder must be submitted to a

magnetic test to detect the presence of quenching cracks,

cracked cylinders shall be rejected and destroyed.

NK TECH CO.,LTD.


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4.5.2 Chrome Molybdenum steel of 4130X cylinder will be quenched by oil or other suitable medium and tempered.

A. The steel temperature on quenching shall be that recommended for

the steel analysis, but in no case shall exceed 1750℉.

B. The steel will be temperd at temperature not less than 1000℉.

C. All cylinders if water quenched or quenched with liquid producing

a cooling rate in excess of 80% of the cooling rate of water,

shall be inspected by MT or PT to detect the quenching crack.

D. The steel temperature on normalizing shall be that recommended

for the steel analysis, but in no cass shall exceed 1650℉.

4.5.3 The cylinders held until inspected by the NK Inspector.

4.5.4 The NK Inspector will verify heat treatmeat records and procedures.

4.5.5 The cylinders completed will be held untill further tests are completed.

4.5.6 All heat treatmeat recording instruments will be calibrated at

intervals as established for this equipment.

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NK TECH CO.,LTD.NK TECH CO.,LTD.


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4.6 TEST

4.6.1 Physical test

A. This test is to determine yield strength, tensile strenght,

elongation, and reduction of area of material.

B. This test will be performed in house or Subcontractor and

required on two specimens cut from one cylinder taken at random out

of each lot of 200 cylinders for ISO 9809 or one test ring for each

lot taken same heat treatment and heat number for KISO 9809.

C. For lots 30 or less, physical test is authorized to be made on

a ring at least 8 inches long cut from each cylinder and

subjected to same heat treatmeat as the finished cylinder.

D. Test specimens will be prepared as specified by ISO 9809

specifications.

E. The yield strength in tension shall be the stress corresponding

to a permanent strain of 0.2 percent of gauge length.

(1) The yield strength shall be determined by either the "off



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set" method or the "extension under load" method as prescri-

bed in ISO standard

(2) For the purpose of strain measurement, the intial strain

shall be set while specimen is under a stress of 12,000 psi,

the strain indicator reading being set at the calculated.

corresponding strain.

(3) Cross-head speed of the testing machine shall not exceed

1/8 inch per minute during yield strength determination. F. Elongation is at least 20 percent for 2-inch gauge length or

at least 10 percent for 8-inch gauge length.

G. The NK and Independent Inspector will verify that the results

comply with ISO 9809 specification.

H. After completion, the QC section or Subcontractor shall record

the results in Physical Test Report and then file.

NK TECH CO.,LTD.


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4.7 Machining

4.7.1 Each cylinder will be threaded and/or machined to order specifica-

tion.

4.7.2 When the taper threads are used, the length of thread will be no

less than as specified for American Standard of National GAS

Threads.

4.7.3 When the straight threads are used, the threads will have at least

6 engaged threads and gaskets is required to prevent leakage.

4.7.4 The NK Inspector will verify the threads specification by using

a thread gauge and may use any other additional instruments, if

necessary and then record the result on the Machining Inspection

Report.

4.7.5 All gauge will be checked for calibration at established interval.

4.8 Tare Weight Testing

The cylinder will be weighted prior to the hydrostatic test.

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Then the cylinder will be filled with water or a substance suitable

for this test and the difference between the two weight is recordde

in the Hydrostatic Test Report.

The accuracy of the test must be within 1 percent.

4.9 Hydrostatic Test

This test will be performed in accordance with Hydrostatic Test Procedure


4.10 Leakage Test

This test will be performed in accordance with Hydrostatic Test Prodcedure


NK TECH CO.,LTD.


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4.12 Cleaning

4.12.1 The cylinders will be cleaned internally by means of steam if

required by customer, shot blasting and/or chemical cleaning.

4.12.2 The NK and Independent Inspector will inspect the inside of

closure heads of the cylinder's visually by using a light or

borescope for folding, thinning or any discontinuities in the

material.

4.13 Marking and stamping

4.13.1 The stamping will be plain and permanent on the shoulds of formed

head as follows.

A. Each cylinder will be marked per the ISO 9809 specifications

it was manufactured to ; followed by the service pressure.

(ex: Working Pressure 150 bar, Test Pressure 250 bar )

B. A serial number and an identification symbol will be located just

below or immediately following the ISO mark.

C. Independent Inspector's official mark near the serial number.

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date of test will be placed so that the dates of subsuquent tests

may be easily added.

D. The size of marks will be at least 1/4 inch high, if space

permits.

4.13.2 The Independent Inspector will check and review all documentation

for records supplementary to the Inspector's Report.

The Inspector's report will be completed and then signed by the

Independent Inspector.

4.14 Surface Treatment

4.14.1 External surface of all cylinder will be cleaned by using of shot

blasting.

4.15 Painting and Brand Marking

4.15.1 Cylinders will be painted by an spray process.

Color and dry film thickness for painting can be determined

in accordance with painting procedure of QIPP-MPN025-G00-3007

NK TECH CO.,LTD.


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1.0 SCOPE

This procedure specifies the procedure for shop inspection and tests for the

following gas cylinder rack pack.

2.0 INSPECTION PROCEDURE

2.1 Material Inspection

2.1.1 Material in the drawing and material test certificate of the manufacture's issue to check whether the chemical composition and mechanical property

are within the approved drawing(QIPP-MPN025-M00-0003)

2.1.2 The surface of material shall be checked with naked eye for any defect

(dent, crack, corrosions) to see whether its appearance and standard mark

to meet the standard.

Ⅱ. CYLINDER RACK

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INSPECTION PROCEDURE

FOR N2 FILLING SYSTEM

NK TECH CO.,LTD.

.

2.2.1 After installation overall visual and outline shall be checked according

to the specified approved GA drawing(QIPP-MPN025-M00-0001).

2.2.2 Dimension inspection shall include the following,

- Dimension of mounting pad including the size and location of each anchor

bolt hole.

- Clearance and dimension for maintenance or assembly.

- Outline dimension for connection or installation including the size, type and location of accessories.

2.3 Paint Inspection

2.3.1 Paint Inspection report submitted by sub-vendor shall be checked to see

whether to meet the painting and coating specification and procedure

(QIPP-MPN025-G00-3007) required.

NK TECH CO.,LTD.


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1.0 SCOPE


following pressure reducing skid.



2.1.1 Material in the drawing and material test certificate of the manufacture's

issue to check whether the chemical composition and mechanical property

are within the approved drawing(QIPP-MPN025-M00-0004).







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Ⅲ. PRESSURE REDUCING SKID

NK TECH CO.,LTD.

.

2.2.1 After installation overall & welding and outline shall be checked according


2.2.2 Dimension inspection shall include the following,

- Dimension of mounting pad including the size and location of each anchor

bolt hole.

- Clearance and dimension for maintenance or assembly.

- Outline dimension for connection or installation including the size, type and location of accessories.





NK TECH CO.,LTD.


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1.0 SCOPE


following manifold and pipe spool for Cylinder Rack and Pressure Reducing Skid.



2.1.1 Material in the drawing and material test certificate of the manufacture's issue to check whether the chemical composition and mechanical property are

within the approved drawing(QIPP-MPN025-M00-0001/ QIPP-MPN025-M00-0003/

QIPP-MPN025-M00-0004).




-




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Ⅳ. MANIFOLD AND PIPE SPOOL

NK TECH CO.,LTD.

.2.2.1 After working overall visual and outline shall be checked according to

the shop welding procedure( QIPP-MPN025-G00-3006).

2.3 Dimension & Visual Inspection

2.3.1 After installation overall & welding and outline shall be checked according


2.4 Pressure Test

2.4.1 Pressure test report submitted by sub-vendor shall be checked to see whether to meet the specification required. The vessel shall be pneumatically tested

in NK shop in accordance with Hydrostatic test Procedure

(QIPP-MPN025-G00-3004).





NK TECH CO.,LTD.

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