 List of Quality Control Plans and Approval Rev 3/2008

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Table 14.1 Quality Control Plans for site Turbine Rebuild

Ref Number Title Works QCP Number. Approval Status

info. & Comments
Ref:
QCPU4936/KOM6/0 HP Turbine 4.1 QCPU4936/KOM6/01/01 Approved 13/02/2008
1 Rebuild By EED/CED
LP Turbine 4.1 QCPU4936/KOM6/01/02 Approved 13/02/2008
Rebuild By EED/CED
Valves & Steam 4.1 QCPU4936/KOM6/01/03 Approved 13/02/2008
Chests Rebuild By EED/CED
Bearing & 4.1 QCPU4936/KOM6/01/04 Approved 13/02/2008
Pedestal Rebuild By EED/CED
Barring Gear 4.1 QCPU4936/KOM6/01/05 Approved 13/02/2008
By EED/CED
Coupling & 4.1 QCPU4936/KOM6/01/06 Approved 13/02/2008
Alignment BY EED/CED
QCPU4936/KOM7/0 HP Turbine 4.1 QCPU4936/KOM7/01/01 Approved 13/02/2008
1 Rebuild By EED/CED
LP Turbine 4.1 QCPU4936/KOM7/01/02 Approved 13/02/2008
Rebuild By EED/CED
Valve, Valve 4.1 QCPU4936/KOM7/01/03 Approved 13/02/2008
Gear & Steam By EED/CED
Chests Rebuild
Bearing & 4.1 QCPU4936/KOM7/01/04 Approved 13/02/2008
Pedestal Rebuild By EED/CED
Coupling & 4.1 QCPU4936/KOM7/01/05 Approved 13/02/2008
Alignment By EED/CED
Barring Gear 4.1 QCPU4936/KOM7/01/06 Approved 13/02/2008
By EED/CED

Table 14.2 Quality Control Plans for offshore (Rugby) Refurbishment

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Ref Number: Title Works info. QCP Number Approval Status

Ref: & Comments

QCPU4936/KOM6/ HP Rotor 2.15.6.2 92/388 EED/CED made comments, QCPs

02 send back to Rugby for
amendments
LP Rotor 2.16.4.2 92/389 EED/CED made comments, QCPs
send back to Rugby for
amendments
HP 2.15.3.2 92/392
Diaphragm
LP Diaphragm 2.16.3.2 92/393 EED/CED made comments, QCPs
Stage 1 send back to Rugby for
amendments

QCPU4936/KOM7/ HP Rotor 2.18.6.2 92/390 EED/CED made comments, QCPs

02 send back to Rugby for
amendments
LP Rotor 2.19.4.2 92/391 EED/CED made comments, QCPs
send back to Rugby for
amendments
HP 2.18.3.2 92/394
Diaphragm
LP Diaphragm 2.19.3.2 92/395 EED/CED made comments, QCPs
Stage 1 send back to Rugby for
amendments

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Table 14.3 Quality Control Plans for onshore (Local) Refurbishment

Ref Number: Title Works QCP Contractor/ Approval Status

info. Ref: Number subcontractor & Comments
QCPU4936/K RHS HP GV 2.14.2.2 CSS- MAN Turbo Rejected by Alstom Power
OM6/03 Steam Chest T0163 South Africa Service UK/CJE
LHS HP and 2.14.3.2 Unknown Unknown waiting for the
GV Steam appointment of
Chest Subcontractor
HP Cylinder 2.15.1.2 Unknown Unknown waiting for the
appointment of
Subcontractor
HP Cylinder 2.15.4.2 TM 017 Team Machine Approved By Both
liner No. 1 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Cylinder 2.15.4.2 TM 018 Team Machine Approved By Both
liner No. 2 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment

HP Cylinder 2.15.4.2 TM 019 Team Machine Approved By Both

liner No.3 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment

HP Nozzle 2.15.5.2 Approved By BothMAN Turbo

South Africa
EED/CED and Alstom
Power Service UK/CJE
HP Gland 2.15.7.2 TM 011 Team Machine Approved By Both
Bush No. 1 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Gland 2.15.7.2 TM 012 Team Machine Approved By Both
Bush No. 2 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Gland 2.15.7.2 TM 013 Team Machine Approved By Both
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Bush No. 3 EED/CED and Alstom

Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Exhaust 2.15.7.2 TM 014 Team Machine Approved By Both
Gland No.4 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
LP Inner 2.16.1.2 Unknown Unknown waiting for the
Cylinder appointment of
Subcontractor
LP Outer 2.16.2.2 APS Refer to rebuild
Cylinder
Pedestals 2.16.5.2 APS Refer to rebuild

Electric 2.16.6.2 QCPU493 APS DONE WAITING

Turning Gear 6/KOM6/0 CED/EED APPROVAL
(barring gear) 3/01

Internal 2.2.3 P-9292-1 Corrocoat SA Approved By Both

refurb oil tank EED/CED and Alstom
Power Service UK/TS
31/03/08

QCPU4936/K RHS HP GV 2.17.1.2 CSS-T- MAN Turbo

Rejected by Alstom Power
OM7/03 Steam Chest 0164
Service UK/CJE South Africa
LHS HP and
2.17.1.2 Unknown
Unknown waiting for the
GV Steam appointment of
chest Subcontractor
HP Cylinder
2.18.1.2 Unknown Unknown waiting for the
appointment of
Subcontractor
HP Cylinder Approved By Both
Liner No.1 2.18.4.2 TM 002 Team Machine EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Cylinder Approved By Both
Liner No.2 2.18.4.2 TM 003 Team Machine EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Cylinder Approved By Both
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Liner No.3 2.18.4.2 TM 004 Team Machine EED/CED and Alstom

Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Nozzle 2.18.5.2 MAN Turbo Approved By Both
South Africa EED/CED and Alstom
Power Service UK/CJE

HP Gland 2.18.7.2 TM 007 Team Machine Approved By Both

Bush No. 1 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Gland 2.18.7.2 TM 008 Team Machine Approved By Both
Bush No. 2 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Gland 2.18.7.2 TM 009 Team Machine Approved By Both
Bush No. 3 EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Exhaust TM 010 Team Machine Approved By Both
Gland EED/CED and Alstom
Power Service UK/TS
01/04/08
#Send back to Team
Machine for amendment
HP Cylinder 2.18.10.2
keys and
expansion
arrangements
LP Inner 2.19.1.2 Unknown Unknown waiting for the
Cylinder appointment of
Subcontractor
LP Outer 2.19.2.2 APS Refer to rebuild
Cylinder
Pedestals 2.19.5.2 APS Refer to rebuild
Electric 2.19.6.2 QCPU493 APS DONE WAITING
Turning Gear 6/KOM7/0 CED/EED APPROVAL
(barring gear) 3/01
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Internal 2.2.3 P-9292-2 Corrocoat SA Approved By Both

refurb oil tank EED/CED and Alstom
Power Service UK/TS
31/03/08

Table 14.4 Quality Control Plans for offshore (Rugby) Material

APS UK applied for 3.1 or 3.2 certification from Eskom/CED-EED

Ref Number: Title QCP Comments Approval Status

Number & Comments
QCPU4936/KOM/6,7/ STV 91/004 Moving blades
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04 M13102
STV 91/005 Moving blades
M13101
STV 91/008 Blades
M13111
STV 91/011 Fixed blades
M13112
30/430 92/049 Valve body
forging
BS970 92/061
722M24T
30/227 92/095
STV 92/114 Diaph. Rings
M16101
STV 92/187 Moving blades
M13131
STV 92/398
M13134
STV 92/414 HP controllers
M13122

Table 14.5 Quality Control Plans for offshore (Rugby) Manufacture

APS UK applied for 3.1 or 3.2 certification from Eskom/CED-EED
Ref Number: Title QCP Comments Approval Status
Number & Comments
QCPU4936/KOM/6,7/0 Manufacture of 92/043

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5 machined Parts
Moving Blade 92/018
Manufacture
Hard Faced 92/022
component
manufacture
Manufacture of 92/030 HP STG1
spacer band nozzle plate
diaphragms
Manufacture of 92/036
nitrided / nito-
carburised
components
Manufacture of 92/037
white metalled
components

Table 14.6 Quality Control Plans for Systems Refurbishment (KOG)

QCP’s for the main turbine scope are being reviewed by Jon Dye
Comments on KOG QCP’s for auxiliary systems scope are in the table below

Ref Number: Title QCP Work Scope Approval Status

Number & Comments
QCPU4936/KOM6/0 Replacement of 2.4.2 QCP 11.4
6 three off relay oil
filters with duplex
filter
Dismantling , QCP 11.5
cleaning and
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reinstallation of
turbine and
generator oil piping
Dismantling, QCP 11.6
cleaning and
reinstallation of
lubrication oil
piping local to
coolers and pumps
Exchange of valves QCP 11.7
and supply of the
required
components as
specified for the
lubrication oil relay
systems
Dismantling, QCP 11.8
cleaning and
reinstallation of the
oil vapour extractor
fans piping from top
of oil tank to the
turbine hall roof
Inatallation of three
new drains

QCPU4936/KOM7/0
6

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Table 14.7 Quality Control Plans for Systems Manufacture (KOG)

There is correspondence between KOG Lee Chapman and Stewart APS UK

Ref Number: Title QCP Number Approval Status

& Comments
QCPU4936/KOM6/0
7

QCPU4936/KOM7/0
7

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Table 14.8 Quality Control Plans for Systems BOM

Ref Number: Title QCP Number Approval Status

& Comments
QCPU4936/KOM6/0
8

QCPU4936/KOM7/0
8

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Table 14.9 Quality Control Plans for Commissioning

Ref Number: Title QCP Number Approval Status

& Comments
QCPU4936/KOM6/ Main Turbine KOM/6/MA*/Cl/001
9
Lubricating, Jacking Oil KOM/6/MAV/Cl/001
and ETG
Gland Steam (including KOM/6/MAW/Cl/001
Alstom Aux Steam
Extent)
Relay Oil System KOM/6/MAX/Cl/001
Turbine Drains KOM/6/MAL/Cl/001
Bled Steam Non Return KOM/6/MAM/Cl/001
Valves
(NRV)
QCPU4936/KOM7/ Main Turbine KOM/7/MA*/Cl/001
9
Lubricating, Jacking Oil KOM/7/MAV/Cl/001
and ETG
Gland Steam (including KOM/7/MAW/Cl/001
Alstom Aux Steam
Extent)
Relay Oil System KOM/7/MAX/Cl/001
Turbine Drains KOM/7/MAL/Cl/001
Bled Steam Non Return KOM/7/MAM/Cl/001
Valves
(NRV)
Main Generator KOM/7/MK*/Cl/001
Seal Oil System KOM/7/MKW/Cl/001

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