EXHIBIT B-20 FACTORY INSPECTIONS AND ON-SITE TESTS

T&I-1 GENERAL FACTORY TESTS AND INSPECTIONS T&I-1.1 General requirements

Tests and inspections shall include electrical, mechanical, hydraulic or any other tests to ensure that the plant being supplied complies with the requirements of the Specification and with the standards as applicable to the plant. The whole of the plant covered by this contract will be subjected to inspection and test by MARAFIQ during the manufacture, erection and on completion. Contractors costs associated with all inspections and testing shall be borne by Contractor. Contractor and its appointed subcontractors and vendors are required to comply with the minimum requirements for quality assurance and quality control (inspection and tests) to be applied to goods and services as detailed in the equipment specifications. Contractors costs associated with all inspections and testing shall be borne by Contractor. MARAFIQ shall be given all reasonable access to the manufacturers works at all stages of manufacture and the option of witnessing all tests. Sufficient notice in writing (minimum of 30 working days for tests at manufacturers works) shall be given to enable the necessary arrangements to be made. If the plant or any portion thereof fails under test to give the required performance, such further tests which are considered necessary by MARAFIQ shall be carried out by Contractor and the whole cost of the repeated tests shall be borne by Contractor. This also applies to tests carried out at subcontractors works. Tests shall be conducted in accordance with the specified standards. For equipment not covered by such test standards, nor specifically mentioned in the specification, the test procedure shall be agreed between MARAFIQ and Contractor. All important forgings are to be jointly examined at the manufacturers factory by MARAFIQ and by representatives of the manufacturer during forging and heat treatment. An approved method of radiographic or other non-destructive testing is to be used for proving all welding associated with pressure vessels. Contractor shall supply suitable test pieces of all materials as required by MARAFIQ.

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Instrumentation, control and distributed control system will be subject to Factory Acceptance Tests (FAT), which will be carried out at Contractors works. These tests will be carried out after Contractor has completed all his integrated system testing in the Works and consists of General System Testing and Performance Testing. In addition to particular inspections and tests specified herein, MARAFIQ reserves the right to carry out any such other inspections and tests as he may deem necessary to ensure that the works complies with the requirements of the specification. T&I-1.2 Materials

All materials must be supplied in accordance with ASTM or equivalent internationally recognized standards. Contractor shall indicate the generic material type(s) being processed, ie 1 per cent Cr steel, 2 per cent Cr. steel, 9 per cent Cr. steel, stainless steel, etc., and the nature of the work, ie forging, casting, fabrication work, etc. All materials eg plates, sheet, bars, forgings, castings, tubes, pipes and welding consumables etc. must be supplied with certification detailing the chemical composition, mechanical properties and heat treatment. Contractor shall provide test pieces as required by MARAFIQ to enable it to confirm the quality of the material supplied under the Contract. Such test pieces shall be prepared and supplied free of charge and any cost of the tests shall be borne by Contractor. If any test piece fails to comply with the requirements of the appropriate specifications for the material in question, MARAFIQ may reject the whole of the material represented by that test piece; Contractors or subcontractors designers and metallurgists will be consulted before any material is so rejected. If MARAFIQ is furnished with certified particulars of tests which have been carried out for Contractor by the suppliers of material, it may, at its own discretion, dispense with the previously mentioned tests. T&I-1.3 Castings

Castings where defined below for specific components or equipment shall be examined by Magnetic Testing (or penetrant testing for non-magnetic castings) and Ultrasonic Testing using established procedures and acceptance standards, which have been approved by Contractor and submitted. Weld repairs may be made at the foundry prior to final heat treatment without the permission of MARAFIQ, however records and maps showing the excavation sizes and defect types shall be submitted prior to commencement

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of repairs. Major repairs are defined as excavations >20 per cent of the wall thickness or >25 mm deep, or >65 cm2, or which result in leakage on hydrostatic test. All other repairs are classed as minor repairs. Major weld repairs shall not be made after rough machining without the prior written agreement of MARAFIQ. Requests to repair after rough machining shall be accompanied by the weld repair procedure, the supporting procedure qualification report and a map indicating the defect types and the dimensions of the excavations. Minor repairs after rough machining shall be reported to Marafiq. T&I-1.4 Forgings

Forgings shall be supplied in compliance with the applicable standards and specifications except where modified elsewhere in this document. Forgings as defined below for specific components or equipment shall be examined by ultrasonic testing after rough machining. Bores, fillets and changes of section shall be examined by magnetic testing (penetrant testing for non-magnetic materials). T&I-1.5 Fabrication and welding

All fabrication welding and, where agreed in writing by MARAFIQ, repair welding must be carried out using written and qualified procedures, welders and operators except where modified and agreed in writing with Marafiq. At least 8 weeks prior to commencing fabrication Contractor shall, except where otherwise agreed by MARAFIQ, submit for review four copies in the English language of: a) Welding procedures together with the relevant procedure qualification records. b) Non destructive testing procedures. c) Heat treatment procedures. Welding procedures and welders qualifications shall be in accordance with the latest revision of ASME/ANSI/AWS or equivalent internationally recognized codes and standards. The welding procedures submitted for approval shall include all of the details required by ASME/ANSI/AWS, both essential and non-essential variables for the particular welding process(es) together with the procedure qualification records and a detailed sketch of the weld joint. Contractor shall maintain for review, or if requested shall submit to MARAFIQ documentary evidence of the competency of all welders employed on the Contract. Where documentary evidence does not exist welders' qualification tests will be required by MARAFIQ. If in the opinion of MARAFIQ the welders

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are not carrying out the work in a suitable manner MARAFIQ reserves the right to call for samples of welding for examination and test. Contractor shall bear all costs for carrying out such tests. For the purposes of identification, the welders name and/or check number shall be retained by Contractor as part of the Quality Assurance System. These documents shall be made available for review by MARAFIQ. In no case whatsoever will stamping or hammering of alloy material be allowed. Welding consumables, eg electrodes, filler wires, flux and shielding gas shall deposit weld metal that has mechanical properties at least equal to the minimum values required for the parent material. All consumables shall deposit weld metal of similar composition as used in the procedure and welders' qualification tests. Contractors welding plant and ancillary equipment shall be in accordance with the appropriate parts of ASME/ANSI/AWS and shall be maintained in good working order. Permanent backing rings are not permitted and temporary backing rings shall only be used as allowed by the relevant approved welding procedure. All surfaces for welding shall be clean and free from paint, oil, grease, rust, scale or other material detrimental to welding. All butt weld preparations shall be completed by machining, grinding, machine or manual flame cutting with subsequent grinding. The use of temporary attachments welded to components shall be avoided where possible. If used, the attachments shall be removed flush with the base metal after they have served their purpose and the area of attachment shall be examined by the method specified for permanent fillet welds in the system. The carbon contents shall not exceed 0.25 per cent for carbon and carbonmanganese steels, which are to be welded unless otherwise approved in writing by MARAFIQ. Where post weld heat treatment is required by the fabrication specification, the heat treatment charts showing temperature time shall be retained by the Contractor. These charts shall indicate the heating and cooling rates, holding temperature and time and shall clearly identify the component(s) or weld(s) heat treated. Sufficient thermocouples shall be in contact with the furnace load to ensure adequate control and monitoring of heat treatment. Attachment shall be by capacitor discharge method unless otherwise agreed by MARAFIQ. Local heat treatment of welds shall be carried out using electric resistance heating methods only.

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Welding after post weld heat treatment is prohibited. Should it become necessary to carry out welding on a work piece which has undergone post weld heat treatment before, the work piece shall undergo a new heat treatment process, the procedure of which shall be sufficiently in advance submitted to MARAFIQ for approval. Welding in the fabrication shop or at Site shall be done under the supervision of a qualified welding engineer. Contractor shall submit a document relating the weld procedure, weld finish, acceptance criteria and the extent and method of non-destructive testing for each weld or group of welds. The welding procedures shall be submitted in a single revision serviced document covering each item of plant at each manufacturing location. A weld map shall be included showing the application of each welding procedure. The MMA (SMAW), SAW, TIG (GTAW), MIG (GMAW) (excluding shortcircuiting mode), and FCAW (excluding self-shielded) welding processes may be used. Other welding processes may be used only with the written approval of MARAFIQ. The following conditions shall apply: Unless welding procedure qualification tests have proved otherwise. A preheat temperature of 100C minimum shall be used for welding carbon and carbon-manganese steel where:

i.

The root pass in tube and pipe single sided butt welds in pressure parts shall be made using the TIG (GTAW) welding process with the addition of filler wire. The root and second pass in tube and pipe single sided butt welds in pressure parts shall be protected with an inert gas purge on the bore side during welding of 2 per cent Cr and higher materials.

ii.

iii.

AWS Type ER309 or E309 welding consumables shall be used for joining carbon steel to stainless steel where the service temperature is less than 150C. For service temperatures above this value Ferritic/austenitic transition joints in pressure parts shall be made with welding consumables to AWS Class ERNiCr-3 or ERNiCrFe-3 unless otherwise agreed in writing by MARAFIQ.

iv.

Weld interpass temperatures for austenitic stainless steels shall not exceed 200 degrees centigrade.

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The thickness is greater than 20 mm and non-hydrogen controlled weld metal is used. The thickness is greater than 30 mm with hydrogen controlled weld metal (<15 mls of diffusible hydrogen per 100 gms of deposited metal). vi. In the case of X10CrMoVNb9-1 (T/P91) the following shall apply: The filler wires are to be approved by MARAFIQ the use of G grade electrodes and wires is prohibited. Welding consumables to be covered by actual product certification typical certificates are not acceptable. The certification must be submitted for approval prior to the consumables being used. Pipe and tube butt joints must have the root pass completed using the TIG (GTAW) process and a back purge shall be used for at least the first two passes. A minimum preheat of 200C must be used unless proven otherwise, the use of flame heating is prohibited, one of the methods to be used: -a) electrical heating pads or b) induction heating with either method the temperature shall be monitored by thermocouples with calibrated chart recorders. A maximum interpass temperature of 300 C shall be used measured on the last deposited weld layer using temperature indicating crayons or calibrated pyrometers. T&I-1.6 Non-destructive testing NDT of castings, wrought products and weldments shall be carried out in compliance with the applicable international standards and specifications using written procedures and agreed acceptance criteria except where otherwise specified by MARAFIQ. The techniques of ultrasonic, radiographic, magnetic particle, liquid penetrant and leak detection methods applicable to all the principle items of plant shall be to the approval of MARAFIQ. Dye penetrant examination shall not be used on ferritic materials. NDT Operators shall be independently certified in accordance with an appropriate, accredited scheme eg the Personnel Certification in Nondestructive testing (PCN) scheme and shall be certified to level II or higher of that system. Alternative NDT qualifications equivalent to PCN level II may be submitted to MARAFIQ for approval. Where in-house qualification systems are employed these will be subject to quality audit by MARAFIQ. Contractor shall submit a document relating the weld procedure, weld finish, acceptable criteria and the extent and method of non-destructive testing for each weld or group of welds.

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All contractual non-destructive-examinations shall be carried out after any applicable heat treatment. Contractor shall institute and maintain a record of all non-destructive tests including those identifying rejections and repairs and these records shall be readily available for verification by MARAFIQ. Where requested the welding, heat treatment and manufacturing procedures shall be submitted. T&I-2 SPECIFIC FACTORY TESTS AND INSPECTIONS T&I-2.1 T&I-2.1.1 Mechanical systems and equipment General

In addition to provisions above Contractor as a minimum shall ensure that all materials, castings, forgings and welding consumables used in the construction of the plant and equipment including piping, mountings, fittings and ancillary components are supplied in compliance with the relevant group of Standards and their own manufacturing specifications. Contractor shall ensure that at each stage of manufacture all tests and inspections required by Contractors own manufacturing specifications are completed and documented. In addition any additional tests and inspections required to demonstrate compliance with contract specification must be completed in compliance with this specification. All material certification, non-destructive test reports, weld records, heat treatment charts and reports, dimensional survey reports, hydrostatic test charts and reports, balance and over-speed reports and clearance records produced during manufacture and testing shall form part of the history document. The tests shall be arranged to represent working conditions as closely as possible. Type tests when called for shall be made on equipment, which has previously passed its routine tests. Where type tests have been carried out under previous contracts on equipment similar in all essential respects to the equipment included in the Contract, MARAFIQ may waive the type tests on production of complete test records relating to the equipment concerned.

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T&I-2 .1.2

Steam turbine

The following tests shall be carried out on the steam turbine at the manufacturer's works prior to despatch to Site, all procedures are to be provided for MARAFIQ approval: T&I-2 .1.2.1 Castings Castings supplied for the main inner and outer casings, valve chest casings and blade-retaining components shall be subject to 100 per cent examination by Magnetic Testing (or liquid penetrant testing for non-magnetic castings) and 100 per cent Ultrasonic Testing, the acceptance criteria to be agreed by MARAFIQ. MARAFIQ may request additional Radiographic Examination where the results of the completed tests are considered inconclusive. Agreed repair welds and fabrication welds shall be subject to the same control as the main casting. All testing shall be completed following final heat treatment as a minimum. Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test and hydraulic test reports shall be supplied for each component part. Material traceability shall be maintained throughout manufacture by Contractor T&I-2 .1.2.2 Forgings Forgings supplied for the rotors, rotor discs and valve spindles shall be subject to 100 per cent examination by Ultrasonic Testing after rough machining Fabrication welds if applicable shall be subject to ultrasonic testing after final machining. Fillets and changes of section of forgings and fabrications shall be examined by magnetic testing (penetrant testing for nonmagnetic materials). Forgings and rolled sections for stationary and rotating blades shall be ultrasonic testing and magnetic testing (penetrant testing for non-magnetic materials). All testing shall be completed following final heat treatment as minimum. Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test and hydraulic test reports shall be supplied for each component part. Material traceability shall be maintained throughout manufacture by Contractor. T&I-2 .1.2.3 Pre-assembly On completion of machining operations and prior to assembly a dimensional survey of all component parts shall be completed and records produced. The completed turbine rotors shall be subject to run-out, balance and overspeed tests, as follows :

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Static and dynamic balancing of the bladed turbine rotors shall be carried out with dynamic balance checked over the complete speed range up to 20 per cent over speed, and including critical speeds and employing at least two (2) balancing planes. Balancing shall be carried out to ISO 1940/1, grade G2.5 as a minimum. The turbine rotor over speed test shall be run for a period of at least two minutes at 20 per cent over speed or a speed of 5 per cent above the maximum calculated over speed that would occur by the sole action of the over speed trip device, whichever is greater. Prior to and after the over speed test the fundamental (flexural) blade vibration frequencies of the assembled blades or banded groups of blades shall be measured. In addition, each finished rotor blade of the last LP turbine stage shall undergo a stationary check of the blade vibration frequencies prior to installation on the rotor. Turbine casings and pressure retaining components (including steam chests and piping as appropriate) shall be subject to hydrostatic tests at a pressure of 1.5 times the rated or design pressure which ever is greatest, and where applicable, valve seat leakage tests shall be carried out. T&I-2 .1.2.4 Assembly During and at completion of the assembly stages of the turbine clearance checks shall be made to ensure radial and axial clearances between blades, shafts and seals are maintained within design and drawing parameters. All material certification, non-destructive test reports, weld records, heat treatment charts and reports, dimensional survey reports, hydrostatic test charts and reports, balance and over-speed reports and clearance records produced during manufacture and testing shall form part of the history document to be submitted. Detailed test procedures shall be submitted by Contractor and shall be subject to MARAFIQs approval. T&I-2 .1.3 Steam turbine governor

The governor shall be bench tested to demonstrate droop characteristics, governor position, speed and oil pressure, position and oil pressure of throttle valve servo system, and speed of closing the emergency stop valves. T&I-2 .1.4 Boiler and auxiliary plant

T&I-2 .1.4.1 Boiler The supply, fabrication and testing of the boiler shall comply with the requirements of ASME Section 1 or other technically equivalent internationally recognized standards. To the greatest extent practicable drums, headers,

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tube panels and integral pipework shall be prefabricated and tested at Contractor's workshops and transported to site prepared for erection. Production control test plates shall be provided for each type of weld joint in the drum fabrication and shall be, in the case of longitudinal weld seams be attached to the end of one seam and welded as a continuation as the main weld seam. The material shall be selected from the one of the casts used in the drum fabrication. Welding consumables shall be from the same batch as used during welding of the drum. Boiler drums, other cylindrical components with an internal diameter greater than 600 mm and components which are not reasonably accessible after assembly shall be subject to hydrostatic test at a test pressure of 1.5 times the maximum permissible working pressure as individual components prior to assembly into the boiler. All testing shall be completed following final heat treatment as minimum. Material traceability shall be maintained through out manufacture. T&I-2 .1.4.2 Boiler drums a) 100 per cent Magnetic Particle Inspection (MPI) of all plate butt weld preparations, machined or flame cut and all openings for set-on branches 25 mm thickness and above. 100 per cent ultrasonic inspection of the shell plate area extending 75 mm each way for set-on branches of 25 mm thickness and above and load carrying attachment locations (eg lifting lugs and support brackets) before commencement of welding. 100 per cent radiography of main seams, longitudinal and circumferential. 100 per cent MPI of main seams, longitudinal and circumferential. 10 per cent MPI of stub welds up to and including 100 mm o/d in all thicknesses. 100 per cent MPI of nozzle welds over 100 mm o/d in all thicknesses. 100 per cent ultrasonic inspection of the attachment welds of stubs and branches of 25 mm thickness and above. 10 per cent ultrasonic testing of thicknesses 15 mm and above but less than 25 mm. 100 per cent MPI of the attachment welds made directly to pressure bearing components 100 per cent MPI of all areas where temporary attachments have been removed. 100 per cent ultrasonic examination of attachment welds of drum lifting lugs.

b)

c) d) e) f) g) h) i) j) k)

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Lifting lug attachment welds shall have the toes dressed prior to 100 per cent MPI of the weld. T&I-2 .1.4.3 Headers a) 10 per cent radiography of butt, branch and nozzle welds up to and including 100 mm o/d or up to and including 19 mm wall thickness. 100 per cent radiography of butt and branch welds over 100 mm o/d or greater than 19 mm wall thickness. 10 per cent MPI of butt welds up to and including 100 mm o/d in all thicknesses. 100 per cent MPI of butt welds over 100 mm o/d in all thicknesses. 100 per cent MPI of the attachment welds of load carrying parts. 10 per cent MPI of the attachment welds of non-load carrying parts. 100 per cent MPI of all areas where temporary attachments have been removed. Random hardness testing on all allow steel welding where post weld heat treatment has been carried out. welding electrodes or filler wire with base material.

l)

b) c) d) e) f) g) h) i)

T&I-2 .1.4.4 Tube panels a) 100 per cent radiography of all butt welds in tubes over 100 mm o/d or having a wall thickness greater than 19 mm. 100 per cent testing shall also be carried out on close pitched tubes where site access is difficult. 25 per cent radiography of all butt welds for superhreater and reheater tubes 100 mm o/d or less or not greater than 19 mm thick. 10 per cent radiography of all other butt welds in tubes 100 mm o/d or less, or not greater than 19 mm thick. Random hardness testing on all allow steel welding where post weld heat treatment has been carried out. Random spectroscopic testing for high pressure joints for confirmation of welding electrodes or filler wire with base material.

b)

c) d) e)

Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test and hydraulic test reports shall be supplied for each component part. The format of test records shall be in accordance with the document requirements of the applicable standard.

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The completed boiler shall be marked both above the manhole of the main drum, to each part of the plant and to a plate permanently attached to the steel structure. T&I-2 .1.4.5 Forced draught, induced draught and gas recirculation fans The supply, fabrication and testing of each fan shall comply with AMCA (Air Movement and Control Association) or other internationally accepted equivalent. Cast and forged parts shall comply generally with the general clauses of this specification. Butt welds in rotating parts shall be subject to 100 per cent radiographic examination and 100 per cent magnetic testing. Fillet welds shall also be subject to 100 per cent magnetic testing. Penetrant testing may be applied for non-magnetic materials only. All testing shall be completed following final heat treatment as minimum. Material traceability shall be maintained through out manufacture. The completed fan impeller of each fan shall be subject to final balance in compliance with applicable ANSI/ACMA or equivalent internationally recognized code/standard. Full fan performance tests to demonstrate volumetric and static pressure shall be carried out in the suppliers works on at least two (2) fans of each type and size using a test bed drive motor; MARAFIQ shall identify from which Unit the fans are to be tested. Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test for each component, together with balance and performance test reports shall be supplied for each fan. T&I-2 .1.4.6 Sootblowers Valves shall be subject to seat leakage test and sootblowers assembled for operational tests prior to final painting. The control panels shall also be subject to a simulated functional test. Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test and hydraulic test reports shall be supplied for each component part. Material traceability shall be maintained throughout manufacture. T&I-2 .1.4.7 Air and flue gas dampers The damper manufacturer shall undertake complete leakage, deflection, and pressure load tests. The tests shall be performed on each of the dampers and shall illustrate the amount of leakage through the closed damper under rated conditions of pressure, temperature, and volume as well as the amount of blade deflection. Each damper assembly with actuator shall be operated completely independently a minimum of five times and shall be inspected by MARAFIQ to determine that all components function properly. The test shall be conducted to determine whether time of closing is within specified limits.

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Each damper shall be subjected to the maximum system differential pressure for a period of not less than five minutes. The test chamber shall be so constructed that flow measuring sections, transitions, and damper connections from the transitions allow no leakage of flow or pressure to ambient. Inspection of each damper during and after the pressure test shall determine: a) b) The extent to which blades, frames, and seals have been distorted or deflected. Deflections shall be measured and recorded. That the physical change or distortion that occurs has no affect on the operation of the damper under full load pressure.

Test chamber shall be airtight and shall not leak to ambient under test conditions. Leakage through the closed damper shall be measured by the use of an orifice plate upstream of the damper and damper transition. Measurement shall be in accordance with ASME recommended practices and American Gas Association practices. Flow straighteners shall be used upstream of the orifice plate, the distance upstream as specified by the orifice manufacturer. A static pressure tap, located downstream of the orifice plate and of the flow straighteners, shall be used in conjunction with an inclined monometer to indicate and allow adjustment of design static pressure against the closed damper. All readings shall be corrected to standard air density. T&I-2 .1.4.8 Blowdown plant The blowdown vessel and associated valves and pipework shall be designed, manufactured and tested to ANSI B31.1/ASME VIII and associated specifications as appropriate. Butt welds in shells, heads, nozzles and branches shall be subject to 10 per cent radiographic examination, with a minimum length of 200 mm examined at each location. Locations in the shell and heads shall include but not be limited to intersection of longitudinal and circumferential welds. In addition where openings occur in or within 12 mm of a weld seam, the weld shall be examined for a length equal to the opening on each side of the opening. Butt welds in nozzles and branches shall be divided into groups of 10 or less. A minimum of one complete circumferential and longitudinal butt joints shall be examined from each group. Nozzle, branch and compensation plate attachment welds shall also be subject to 100 per cent magnetic testing. All other welds including other attachment welds shall be examined by magnetic testing over 10 per cent of their overall length. Dye-penetrant testing may be applied for non-magnetic

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materials only. The completed vessel shall be subject to hydraulic test at a minimum of 1. 5 times the vessel maximum working/design pressure. Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test and hydraulic test reports shall be supplied for each component part. Material traceability shall be maintained throughout manufacture. T&I-2 .1.5 Flue gas desulphurization plant

T&I-2 .1.5.1 General In addition to the general requirements for inspection and testing as defined above, Contractor as a minimum shall ensure that all materials, castings, forgings and welding consumables used in the construction of the plant and equipment including piping, mountings, fittings and ancillary components are supplied in compliance with the ASTM/ASME Standards and their own manufacturing specifications. Contractor shall ensure that at each stage of manufacture all tests and inspections required by Contractors own manufacturing specifications are completed and documented. In addition any additional tests and inspections required to demonstrate compliance with Contract specification must be completed in compliance with this specification. T&I-2 .1.5.2 Seawater booster pump The design, construction and testing of the FGD seawater booster pumps shall be in accordance with relevant internationally accepted Codes and Standards, including the rules and recommendations of the HI (Hydraulic Institute) Standards, and ASME Power Test Codes in their latest and relevant edition unless more rigid requirements are stipulated in this Specification. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the pump (casing, shaft, impeller, bearings etc), in accordance with the relevant ASTM or equivalent standard. The suction (if applicable) and pressure casings of each pump shall be hydrostatically tested to 1.5 times the applicable maximum operating/design pressure. Assembled pump rotors shall be statically and dynamically balanced in accordance with the requirements of ISO 1940-1, Grade G6.3 and overspeed tested to 110 per cent of their rated operating speed. Each seawater FGD booster pumps shall undergo functional and performance tests in accordance with the requirements of the ISO 9906

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Grade 1 to verify conformance with the specific requirements of pump capacity, delivery head, efficiency, and maximum guaranteed power demand. No negative tolerances shall be allowed on the guaranteed pump delivery head and capacity. One pump shall be subject to a NPSH test (3 per cent head drop). During the performance tests, vibration, temperature rise and noise of the pumps shall also be recorded. Certified test curves shall be submitted to MARAFIQ for each pump. These curves shall show variation in discharge head, NPSH required, pump efficiency and input power against flow throughout the range of operating conditions, including shut-off, and shall be corrected where necessary to site conditions. Each curve sheet shall be individually numbered with the associated pump clearly identified and shall contain complete information including rotational speed, impeller diameters, design operating points and other pertinent information. T&I-2 .1.6 Steam surface condenser and associated plant

T&I-2 .1.6.1 General The Condenser shall be designed, manufactured, inspected and tested in accordance with the requirements of the Heat Exchange Institute (HEI) or equivalent standard. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the condenser (shell plate, waterbox, tubes, etc), in accordance with the relevant ASTM or equivalent standard. The condenser shell, tube plate, hotwell and steam dome shall be preassembled at the manufacturers works and match marked to facilitate assembly and alignment at site. T&I-2 .1.6.2 Condenser tubes and tube plate Condenser tubes shall be examined and tested in accordance with the relevant ASTM B338 or equivalent approved standard. Tube materials shall be mechanically tested and certified on the basis of 0.2 per cent sample of each batch with a minimum of one tube per batch, with NDE, hydrostatic pressure, dimensional and surface finish tests to be completed and certified on each tube. Materials susceptible to inter-crystalline cracking are to be tested, in the weld seam area, at a rate of one specimen per 1000 tubes per melt. 10 per cent of tube bends are to be subject to ovality and thickness checks and 100 per cent of these shall be subject to liquid penetrant examination.

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Clad plate (if supplied) produced by explosive cladding shall be subjected to a 100 per cent ultrasonic inspection of the bond. The proposed method & acceptance criteria are to be agreed with MARAFIQ prior to the order being placed for the supply of the plate. Lack of bonded areas or defects in the cladding may only be repaired at the sole discretion of MARAFIQ and shall be restricted to less than 5 per cent of the plate surface. Contractor shall submit the tube/tubeplate fixing and inspection/testing procedure to Marafiq for review. The procedure shall detail the provision for the periodic pullout testing of test samples during fabrication. The condenser tube fixings will be tested by Contractor for tightness. Approved methods are: a) b) black light test with a fluorescein solution, to enable any faulty tube fixings to be located by means of a mercury vapour lamp vacuum tests, applied where necessary.

T&I-2 .1.6.3 Hydrostatic testing Waterboxes and tubes for each condenser module shall be hydrostatically tested in accordance with HEI standards to a pressure of 1.3 times the maximum working/design pressure of the circulating water system but not less than 25 psig (1.7 barg). The test pressure shall be held for at least 1 hour, during which there shall be no visible leakage. All shop hydrotesting shall be performed prior to applying any paint, coating or lining to the boundary joints. T&I-2 .1.6.4 Air extraction equipment Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the air extraction equipment casings, shafts, impellers, guide vanes, etc), in accordance with the relevant ASTM or equivalent standard. All air extraction equipment, pipes or fittings intended for use in the air extraction service system and which cannot under running conditions be subjected to a higher pressure than atmospheric shall be hydrostatically tested to 1.5 times the maximum working/design pressure or 0.7 bar (gauge), whichever is the greater. A minimum of one condenser air evacuation pump and one waterbox air evacuation pump per condenser unit shall be subject to shop performance test with dry air in accordance with ISO 1608 (or other Internationally equivalent standard) to demonstrate proper operation and capacity, which correlates to the specified performance requirements. Certified test reports and material traceability shall be furnished.

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T&I-2 .1.6.5 Condensate pumps The design, construction and testing of the Main Condensate pumps shall be in accordance with relevant internationally accepted Codes and Standards, including the rules and recommendations of the HI (Hydraulic Institute) Standards, and ASME Power Test Codes in their latest and relevant edition unless more rigid requirements are stipulated in this Specification. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the pump (bellmouth, casing, shafts, impellers, guide vanes, etc), in accordance with the relevant ASTM or equivalent standard. The suction and pressure casings of each pump shall be hydrostatically tested to 1.5 times the applicable maximum operating/design pressure. Assembled pump rotors shall be statically and dynamically balanced in accordance with the requirements of ISO 1940/1, Grade 6.3, and overspeed tested to 110 per cent of their rated operating speed. At least three (3) condensate pump shall undergo functional and performance tests in accordance with the requirements of the ASME Power Test Code ISO 9906 Grade 1 to verify conformance the pump characteristics including pump capacity, generated head, efficiency, and consumed power demand. No negative tolerances shall be allowed on the guaranteed pump delivery head and capacity. At least three (3) pumps shall be subject to NPSH test (3 per cent head drop) as part of the performance test. Any spare pump/rotating assembly shall also undergo shop performance test. During the performance tests, vibration, temperature rise and noise of the pump shall also be recorded. Should any pump fail to meet the performance test requirements then in addition to repeating the test on that pump, Marafiq reserves the right for tests to be carried out on additional pumps at Contractors expense. Any modifications made to correct the performance of the pump shall be to the approval of MARAFIQ and as appropriate shall also be carried out on all other pumps. Certified test curves shall be submitted to MARAFIQ for each pump. These curves shall show variation in discharge head, NPSH required, pump efficiency and input power against flow throughout the range of operating conditions, including shut-off, and shall be corrected where necessary to site conditions. Each curve sheet shall be individually numbered with the

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associated pump clearly identified and shall contain complete information including rotational speed, impeller diameters, design operating points and other pertinent information. T&I-2 .1.7 Feedwater heaters and deaerator

The design, construction, inspection and testing of the Feed water heaters and Deaerator shall be in accordance with relevant internationally accepted Codes and Standards, including the rules and recommendations of the Heat Exchange Institute (HEI) standards and the ASME Boiler and Pressure vessel code, Section VIII in their latest and relevant edition unless more rigid requirements are stipulated in this Specification. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the vessels and heat exchangers (shell, header, tubes, trays etc), in accordance with the relevant ASTM or equivalent standard. T&I-2 .1.7.1 Tubes Heater tubes shall be examined and tested in accordance with the applicable ASTM or equivalent approved standard. Tube materials shall be mechanically tested and certified on the basis of 0.2 per cent sample of each batch with a minimum of one tube per batch, with NDE, hydrostatic pressure, dimensional and surface finish tests to be completed and certified on each tube. Materials susceptible to inter-crystalline cracking are to be tested, in the weld seam area, at a rate of one specimen per 1000 tubes per melt. 10 per cent of tube bends are to be subject to ovality and thickness checks and 100 per cent these shall be subject to liquid penetrant examination. Contractor shall submit the tube/tubeplate fixing and inspection/testing procedure to MARAFIQ for review. T&I-2 .1.7.2 Hydrostatic tests The feed water heaters and deaerator shall be hydrostatically tested in accordance with the ASME code, Section VIII, Division 1. As a minimum, the following should be considered. The waterbox and tube bundle of the LP/HP feedwater heaters shall be hydrostatically tested to 1.5 times the design pressure of the respective condensate/feedwater system. The hydrostatic test pressure for the shell (steam) side of each feed water heater shall correspond to 1.5 times the respective steam side design pressure for that heater. The feedwater storage tank and deaerator shall be tested at 1.5 times the vessel design pressure.

P.O. Number : 7200018725

T&I-2 .1.8

Boiler feed water pumps

The design, construction and testing of the Boiler Feed Pumps (BFPs) shall be in accordance with relevant internationally accepted Codes and Standards, including the rules and recommendations of the Hydraulic Institute (HI) Standards, and ASME Power Test Codes in their latest and relevant edition unless more rigid requirements are stipulated in this Specification. The BFP variable speed fluid coupling (if applicable) shall be designed, constructed and tested in accordance with relevant internationally accepted Codes and Standards, including the rules and recommendations of the AGMA codes in their latest and relevant edition unless more rigid requirements are stipulated in this Specification. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the pump and fluid coupling (casing, impellers, shafts, diffuser, screws, nuts, sealings, etc), in accordance with the relevant ASTM or equivalent standard. The suction and pressure casings of each pump shall be hydrostatically tested to 1.5 times the applicable maximum operating/design pressure. Assembled pump rotors shall be statically and dynamically balanced in accordance with the requirements of ISO 1940/1, Grade 2.5 and overspeed tested to 110 per cent of their rated operating speed. Shaft couplings shall be dynamically balanced and match marked. T&I-2 .1.8.1 Pressure and booster pump functional and performance tests All pumps shall undergo functional tests and at least three (3) boiler feed pumps shall undergo performance tests in accordance with the requirements of the ISO 9906 Grade 1 to verify conformance with the specific requirements of pump capacity, delivery head, efficiency, and consumed power demand. No negative tolerances shall be allowed on the guaranteed pump delivery head and capacity. During the performance tests, pump vibration in accordance with ISO 10816/ISO 7919 shall be measured, temperature rise and noise shall also be recorded. At least three (3) pumps shall be subject to NPSH test (3 per cent head drop) as part of the performance test.

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Any spare pump/rotating assembly shall also undergo shop performance test. Interchangeability of spare inner assemblies or pump cartridges shall also be demonstrated in the suppliers shop. Should any pump fail to meet the performance test requirements then in addition to repeating the test on that pump, MARAFIQ reserves the right for tests to be carried out on additional pumps at Contractors expense. Any modifications made to correct the performance of the pump shall be to the approval of MARAFIQ and as appropriate shall also be carried out on all other pumps. Certified test curves shall be submitted to MARAFIQ for each pump. These curves shall show variation in discharge head, NPSH required, pump efficiency and input power against flow throughout the range of operating conditions, including shut-off, and shall be corrected where necessary to site conditions. Each curve sheet shall be individually numbered with the associated pump clearly identified and shall contain complete information including rotational speed, impeller diameters, design operating points and other pertinent information. T&I-2 .1.9 Plant cooling water system heat exchanger

The design, construction, inspection and testing of the heat exchangers shall be in accordance with relevant internationally accepted Codes and Standards, including the rules and recommendations of the Heat Exchange Institute (HEI) standards and the ASME Boiler and Pressure vessel code, Section VIII in their latest and relevant edition unless more rigid requirements are stipulated in this Specification. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the vessels and heat exchangers (shell, header, tubes, trays etc), in accordance with the relevant ASTM or equivalent standard. Tubes shall be examined and tested in accordance with the applicable ASTM or equivalent approved standard. Tube materials shall be mechanically tested and certified on the basis of 0.2 per cent sample of each batch with a minimum of one tube per batch, with NDE, hydrostatic pressure, dimensional and surface finish tests to be completed and certified on each tube. Materials susceptible to inter-crystalline cracking are to be tested, in the weld seam area, at a rate of one specimen per 1000 tubes per melt. Contractor shall submit the tube/tubeplate fixing and inspection/testing procedure to MARAFIQ for review. The heat exchanger shall be hydrostatically tested in accordance with the ASME code, Section VIII, Division 1 to a minimum test pressure of 15 bar or a defined as follows, whichever greater. The waterbox and tube bundle shall be hydrostatically tested to 1.5 times the rated design pressure of the circulating

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water system. The hydrostatic test pressure for the shell side shall correspond to 1.5 times the respective design pressure of the cooling water system. T&I-2 .1.10 Fuel oil supply system The fuel oil supply system shall be designed, manufactured and tested in accordance with the requirements of the applicable API/ANSI B31 or equivalent internationally recognized codes and standards. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the fuel oil system, in accordance with the relevant ASTM or equivalent standard. T&I-2 .1.10.1 Fuel oil transfer and forwarding pumps The pump casing shall be subject to 100 per cent magnetic particle testing of all surfaces and radiographic examination of critical areas and changes in section. The material for the pump screws shall be examined by ultrasonic and magnetic particle testing in the rough machined condition and by liquid penetrant when finally machined. The pump body shall be subject to hydraulic test at 1.5 times the maximum operating/design pressure. Three (3) main fuel oil pumps and one (1) of each type and size of other oil pumps shall be subject to performance tests conducted in accordance with the method and procedure as described under the Test Code of the Hydraulic Institute (HI) Standards, latest edition. The Contract drive motor shall be used unless otherwise agreed in writing with MARAFIQ. Vibration and temperature rise and noise shall also be recorded in accordance with the specified code and standards. Should any pump fail to meet the performance test requirements then in addition to repeating the test on that pump, MARAFIQ reserves the right for tests to be carried out on additional pumps at the Contractors expense. Any modifications made to correct the performance of the pump shall be to the approval of MARAFIQ and as appropriate shall also be carried out on all other pumps. Certified test curves shall be submitted to MARAFIQ for each pump. These curves shall show variation in discharge head, NPSH required, pump efficiency and input power against flow throughout the range of operating conditions, including shut-off, and shall be corrected where necessary to site conditions. Each curve sheet shall be individually numbered with the associated pump clearly identified and shall contain complete information including rotational speed, impeller diameters, design operating points and other pertinent information.

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T&I-2 .1.10.2 Fuel oil heaters The heater shall be designed, manufactured and tested to ASME VIII Division 1 or other international accepted Standard. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the system. The completed vessel shall be subject to hydraulic test at 1.5 times the maximum working/design pressure on both the shell and tube sides. T&I-2 .1.11 Steam transformer Shop tests of the steam transformer shall generally consist of material, welding and hydraulic pressure tests, and of final inspection, all subject to the approval of MARAFIQ. The design, construction, inspection and testing of the heat exchangers shall be in accordance with the ASME Boiler and Pressure vessel code, Section VIII in their latest and relevant edition. Contractor shall submit reports/records of chemical analysis, mechanical tests, eg tensile strength, elongation, notch impact tests, for the main components of the vessels and heat exchangers (shell, header, tubes etc), in accordance with the relevant ASTM or equivalent standard. The heat exchanger shall be hydrostatically tested in accordance with the ASME code, Section VIII, Division 1 to a minimum test pressure of 1.5 times the maximum working pressure on both the shell and tube sides. T&I-2 .1.12 Compressed air system

The compressed air system shall be designed, manufactured and tested in accordance with the requirements of the applicable ASME/ANSI or equivalent internationally recognized codes and standards. A minimum of two (2) air compressors shall be subject to performance test at the manufacturers works, in accordance with the appropriate standard while the rest will be tested at site to assure proper capacity, pressures and temperatures as well as to confirm that all mechanical and electrical parts are functioning properly. Any defects discovered, as a result of this test, shall be corrected by the Contractor and the unit will be retested. Copies of performance test curves shall be provided for each compressor tested. The curves shall indicate the actual test conditions and observed points. The air receivers shall be designed, manufactured and tested to ANSI/ASME Section VIII or equivalent internationally recognized codes and standards.

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Each vessel shall be hydrostatically tested at 1.5 times the vessel design pressure all test records shall be provided. T&I-2 .1.13 Demineralized water treatment plant All pressure vessels within the water treatment plant shall be designed, manufactured and tested to ANSI/ASME Section VIII or equivalent internationally recognized codes and standards. Each vessel shall be hydrostatically tested at 1.5 times the vessel design pressure. T&I-2 .1.14 Fire protection and detection systems All fire fighting equipment and materials shall comply with NFPA regulations and be FM/UL listed and approved. T&I-2 .1.15 Pumps and fans T&I-2 .1.15.1 General The following section defines the minimum requirements for inspections, examinations and tests to be performed at the manufacturers works for miscellaneous pumps, fans and compressors to be supplied under this Contract. For details of inspections and test to be carried out on specific items of equipment, refer to the relevant sections and applicable codes and standards. T&I-2 .1.15.2 Materials All important forgings, castings and fabrications shall be tested and examined in accordance with the requirements as defined above. Repair welds, where agreed by MARAFIQ, and fabrication welds shall be subject to the same control as the main forging/casting. Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test and hydraulic test reports shall be supplied for each component part. T&I-2 .1.15.3 Manufacturing inspection and tests Pump/fan casings shall be hydrostatically tested for leakage at not less than 150 per cent of the applicable maximum operating/design pressure. Assembled rotors shall be statically and dynamically balanced in accordance with the requirements of ISO 1940/1, and overspeed tested to 110 per cent of their rated speed.

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Vibration readings shall be taken during subsequent running tests in accordance with ISO 10816/ISO 7919 on the complete item to demonstrate satisfactory balance. This requirement may be waived at MARAFIQs discretion in the case of small items. T&I-2 .1.15.4 Functional and performance tests All pumps and fans shall undergo functional testing at the manufacturers works in accordance with the applicable codes and standards, to demonstrate compliance with the requirements of this specification. Unless otherwise specified, the first unit of each type and rating shall undergo a complete performance test including vibration tests. Subsequent units need only be tested at the duty point. For small, series production units, evidence and curves of a previous type test undertaken on an identical design of pump or fan may be acceptable instead of further complete performance test, but approval must be sought from Marafiq in each case. A test at the duty point shall in any event be conducted. As far as possible, tests on pumps in the manufacturers factory shall be carried out under conditions as close as possible to the rated conditions. The contract drive motor shall be used unless otherwise agreed in writing with MARAFIQ. Unless otherwise specified, the following codes and standards shall apply : a) b) Pump performance: in accordance with ISO 9906 or other Internationally accepted standard. Fan performance: in accordance with Air Movement and Control Association (AMCA) Standard 210-99.

Performance curves, based on actual tests unless prototype tests are accepted, shall be submitted to MARAFIQ for each pump. These curves shall show variation in discharge head, net positive suction head required, pump efficiency and input power against flow throughout the range of operating conditions, including shut-off, and shall be corrected where necessary to site conditions. Each curve sheet shall be individually numbered with the associated pump clearly identified and shall contain complete information including rotational speed, impeller diameters, design operating points and other pertinent information. Fan performance curves shall be based upon tests of the full size fan offered and include static pressure, brake power, and static efficiency plotted against volume.

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T&I-2 .1.16 Pipework For pipe materials in the makers works NDT and hydraulic tests shall be conducted in accordance with the relevant ASTM/ANSI or equivalent internationally accepted codes and standards . T&I-2 .1.17 Valves and fittings All valves shall be designed, manufactured and tested in accordance with the requirements of the applicable internationally recognized codes and standards as specified. Castings supplied for valve bodies, bonnets and other pressure retaining components shall be subject examined by magnetic testing (or penetrant testing for non-magnetic castings) and ultrasonic testing in critical areas and changes in section. The dimensions, particularly the wall thickness shall be checked. MARAFIQ may request additional radiographic examination where the results of the completed tests are considered inconclusive. Repair welds, where agreed by MARAFIQ, and fabrication welds shall be subject to the same control as the main casting. The material analysis of valves with alloy-steel bodies shall be checked by means of a spectroscopic test. All heat treatment diagrams and protocols pertaining to valve bodies of alloy-steel shall be checked for correct heat treatment before shipment. All assembled valves shall be pressure tested to 150 per cent their maximum operating pressure at the manufacturers works. Seat leakage tests shall be carried out as per the Code requirements. Valves shall be subject to hydraulic, seat leakage and where applicable functional tests with the contract actuators and controls, all in accordance with the relevant code/standard and applicable Contract requirements, prior to release for shipment to site. Certification of chemical analysis, mechanical properties, heat treatment, nondestructive test and hydraulic test reports shall be supplied for each component part. For each valve, Contractor shall issue an inspection certificate confirming the results of the tests specified herein. Safety, discharge, check and stop valves and associated fittings shall be supplied and tested in compliance with the specified standards or other approved equivalent.

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T&I-2 .2 T&I-2 .2.1

Tests on electrical systems and equipment General

The equipment provided is subject to inspection and tests by MARAFIQ during the course of manufacture and on completion in order to ensure compliance with this Specification. Contractor shall give MARAFIQ at least 15 days notice of materials for inspection or test. For tests of long duration at least one months notice shall be given. Contractor shall provide to MARAFIQ as soon as practicable after tests have been witnessed two copies of the relevant test certificates. These shall contain details of each test performed. Records, results and calculations of all electrical tests shall be provided. All instruments used shall have valid calibration certificates, and calibration data shall be made available to MARAFIQ on demand. All the inspection, measuring and test equipment required for inspections and tests shall be provided by Contractor. Contractor shall provide type test certificates for identical or essentially similar equipment which satisfies MARAFIQ. Such certified results shall be presented to MARAFIQ for consideration no later than six months after the Contract date. If appropriate type test certification can not be provided to satisfy MARAFIQ then type tests shall be carried out in accordance with the requirements of relevant standards and this Specification. Three copies of test certificates detailing all the works tests performed shall be issued by Contractor to MARAFIQ within one months of completion of works tests on each item of plant or equipment. T&I-2 .2.2 Generator

T&I-2 .2.2.1 Inspection and testing during manufacture The following tests shall be performed, as applicable, during the course of manufacture: a. b. Rotor forging and rotor end winding retaining rings. An approved series of non destructive tests. Overspeed. At 1.2 pu rated speed for 2 minutes on complete rotor in hot state. Vibrations of shaft and bearings shall be measured before, during and after the overspeed test. Oil coolers and other fluid/water coolers. Hydraulic pressure test of 1.5 x working pressure, applied to both sides of each cooler. Cooler tubes. Hydraulic pressure test of 1.5 x working pressure applied to each individual tube. Rotor winding. High voltage tests and RSO tests to be carried out as appropriate to the stage of manufacture.

c. d. e.

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f.

g. h. i.

Stator core. An approved test at approximately rated flux at rated frequency on the core before winding to give an indication of core loss, to verify the efficacy of the interlaminar insulation and correct assembly. Stator winding. Tests in accordance with IEC 60894 including random sample test. Generator casing (hydrogen cooled machine). Hydraulic pressure test at 1.5 times highest working pressure. Gas coolers (hydrogen cooled machine). Hydraulic pressure test at 1.5 times working pressure applied to water circuit side of coolers.

T&I-2 .2.2.2 Routine tests The following tests shall be carried out on each generator complete with associated excitation, cooling, control and auxiliary equipments: a. b. c. d. e. f. Generator casing (hydrogen cooled machine). pressure. Leakage test at rated gas Winding resistances. The stator and rotor winding resistances and relevant cold state temperatures shall be measured. Phase sequence. marked. The phase sequence shall be checked and permanently No-load saturation characteristic. The no-load saturation characteristic shall be measured in accordance with IEC 60034-4. No-load heat run. The stabilized temperature rises, temperatures and losses at rated voltage and rated speed shall be measured. Short circuit characteristic. The sustained three-phase short circuit characteristic shall be measured in accordance with IEC 60034-4. The direct-axis synchronous reactance and the short circuit ratio shall be determined from the results of the no-load saturation and sustained three-phase short circuit tests. Short circuit heat runs. The stabilized temperature rises, temperatures and losses at rated current and rated speed shall be measured. Unexcited run. The stabilized temperature rises, temperatures and losses with the generator unexcited at rated speed shall be measured. Temperature rises and temperatures. The temperature rises and temperatures at rated output of the generator shall be predicted from the results of the no-load and short-circuit heat runs and the unexcited run by an approved method. Vibration. tests. Vibration of all bearings shall be measured during the running High voltage tests. The stator shall be tested, with the rotor in position, in accordance with IEC 60034-1. The rotor shall be tested both at standstill and at rated speed in accordance with IEC 60034-1. Insulation resistance. The insulation resistance of both the stator and rotor windings shall be measured before and after the respective high voltage tests.

g.

h. i.

j. k.

l.

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Rotor impedance. The rotor impedance to an alternating voltage shall be measured before and after the running tests. Dielectric measurements. The dielectric loss angle (tan delta), capacitance to earth and dielectric loss energy characteristics shall be measured for each phase of the stator windings. T&I-2 .2.2.3 Type tests The following test shall be carried out on the first generator complete with associated excitation, cooling, control and auxiliary systems and equipment: a) Voltage waveform and harmonic analysis. The waveforms of the generator phase and line voltages at rated speed and voltage on opencircuit shall be recorded and harmonic factor measured in accordance with IEC 60034-4. Sudden three-phase short-circuit tests. The sudden three-phase short-circuit tests shall be carried out in accordance with IEC 60034-4. The tests shall be made with the generator excited to produce 0.3, 0.5 and 0.7 p.u. rated voltage on no-load. Saturated and unsaturated values of the direct-axis subtransient reactance and direct-axis transient reactance together with the directaxis subtransient short-circuit time constant, the direct-axis short-circuit time constant and the armature short-circuit time constant shall be determined from the results of the tests. Following the sudden short-circuit tests the generator shall be inspected in detail to check for damage and distortion in the windings and support structure. c) Negativesequence reactance. The negative-sequence reactance shall be determined from the application of single-phase voltage to the three phases in accordance with IEC 60034-4. Zero-sequence reactance. The zero-sequence reactance shall be determined from the application of single-phase voltage to the three phases in accordance with IEC 60034-4. Standstill frequency response tests. Standstill frequency response tests shall be carried out using applied variable frequency voltage in accordance with IEEE Standard Procedure 115 to measure the directaxis and quadrature-axis operational impedances and the armature to field transfer function and impedance. From these measurements the direct-axis and quadrature-axis operational inductances shall be derived. An approved curve fitting procedure shall be used to determine model parameters from standstill frequency response data taking account magnetic non-linearity. The synchronous machine model shall be subject to the approval of the Marafiq. Losses and efficiency. Tests shall be performed to determine the generator losses including those associated with the excitation system and equipment.

b)

d)

e)

f)

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The efficiency of the generator shall be derived from the results of these tests. Losses and efficiency shall be stated for: 0.25, 0.5, 0.75 and 1.0 p.u. generator rated output. T&I-2 .2.3 Excitation equipment

T&I-2 .2.3.1 General Type and routine tests shall be carried out on all the excitation equipment and associated control equipment. The type tests shall include environmental tests. T&I-2 .2.3.2 Thyristor rectifier type tests The excitation rectifier shall be type tested in accordance with IEC 60146. The light load test shall be performed at a voltage equivalent to that existing at the excitation transformer secondary terminals when the generator terminal voltage is at the maximum steady state value. Current and temperature rise tests shall be performed at the excitation system rated current as defined in the Specification. Cooling conditions during the temperature rise test shall represent site conditions. During these tests the current equivalent to field forcing conditions shall be applied for 10 seconds at agreed intervals. The ability of the rectifier to withstand the field current induced by a sudden short-circuit at the generator terminals at full load shall be demonstrated. The insulation test voltage applied to the equipment shall not be less than the test voltage applied to the generator field winding insulation. Test details and methods shall be agreed with, and approved by MARAFIQ. T&I-2 .2.3.3 Thyristor rectifier routine tests Routine tests in accordance with IEC 60146 shall be performed on all rectifier equipment. The insulation test voltage shall not be less than the test voltage applied to the generator field winding insulation. Test details and methods shall be agreed with, and approved by MARAFIQ.

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T&I-2 .2.3.4 Excitation transformer type tests Transformers for the thyristor rectifier equipment shall be type tested in accordance with IEC 60076 and IEC 60146. Temperature rise tests shall be carried out at rated current with the primary voltage at the generator nominal terminal voltage and also at the maximum steady-state generator terminal voltage. Cooling conditions for the transformer shall be equivalent to conditions which will exist in service. Test details and test methods shall be agreed with, and approved by MARAFIQ. T&I-2 .2.3.5 Excitation transformer routine tests Transformers for the thyristor rectifier equipment shall be subjected to routine tests in accordance with IEC 60076 and IEC 60146. Test details and test methods shall be agreed with, and approved by MARAFIQ. T&I-2 .2.3.6 Field suppression and circuit breaker equipment type tests Type tests shall be carried out to prove that the field suppression and circuit breaker equipment has the capability to operate safely under the maximum prospective fault conditions. Test details and test methods shall be agreed with, and approved by MARAFIQ. T&I-2 .2.3.7 Field suppression and circuit breaker equipment routine tests Routine tests shall be carried out on the circuit breaker equipment to demonstrate correct mechanical operation, electrical controls and auxiliary circuits. High voltage withstand tests shall be carried out on the complete field suppression and circuit breaker equipment. Test details and test methods shall be agreed with, and approved by MARAFIQ. T&I-2 .2.3.8 Excitation control equipment type tests Type tests shall be carried out on the excitation control equipment to demonstrate performance of the equipment as required by the Specification. Test details and test methods shall be agreed with, and approved by MARAFIQ. T&I-2 .2.3.9 Excitation control equipment routine tests Routine tests shall be carried out to prove the correct assembly and functioning of the equipment. Test details and test methods shall be agreed with, and approved by MARAFIQ.

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T&I-2 .2.4

IP Bus Duct

Type tests: A complete section of IP bus duct equipment incorporating an approved selection of fittings, connections etc., with at least one right angle bend and a vertical section shall be erected as in-service for the purpose of these tests. Tests shall be carried out as follows: a) Test of fault current carrying capability. The rated fault current carrying capacity, as stated in the Schedule shall be proven by means of short circuit tests. Temperature rise. The temperature rise shall be measured at points to be selected by the Marafiq and shall, unless otherwise approved, be by means of maximum reading thermometer fixed to the conductor in an approved manner. Conductivity. The resistance of the lengths of conductors containing joints, flexible connections and connectors when measured, and expressed as a percentage of equivalent lengths without joints, flexible connections or connectors, shall not exceed the figures stated in the technical data sheet. For the resistance tests a current of not less than 100 amperes dc shall be used. The electrodes used for measuring the voltage drops shall be placed 250 mm away from the nearest part of the joints, flexible connections or connectors. The distance between electrodes used to measure the resistance of conductors containing the joints, flexible connections and connectors. Power frequency test. The connection section shall be subjected to an ac high voltage test at the value stated in the technical data sheet for one minute. The test shall be carried out at 60 Hz and the rms voltage shall be measured in an approved manner. Each phase shall be tested separately with the other two phases earthed. The insulation resistance shall be measured before and after the HV test in an approved manner. Routine tests. The extent of and programme for routine tests shall be agreed with MARAFIQ. Neutral earthling equipment

b)

c)

d)

e)

T&I-2 .2.5

Type tests (refer to Section T&I-2 .2. above) and routine tests shall be agreed with MARAFIQ. T&I-2 .2.6 Motors

Tests shall be carried out as defined in IEC 60034. Basic tests as defined shall be made on one motor of each type provided. Duplicate test as defined shall be made on all remaining motors.

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T&I-2 .2.7 a)

Switchgear Type tests. Contractor shall produce a certificate from an independent testing station to demonstrate that his equipment (and its component parts) have been fully tested in accordance with the appropriate IEC Standards and the specified ratings. In the absence of satisfactory evidence, type tests shall be carried out by Contractor. Routine tests. The essential components of each switchgear system shall be routine tested, in accordance with the relevant IEC standard, at the appropriate manufacturer's works. These tests shall include high voltage tests, mechanical operating tests and operating time tests.

b)

And as per material specification E16359 for 380kv T&I-2 .2.8 Transformers a) Type tests. Contractor shall provide evidence of type tests for transformers of similar rating and construction as specified in IEC 60076, IEC 60185 or IEC 60186 for power, current or voltage transformers respectively. In the absence of satisfactory evidence type tests shall be carried out by Contractor. b) Routine tests. The transformers shall be subject to routine tests in accordance with IEC 60076, IEC 60185 or IEC 60186.Testing shall be carried out generally in accordance with the requirements of IEC 60076. No load current at 70 per cent, 100 per cent and 110 per cent shall also be measured. T&I-2 .2.9 DC supplies equipment

Performance tests. One battery shall be subjected to the emergency discharge and recharge time requirements of the Specification. Voltage/time, current/time and specific gravity/time curves shall be plotted throughout the recharge period. The automatic and manual voltage control system and alarm, and indication functions of the chargers shall be demonstrated to the satisfaction of MARAFIQ. T&I-2 .2.10 Protection equipment T&I-2 .2.10.1 Routine tests All relays shall be subjected to routine tests at the manufacturer's works to confirm that they comply with the guaranteed performance and design limits. For measuring relays (ie relays which have a defined setting of the input and/or characteristic quantity subjected to accuracy requirements, eg current, time, etc.) these routine tests shall include as a minimum the following:

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a) b) c)

Measurement of the assigned error(s) under reference conditions, ie measuring accuracy and operating time characteristics. Measurement of the resetting ratios. Dielectric tests as specified in Clause 6 of IEC 60255-5, the test voltage being 2 kV rms. All normally open output contacts of all relays shall withstand a test voltage of 1 kV rms.

For all-or-nothing relays, the routine tests shall include a check of relay operation and resetting, together with the dielectric tests described above. Unless otherwise agreed with MARAFIQ, all unit protection schemes using either biased differential, current balance or voltage balance principles shall be subjected to heavy current conjunctive tests using the actual current transformer windings, which will be used in service. Tests shall be made to prove operating sensitivity, time of operation and to demonstrate stability of the protection under the worst transient external fault conditions. Tests will only be waived if the manufacturer is able to produce type test results for an identical scheme. In this case it will be sufficient to prove that individual component characteristics are identical, eg current transformers are of the same design, have the same magnetization characteristics, knee-point voltage and secondary resistance. Each circulating current protection scheme designed in accordance with this Specification must fulfil the following routine testing requirements: i. Each current transformer, which must be of the low reactance type, shall be individually tested for turns ratio, secondary winding resistance and excitation characteristic up to a secondary voltage equal to 120 per cent of the kneepoint voltage. The VA consumption at operation of current operated relays shall be measured and shall not exceed the maximum value declared by the manufacturer. The operating current of voltage relays shall be measured and shall not exceed the maximum value declared by the manufacturer. Type tests

ii.

Iii

T&I-2 .2.10.2

Approved type tests shall be carried out in the manufacturer's works on each type of protective system. During the tests, ancillary equipment shall be erected and connected so as to reproduce service conditions as closely as possible. Where type tests have been carried out on similar protective equipment, MARAFIQ may waive the type tests on production of complete test records. For circulating current protective schemes using high impedance relays, calculation of the predicted performance will be accepted in lieu of type testing of each individual scheme. However, type test results must be available for inspection.

P.O. Number : 7200018725

T&I-2 .2.11 Instrument transformers Current and voltage transformers shall be tested in accordance with the requirements of IEC 60185 and IEC 60186 respectively. T&I-2 .2.12 UPS equipment Type tests and routine tests shall be agreed with MARAFIQ. T&I-2 .2.13 Cables Cables shall be tested in accordance with the following standards: All cables: IEC 60332-3 Power cables: IEC 60502 and IEC 60811 Wiring cables: IEC 60227 Multicore and instrumentation cables: IEC 60189 and IEC 60708. T&I-2 .2.14 Metering and instruments Indicating and recording instruments shall be tested in accordance with the requirements of IEC 60051 and IEC 60258 respectively. Integrating meters shall be tested in accordance with the requirements of IEC 62052 and IEC 62053. Transducers associated with metering shall be tested in accordance with the requirements of IEC 60688. T&I-2 .2.15 Synchronizing equipment Automatic synchronizing and check synchronizing equipment shall be tested to demonstrate compliance with the specified requirements. Test details and methods shall be agreed with, and approved by MARAFIQ. T&I-2 .2.16 Steam turbine, DCS/SCADA and auxiliary stand-alone control systems For each separate control system, the correct operation of all inputs, outputs, control functions, monitoring functions, operator display systems, printing systems and all associated systems shall be tested to a test specification, which shall be approved by MARAFIQ in advance of the factory acceptance testing. The factory acceptance testing shall be witnessed by MARAFIQ.

P.O. Number : 7200018725

T&I-3 SITE TESTS T&I-3.1 Preliminary tests on site

The preliminary tests at Site mainly comprise the functional, precommissioning and commissioning tests to demonstrate whether the equipment meets the requirements of the Contract and the safety conditions, whether it has been executed with satisfactory workmanship and whether the equipment is in conformity with the prevailing Standards and Codes and Good Engineering Practice. All site tests shall be in accordance with procedures approved by MARAFIQ and witnessed as required by the approved inspection and test plan. Pre-commissioning activities shall ensure that all individual mechanical and electrical plant items, and control and instrumentation systems are checked, witnessed and proved. During this period Contractor shall undertake all installation checks, preliminary mechanical and electrical checks, pressure testing, flushing and cleaning of equipment and pipework, proving the integrity of all connections (mechanical and electrical), safety systems and verification that all plant is functionally complete. Where components form part of a system, then each component comprising that system shall be similarly inspected and tested prior to placing the system into service. Static tests to demonstrate interactive operation of components within the system shall also be completed prior to charging or energizing the system for the first time. Commissioning shall include those activities which require operation of substantial amounts of equipment on a co-ordinated basis, in a manner which is generally similar to the operation of the plant in commercial service. Commissioning shall hence include activities such as steam purging or rolling the turbine. Once the component or system is charged, energized or otherwise made live, the Contractor shall conduct further tests to demonstrate that the system and its constituent components function collectively as designed, that individual components operate at varying loads under steady state conditions within their stated operating parameters, and that the components and system respond correctly to transient conditions. After the completion of commissioning of each plant item or system, Contractor shall submit to MARAFIQ a commissioning report for the plant item or system, including the completed commissioning check lists. The report shall summarize the commissioning procedure followed, describe any adjustments or modifications made to the plant, and shall include a statement that the relevant sections of the draft instruction manuals are correct and appropriate, or alternatively include recommendations for corrections to the manuals.

P.O. Number : 7200018725

The commissioning report shall include all measurements settings and adjustments made to the plant during the erection, pre-commissioning and commissioning periods. These shall include pipework spring settings, alarm settings, valve adjustments and similar data. Contractor shall be responsible for the submission to MARAFIQ of all equipment and plant in its supply for Site inspection and tests as required by MARAFIQ. During the course of erecting the Plant, MARAFIQ shall have access for inspecting the progress of the work and checking its accuracy to any extent that may be required. Where manufacture or finishing is done at Site, tests and inspections can be conducted as a replacement for an appropriate workshop test with the approval of MARAFIQ. The preliminary checkout and test runs, the initial loading test of the component and the performance tests shall be carried out by Contractor in the presence of MARAFIQ. Acceptance Tests readings shall be taken with specially calibrated instruments. Site test and inspection shall include the following: CIVIL WORKS a) b) c) d) e) f) g) h) Conduct general soil analysis Field density test Earthwork-trench excavation width depth elevation, compaction, sand bedding, sand fill, soil fill, compaction, check of final grading. Concrete field inspection-forms, placement of concrete, curing and compressive strength test. Waterproofing and damproofing, interior acid resistant coating Building materials inspection Painting and protective coating inspection Pipe installation -Leak and Flow test for sewer lines, casting of manholes, jointing of pipe to manholes.

MECHANICAL Boiler. Boiler pressure parts hydrostatic test. Pre-testing includes: Inspect pump connection, safety valves, gage calibration & vents. Testing works includes : inspect filling with proper water, vents closing, correct water temperature, pressure rising, pressure hold, pressure lowering, visual inspection, emptying and or preservation. Check and inspect steam piping, condensate and drain piping connections including the instrument connections.

Steam Turbine

P.O. Number : 7200018725

Conduct hydrotest on the turbine piping Check and inspect painting, insulation and cladding of turbine Tanks Check welding procedure, welders qualification. Inspect foundation planarity Inspect bottom erection iron sheet positioning, bottom plate welding and conduct vacuum test Inspect for shell erection sheets alignment and sheet clearances, shell welding, visual inspection, NDE examination, radiographic examination. Inspect roof erection sheet positioning. Conduct visual inspection and vacuum or pressure test. Conduct general inspection and measure out of plumb, roundness, peaking, banding. Check hydrotest water level. Visual inspect tank shell, there should be no leaks. Inspect and check the surface preparation works, paint materials, and correct coverage and thickness of painting. Pumps Check installation, shims, alignment, coupling, correct tightening, grounding Run motor, check vibration and balancing, noise Chemical Feed System

Check for equipment installation, grounding, instrument calibration, instrument loops, instrument mounting, valves opening, cleaning, weld procedure, welders qualifications, joint preparation, non-destructive testing and hydraulic test. Material inspection-piping, specialties, expansion joints. Joint preparation inspection. Pipe support, spring support, hangers and other structural attachments check Welding inspection, non-destructive testing, radiography Valve operation, closing & opening fittings, valves, piping

PIPING

P.O. Number : 7200018725

Hydrotesting, cleaning Disinfection (for potable water line) Painting and coating

CRANE & TROLLEY Conduct visual and physical check of bridge, runway rails, trolley, reeving, lubrication, exposed surface coating. Perform functional test, no load test, static load test. Check for trolley and bridge braking distances. HVAC Chilled Water System

Material and installation visual checks, piping welding inspection and leak test, insulation and cladding, electrical power and control cables. Run units, check correct operation of fans, pumps, air handling unit, system instrumentation and control, temperature and humidity control. Check room temperatures.

Split units and Packaged type units Visual material and installation checks, power and control cable checks. Functional test. Check room temperatures. HVAC Testing & balancing Conduct HVAC testing and balancing on all the rooms provided with HVAC. FIRE DETECTION AND PROTECTION Conduct testing and inspection on the firewater system, e.g hydrotesting, flow test. Conduct inspection and functional testing on the fire detection system. Conduct discharge test on the CO2 Fire Protection system recommended test gas. All test shall be in accordance with the NFPA procedures.

P.O. Number : 7200018725

Waiving of any tests shall not release Contractor of his responsibility to fully meet the requirements of the Contract. T&I-3 .2 Final tests at site

Following successful completion of commissioning tests, the plant shall undergo final testing, comprising Reliability and Performance tests, in accordance with Section -D4 PART 4. Prior to the start of final testing, Contractor shall ensure that all necessary monitoring and safety features are implemented for the safe and reliable operation and maintenance of the plant.

P.O. Number : 7200018725