For Approval

IFA

2012-08-17

For Approval

C.H.Jang

J.S.Jeon

H.J.Jo

Rev

Purpose

Issue Date

Description

Prepared
by:

Reviewed
by:

Approved
by:

Owner:

HAJR Electricity Production Company

Contractor:

Sub Contractor:

NK TECH CO., LTD.

Project:

Qurayyah Independent Power Project

Document Title:

Inspection and Test Procedure

Document No.: QIPP-MPN025-G00-3003
Owners Document No.:

QIPP-MPN025-G00-3003

QIPP-MPN025-G00-3003

INSPECTION & TEST PROCEDURE

TABLE OF CONTENTS
GAS CYLINDER

CYLINDER RACK

PRESSURE REDUCING SKID

MANIFOLD AND PIPE SPOOL

NK TECH CO.,LTD.

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QIPP-MPN025-G00-3003

INSPECTION & TEST PROCEDURE

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I. CYLINDER
1.0 SCOPE
This procedure applies to during the process test of high pressure gas cylinder
for Service Gas Supply System.
2.0 PURPOSE
This procedure is to estabilish the methods and requirments for manufacturing
of high pressure gas cylinder's to be used in Qurayyah IPP Project Service
Gas System
3.0 RESPONSIBILITY
3.1 The NK QM inspection personnel is responsible for witness or review the
manufactuing process test and preparing the test reports if required.
3.2 The NK QM Manager is responsible for reviewing & approval for the test reports
4.0 PROCEDURE
4.1. Material Control
4.1.1 The NK and Independent Inspector will verify that the CMTRS(Certified
Material Test Report) issued for the raw material are proper and
that the chemical contents specified are as required.
A.

For Intermediate Manganese steel, carbon 0.38max, manganese

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

B.

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

manganese 0.15/0.30, Phosphorus 0.02max, sulpur 0.01max, silicon
0.10/0.40, chromium 0.90/1.20, Molybdenum 0.15/0.30.

C.

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

analysis of which is slightly out of the specified range, is accetable.
If satisfactory in all other respects, provided the tolerance
allowed in ISO 9809 cylinder specification.

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

coded number and store raw materials in the designated area in yard.
4.1.3 NK will mark the coded number on each raw materials.
A. The NK and Independent Inspector will verify that the heat number
or manufacturing coded numbers, if used, are proper and recored.

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INSPECTION & TEST PROCEDURE

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4.1.4 Wall thickness is measured by using an ultrasonic instrument.

A.

The Independent Inspector will review the calculations for wall

thickness. The NK and Independent Inspector will verify that
each wall thickness meets or exceeds the minimum will thickness
as approved drawing.

B.

The results of the ultrasonic thickness test are recorded on

the Receiving Inspection Report and filed in NK QC Sect after
review by the Independent Inspector.

4.1.5 All accepted rew materials are held until further processing is
performed.
4.2

Each raw materials is cut to required lengths, or

circular blanks.

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

each piece by the cutting operator after which the NK Inspector
and Independent Inspector will verify the correctness of the
transfer.
4.2.2 Each raw materials is cut to the specified or circular blank
required for manufacturing.
4.3

Cleaning & Zinc Phosphating / Soaping

4.3.1 Each tube and circular blank is cleaned by shot blasting and / or
chemical means to remove scale, etc., if necessary, before
further process.
4.3.2 Each circular blank and cup is lubricated by Zinc Phosphating and
Soaping treatment prior to the drawing operations by CUP press &
DDI (Deep Drawing Ironing) press.

NK TECH CO.,LTD.

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INSPECTION & TEST PROCEDURE

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4.4
Spin Forming
4.4.1 One end is preheated to the required temperature.
A.

The preheating furnace operator will check the temperature of

each tube during the preheating and NK inspector will verify
that the temperature is proper compared with the applicable
preheating procedure.

B.

Temperatures are measured during the preheating by use of a

contact thermometer or pyrometer.

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

closing.
4.4.3 Tubes are spun closed while continuing to be heated.
A.

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

contact thermometer or pyrometer.

4.4.4 The spinning operator will watch for and determine if folding has
occurred duriug the spinning process.
4.4.5 The formed tube is removed from the automatic controlled machine and
pressedd to
t the
th required
i d bottom
b tt
shape
h
b a hydraulic
by
h d
li press andd then
th
cooled.
l d
4.4.6 Shotting and Inspection
upon cooling, the inside area of formed tube shall be
cleaned by shotting.
4.4.7 After shotting, the formed tube will be inspected by
the NK and Independent Inspector.
A.

The NK Inspector will inspect whether the thickness

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

B.

The NK Inspector will inspect whether the thickness

of the bottom of the cylinder is, under no condition,
to be less than two times the minimum wall thickness of
the cylinderical shell, such bottom thickness to be
measured within an area bounded by a line representing
the point of contact between the cylinder and

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INSPECTION & TEST PROCEDURE

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floor when the cylinder is in a vertical position,

the Independent Inspector shall verify this have
been performed.
4.4.8 Stamping
After inspection, heat numbers and / or manufacturing coded numbers
will be stamped on the formed area of the accepted tube as follows.
A.

Each cylinder will be marked the representative

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

B.

4.1

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

manufacturing corded numbers shall be selected as per
lot control procedure.

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

the same process as stated above.
4.4.10 Forming the opposite end, surface treatment of the cylinder will be
performed by use of a mechanical method for a smooth and uniform
surface, if any, and inspected by NK inspector.
4.5

Heat Treating

4.5.1 Intermediate manganese steel cylinders will be quenched by oil,

or other suitable medium and tempered.
A.

The steel temperature on quenching shall be that recommended

for the steel anaiysis, but in no case shall exceed 1750.

B.

The steel will be tempered at temperatures not less than 1150.

and after heat treating, each cylinder must be submitted to a
magnetic test to detect the presence of quenching cracks,
cracked cylinders shall be rejected and destroyed.

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INSPECTION & TEST PROCEDURE

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4.5.2 Chrome Molybdenum steel of 4130X cylinder will be quenched by oil

or other suitable medium and tempered.
A.

The steel temperature on quenching shall be that recommended for

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

B.

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

C.

All cylinders if water quenched or quenched with liquid producing

a cooling rate in excess of 80% of the cooling rate of water,
shall be inspected by MT or PT to detect the quenching crack.

D.

The steel temperature on normalizing shall be that recommended

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

4.5.3 The cylinders held until inspected by the NK Inspector.

4.5.4 The NK Inspector will verify heat treatmeat records and procedures.
4.5.5 The cylinders completed will be held untill further tests are completed.
4.5.6 All heat treatmeat recording instruments will be calibrated at
intervals as established for this equipment.

NK TECH CO.,LTD.

QIPP-MPN025-G00-3003

INSPECTION & TEST PROCEDURE

4.6

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TEST

4.6.1 Physical test

A.

This test is to determine yield strength, tensile strenght,

elongation, and reduction of area of material.

B.

This test will be performed in house or Subcontractor and

required on two specimens cut from one cylinder taken at random out
of each lot of 200 cylinders for ISO 9809 or one test ring for each
lot taken same heat treatment and heat number for KISO 9809.

C.

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

a ring at least 8 inches long cut from each cylinder and
subjected to same heat treatmeat as the finished cylinder.

D.

Test specimens will be prepared as specified by ISO 9809

specifications.

E.

The yield strength in tension shall be the stress corresponding

to a permanent strain of 0.2 percent of gauge length.
(1)

The yield strength shall be determined by either the "off

set" method or the "extension under load" method as prescribed in ISO standard

(2)

For the purpose of strain measurement, the intial strain

shall be set while specimen is under a stress of 12,000 psi,
the strain indicator reading being set at the calculated.

(3)

corresponding strain.
Cross-head speed of the testing machine shall not exceed
1/8 inch per minute during yield strength determination.

F.

Elongation is at least 20 percent for 2-inch gauge length or

at least 10 percent for 8-inch gauge length.

G.

The NK and Independent Inspector will verify that the results

comply with ISO 9809 specification.

H.

After completion, the QC section or Subcontractor shall record

the results in Physical Test Report and then file.

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INSPECTION & TEST PROCEDURE

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4.6.2 Flattening Test

A.

One cylinder will be taken at random out of each lot of 200 or

less cylinders for flattening as required by the ISO 9809 specification.
One separated test ring will be taken for each lot of cylinders
for flatting as required by ISO 9809 specification.

B.

Between knife edges, wedge is shaped 60-degree angle and rounded to

1/2 inch radius.
If this apparatus is prepared, longitudinal axis of the cylinder
will be at approximately a 90-degree angle to knife edges.

C.

The test ring must be flattened without cracking to 6 times the

actual wall thickness.

D.

For lots of 30 or less, the flattening test are authorized to be

made on ring at least 8 inches long cut from each cylinder and

E.

subjected to same heat treatmeat as the finished cylinder.

The NK and independent inspector will witness the flattening
test and verify the results comply with ISO 9809 specifications.

F.

After completion of flattening test, the QC section or Subcontractor shall record the results on the physical Test Report.

4.6.3 Chemical Test (if required)

A.

A chemical analysis will be performed on one of the test specimens by the QC section or Subcontractor.

B.

The NK and Independent Inspector will verify that the chemical

contents of the material has not changed and complies with the
requirements as specified in ISO 9809 specifications.

C.

After completion of the chemical test, the QC section or

subcontactor will record the results on the chemical analysis report.

NK TECH CO.,LTD.

QIPP-MPN025-G00-3003

INSPECTION & TEST PROCEDURE

4.7

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Machining

4.7.1

Each cylinder will be threaded and/or machined to order specification.

4.7.2

When the taper threads are used, the length of thread will be no
less than as specified for American Standard of National GAS
Threads.

4.7.3

When the straight threads are used, the threads will have at least
6 engaged threads and gaskets is required to prevent leakage.

4.7.4

The NK Inspector will verify the threads specification by using

a thread gauge and may use any other additional instruments, if
necessary and then record the result on the Machining Inspection
Report.

4.7.5
4.8

All gauge will be checked for calibration at established interval.

Tare Weight Testing
The cylinder will be weighted prior to the hydrostatic test.
Then the cylinder will be filled with water or a substance suitable
for this test and the difference between the two weight is recordde
in the Hydrostatic Test Report.
The accuracy of the test must be within 1 percent.

4.9

Hydrostatic Test
This test will be performed in accordance with Hydrostatic Test Procedure
QIPP-MPN025-G00-3004

4.10

Leakage Test
This test will be performed in accordance with Hydrostatic Test Prodcedure
QIPP-MPN025-G00-3004

NK TECH CO.,LTD.

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INSPECTION & TEST PROCEDURE

4.12

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Cleaning

4.12.1

The cylinders will be cleaned internally by means of steam if

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

4.12.2

The NK and Independent Inspector will inspect the inside of

closure heads of the cylinder's visually by using a light or
borescope for folding, thinning or any discontinuities in the
material.

4.13

Marking and stamping

4.13.1

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

head as follows.

A.

Each cylinder will be marked per the ISO 9809 specifications

it was manufactured to ; followed by the service pressure.
(ex: Working Pressure 150 bar, Test Pressure 250 bar )

B.

A serial number and an identification symbol will be located just

below or immediately following the ISO mark.

C.

Independent Inspector's official mark near the serial number.

date of test will be placed so that the dates of subsuquent tests
may be easily added.

D.

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

permits.

4.13.2

The Independent Inspector will check and review all documentation

for records supplementary to the Inspector's Report.
The Inspector's report will be completed and then signed by the
Independent Inspector.

4.14

Surface Treatment

4.14.1

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

blasting.

4.15

Painting and Brand Marking

4.15.1

Cylinders will be painted by an spray process.

Color and dry film thickness for painting can be determined
in accordance with painting procedure of QIPP-MPN025-G00-3007

NK TECH CO.,LTD.

INSPECTION PROCEDURE
FOR N2 FILLING SYSTEM

QIPP-MPN025-G00-3003

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. CYLINDER RACK
1.0 SCOPE
This procedure specifies the procedure for shop inspection and tests for the
following gas cylinder rack pack.
2.0 INSPECTION PROCEDURE
2.1 Material Inspection
2.1.1 Material in the drawing and material test certificate of the manufacture's
issue to check whether the chemical composition and mechanical property
are within the approved drawing(QIPP-MPN025-M00-0003)

2.1.2 The surface of material shall be checked with naked eye for any defect
(dent, crack, corrosions) to see whether its appearance and standard mark
to meet the standard.
2 2 Dimension & Visual Inspection
2.2
2.2.1 After installation overall visual and outline shall be checked according
to the specified approved GA drawing(QIPP-MPN025-M00-0001).
2.2.2 Dimension inspection shall include the following,
- Dimension of mounting pad including the size and location of each anchor
bolt hole.
- Clearance and dimension for maintenance or assembly.
- Outline dimension for connection or installation including the size,
type and location of accessories.
2.3 Paint Inspection
2.3.1 Paint Inspection report submitted by sub-vendor shall be checked to see
whether to meet the painting and coating specification and procedure
(QIPP-MPN025-G00-3007) required.

NK TECH CO.,LTD.

INSPECTION PROCEDURE
FOR N2 FILLING SYSTEM

QIPP-MPN025-G00-3003

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. PRESSURE REDUCING SKID

1.0 SCOPE
This procedure specifies the procedure for shop inspection and tests for the
following pressure reducing skid.
2.0 INSPECTION PROCEDURE
2.1 Material Inspection
2.1.1 Material in the drawing and material test certificate of the manufacture's
issue to check whether the chemical composition and mechanical property
are within the approved drawing(QIPP-MPN025-M00-0004).
2.1.2 The surface of material shall be checked with naked eye for any defect
(dent, crack, corrosions) to see whether its appearance and standard mark
to meet the standard.
2 2 Dimension & Visual Inspection
2.2
2.2.1 After installation overall & welding and outline shall be checked according
to the specified approved GA drawing(QIPP-MPN025-M00-0001).
2.2.2 Dimension inspection shall include the following,
- Dimension of mounting pad including the size and location of each anchor
bolt hole.
- Clearance and dimension for maintenance or assembly.
- Outline dimension for connection or installation including the size,
type and location of accessories.
2.3 Paint Inspection
2.3.1 Paint Inspection report submitted by sub-vendor shall be checked to see
whether to meet the painting and coating specification and procedure
(QIPP-MPN025-G00-3007) required.

NK TECH CO.,LTD.

INSPECTION PROCEDURE
FOR N2 FILLING SYSTEM

QIPP-MPN025-G00-3003

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. MANIFOLD AND PIPE SPOOL

1.0 SCOPE
This procedure specifies the procedure for shop inspection and tests for the
following manifold and pipe spool for Cylinder Rack and Pressure Reducing Skid.
2.0 INSPECTION PROCEDURE
2.1 Material Inspection
2.1.1 Material in the drawing and material test certificate of the manufacture's
issue to check whether the chemical composition and mechanical property are
within the approved drawing(QIPP-MPN025-M00-0001/ QIPP-MPN025-M00-0003/
QIPP-MPN025-M00-0004).
2.1.2 The surface of material shall be checked with naked eye for any defect
(dent, crack, corrosions) to see whether its appearance and standard mark
to meet the standard.
22.22 Fit
Fit-up
up and welding Inspection
2.2.1 After working overall visual and outline shall be checked according to
the shop welding procedure( QIPP-MPN025-G00-3006).
2.3 Dimension & Visual Inspection
2.3.1 After installation overall & welding and outline shall be checked according
to the specified approved GA drawing(QIPP-MPN025-M00-0001).
2.4 Pressure Test
2.4.1 Pressure test report submitted by sub-vendor shall be checked to see whether
to meet the specification required. The vessel shall be pneumatically tested
in NK shop in accordance with Hydrostatic test Procedure
(QIPP-MPN025-G00-3004).
2.5 Paint Inspection
2.5.1 Paint Inspection report submitted by sub-vendor shall be checked to see
whether to meet the painting and coating specification and procedure
(QIPP-MPN025-G00-3007) required.

NK TECH CO.,LTD.