1. SCOPE……………………………………………………………………..2. REFERENCES 3
3. DEFINITIONS 3
4. REQUIREMENTS ……………………………………………………..4.1 General 4
4.2 Inspection 4.3 Qualification Tests …………………………………………………4.4 Nondestructive Examination 4.5 Spare Rotors 4.6 Repairs ………………………………………………………………..
5. CASING AND OTHER PRESSURE CONTAINING PARTS
INSPECTION 7
5.1 Casting Inspection 5.2 Weld Inspection ………………………………………………………5.3 Forged Steel Inspection 6. ROTOR TESTS AND INSPECTIONS 7. ROTOR BALANCE TEST …………………………………………..8. RUNOUT CHECK 9. HYDROSTATIC TEST 10. CLEARANCE CHECK ………………………………………………….11. MECHANICAL RUNNING TEST 12. OPTIONAL TESTS 13. APPEARANCE AND DIMENSIONAL CHECK ……………….14. INSPECTION AND TEST REPORT 15. APPENDICES 1
TABLE
I
Casting Inspection ……………………………………………………..II
Defect Severity Limits III
Run Test Data
APPENDIX
A Shop Inspection and Test Requirement Checklist for General Purpose
Steam Turbines ………………………………………………………….B Shop Inspection and Test Requirement Checklist for Special Purpose
Steam Turbines
1. Scope
1.1 This standard is for the shop inspection and testing of general purpose steam turbines based on
SES G06-S01, and special purpose steam turbines based on SES G06-S02. Instrumentation and control
systems are not covered by this standard except as pertains to their utilization during mechanical testing of
the turbines.
1.2 This standard supplements the requirements of SES G06-S01 and G06-S02.
2. References
Reference is made in this standard to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
G06-S01 General Purpose Steam Turbines
G06-S02 Special Purpose Steam Turbines
American Society for Testing and Materials (ASTM)
A 278 Gray Iron Castings for Pressure Containing Parts
A 395 High-temperature Ductile Iron Castings
A 418 Method for Ultrasonic Examination of Turbine and Generator Steel Forgings
A 472 Test Method for Heat Stability of Steam Turbine Shafts and Rotor Forgings
A 536 Ductile Iron Castings
E 94 Guide for Radiographic Testing
E 125 Reference Photographs for Magnetic Particle Indications of Ferrous Castings
E 142 Method for Controlling Quality of Radiographic Testing
E 165 Standard Test Method for Liquid Penetrant Examination
E 709 Practice for Magnetic Particle Inspection
American Society of Mechanical Engineers (ASME)
Performance Test Code PTC 6, Steam Turbines
Section V Nondestructive Examination
Section VIII, Div 1 Pressure Vessels
Section IX Welding and Brazing Qualifications
International Standards Organization (ISO)
9000 Quality Systems Management and Quality Assurance Standards
9001 Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation and
Servicing
9003 Quality Systems – Model for Quality Assurance in Final Inspection and Test
9004 Quality Management and Quality System Elements – Guidelines
Manufacturers Standardization Society (MSS)
SP-55 Quality Standard for Steel Castings – Visual Method for Examination of Surface Irregularities
3. Definitions
For the purpose of understanding this standard, the following definitions apply.
Critical Casting Area.
Any area where there is severe stress from internal pressure, or where a casting
defect is anticipated due to casting construction, for example the casing nozzle neck.
Major Welding Repair.
Welding repairs on castings in which the depth of the cavity prepared for repair
welding exceeds 20 percent of the wall thickness or 25 mm, whichever is smaller, or in which the cavity
prepared for repair welding exceeds 65 cm
3
in volume.
Minor Welding Repair.
Welding repairs on castings in which the depth or volume of a cavity prepared for
repair are smaller than those defined as a major welding repair.
Observed.
SABIC shall be notified of the timing of the inspection or test; however, the inspection or test
shall be performed as scheduled with or without the presence of SABIC.
Witnessed.
A hold shall be applied to the production schedule and the inspection or test shall be carried
out with SABIC in attendance. For mechanical running or performance tests, this requires written
notification of a successful preliminary test.
4. Requirements
4.1 General
4.1.1 Inspection, repair and testing requirements in this section shall apply to all turbines specified in this
standard. The vendor shall perform the shop inspections and tests in Appendix A or B of this standard as a
minimum requirement, unless otherwise specified in the requisition, purchase order or individual
specification. Appendix A shall be applicable to SES G06-S01 general purpose steam turbines and
Appendix B shall be applicable to SES G06-S02 special purpose steam turbines.
4.1.2 After advance notice to the vendor, SABIC shall have entry to all vendor and sub-vendor plants that
are in the process of manufacturing, testing, or inspecting the equipment.
4.1.3 Vendor shall notify sub-vendors of SABIC’s inspection and testing requirements.
4.1.4 Vendor shall provide at least 15 working days advance notice to SABIC before conducting witnessed
or observed inspections and tests.
4.1.5 Manufacturing hold points for inspection and testing shall be identified by joint agreement of SABIC,
and the vendor after receipt of the purchase order.
4.1.6 Vendor shall provide the facilities, equipment and apparatus for the specified inspections and tests.
4.1.7 Performance test instrumentation shall be calibrated to within the manufacturers’ tolerances prior to
inspection or test. Vendor shall provide records of instrument calibration to SABIC when requested.
4.1.8 The ASME weld procedure specifications (WPS), procedure qualification records (PQR) and welder
qualification records shall be submitted to SABIC for review and approval before fabrication.
4.1.9 Approved copies of WPS, PQR and welder qualification records shall be available in vendor’s shop,
and shall be available for SABIC review.
4.1.10 Unless exempted by qualification under 4.1.10.2, vendor shall submit a quality assurance and
quality control (QA/QC) program specific for the turbine(s) for SABIC’s review and approval. This submittal
shall be after release of the purchase order, but before starting manufacture.
4.1.10.1 SABIC will review vendor’s quality program. The vendor shall have in effect at all times a QA/QC
program, which clearly establishes the authority and responsibility of those responsible for the quality
system. Persons performing quality functions shall have sufficient and well defined authority to enforce
quality requirements, initiate, identify, recommend and provide solutions to quality problems and verify the
effectiveness of the corrective action.
4.1.10.2 If the vendor’s QA/QC program and facility where the work is to be performed is ISO 9000
certified, then only a copy of the vendor’s ISO 9000 certificate shall be required. In addition, if the vendor’s
facility is ISO 9000 certified, SABIC’s QA audit requirements will be waived in favor of ISO 9000 registrar
audits unless the vendor’s QA/QC program indicates areas of concern.
4.1.10.3 The vendor’s proposed quality system shall fully satisfy all applicable elements of the ISO 9001,
9003 and 9004. The quality system shall provide for the planned and systematic control of all quality
related activities performed.
4.1.11 Any conflict(s) between this standard, SES and industry standards, engineering drawings, and
contract documents shall be resolved at the discretion of SABIC.
4.1.12 Documents shall be provided in units conforming to SES Z01-G04, and shall be written in English
language.
4.2 Inspection
4.2.1 Vendor shall keep the following data available for at least 10 years for review by SABIC upon
request. Alternatively, this data may be offered to SABIC after 5 years:
a. All necessary material certifications, for example mill test reports
b. The vendor’s purchase specifications for all items on bills of materials
c. All test records to verify that the requirements of the standard were met
d. Records of all heat treatments and radiographs, fully identified, whether performed in the normal
course of manufacture or as a part of a repair procedure
e. Results of all quality control tests and inspections
f. Running test data
g. First assembly maintenance and running clearances
4.2.2 The drawings and documents to be used in connection with the shop inspections and tests shall be
approved by SABIC prior to the commencement of those inspections and tests.
4.2.3 Vendor’s standard acceptance criteria required for the specified inspection and test, for example a
clearance check, for which no acceptance criterion is indicated in this standard, shall be certified by SABIC
prior to the commencement of the inspection.
4.2.4 Leaks and defects in pressure containing castings shall not be repaired by impregnation with plastic
or cement compounds. Repair by welding or by plugging shall be in accordance with section 5 of this
standard.
4.2.5 The scope of shop inspection shall be confirmed with SABIC prior to manufacture. As a minimum it
shall include:
a. A check against approved certified outline drawings for main dimensions, baseplate dimensions,
location of foundation bolt holes, pitch tolerance between adjacent bolt holes, size/position/rating of
flanges and coupling guard arrangements
b. An inspection of flange face finish
c. A verification that vendor has performed the specified inspections and tests with satisfactory
results
d. A verification of the required material certification, for example mill test reports, or certification of
material compliance by vendor for standard stocked items and their traceability to the respective
components
e. Vendor’s purchase specifications for the items shown on all bills of materials
f. A check of casing wall thickness
g. Measurement of the final clearances
h. A visual check for good workmanship and finish of internals
i. Verification of taper fits with matched plug and ring set
j. Verification of conformance of painting to specification. All painting of the surface of parts shall
be deferred until the specified inspection of the parts is complete.
k. Verification of casing marking (serial no.), rotation arrow and nameplate data
l. Inspection of preparation for shipment, shipping documents and tags
4.2.6 Cleanliness of the equipment, piping and furnished components shall be verified before and after
assembly at the vendor or sub-vendor plant. During the assembly of the turbine, and prior to testing, all
components, piping and appurtenances shall be cleaned to remove foreign substances, corrosion
products and mill scale.
4.3 Qualification Tests
All welding of piping and pressure containing parts and any weld repairs shall be performed by operators
and procedures qualified in accordance with ASME Section IX.
4.4 Nondestructive Examination
Nondestructive examination shall be in accordance with the following procedures and acceptance criteria,
unless otherwise noted:
a. Radiographic Examination
(i) Radiographic examination shall be in accordance with ASTM E 94 and E 142.
(ii) The acceptance standard used for welded fabrications shall be ASME Section VIII, Div 1, UW-51
(100 percent) and UW-52 (spot). Spot radiography shall consist of one 152 mm spot radiograph for
each 7.6 m of weld on each casing. As a minimum, one spot radiograph shall be required for each
welding procedure and welder used for pressure containing welds.
(iii) The acceptance standard used for castings shall be ASME Section VIII, Div 1, Appendix 7.
b. Ultrasonic Inspection
(i) When specified, all forgings and bar stock for major rotating elements shall be 100 percent
ultrasonically inspected after rough machining, in accordance with ASTM A 418. SABIC and vendor
shall mutually agree upon acceptance criteria.
(ii) Ultrasonic inspection shall be in accordance with ASME Section V, Article 5.
(iii) The acceptance standard used for welded fabrications shall be ASME Section VIII, Div 1,
Appendix 12.
(iv) The acceptance standard used for castings shall be ASME Section VIII, Div 1, Appendix 7.
c. Magnetic Particle Inspection
(i) Both wet and dry methods of magnetic particle inspection shall be in accordance with
ASTM E 709
(ii) The acceptance standard used for welded fabrications shall be ASME Section VIII, Div 1,
Appendix 6. The acceptability of defects in castings shall be based on a comparison with the
photographs in ASTM E 125. For each type of defect, the degree of severity shall not exceed the limits
specified in ASME Subsection 6.1, Paragraph (4).
d. Liquid Penetrant Inspection
(i) Liquid penetrant inspection shall be in accordance with ASME Section V, Article 6 and
ASTM E 165.
(ii) The acceptance standard used for welded fabrication shall be ASME Section VIII, Div 1,
Appendix 8. The acceptance standard used for castings shall be ASME Section VIII, Div 1,
Appendix 7.
4.5 Spare Rotors
All spare rotors shall receive the tests and inspection specified in sections 6, 7, 8 and 10. Spare rotors
ordered to permit concurrent manufacture, shall also be given the mechanical running test as specified in
section 11.
4.6 Repairs
The following repairs shall need prior SABIC approval, whether at shop or site. If parts/items/components
are repaired without obtaining prior SABIC approval, they will be rejected by SABIC:
a. Major weld repairs
b. Repairs to leaking pressure containing parts
c. Straightening of shafts
d. Rectification of fits/tolerances/clearances by the application of metal coatings or overlays
e. Repairs to rotating parts that result in deviation from the original drawings
f. Repairs necessitated by internal rubs for any reason
g. Repairs/alterations to bearings
h. Repairs/alterations to shaft sealing systems
5. Casing and Other Pressure Containing Parts Inspection
5.1 Casting Inspection
Pressure containing parts of the casting, for example the casing and trip and throttle valve bodies, shall be
in accordance with SES G06-S01 or G06-S02 as applicable and, as a minimum, shall conform to the
requirements of this subsection.
5.1.1 All castings shall be visually inspected in accordance with MSS SP-55 to ensure that they are sound
and free from shrink holes, blow holes, cracks, scale, blisters or other similar injurious defects. In addition
to the visual inspection, all castings shall be subject to the inspection specified in Table
I: Table I Casting Inspection
5.1.2 Ferrous castings shall not be repaired by welding, peening, plugging, burning-in or impregnating,
except as follows:
a. Weldable grades of steel castings may be repaired by welding using a qualified welding
procedure based on ASME Sections VIII and IX
b. Gray cast iron or nodular iron may be repaired by plugging, within the limits specified in
ASTM A 278, A 395 or A 536. The drilled holes for a plug shall be carefully examined by liquid
penetrant examination to ensure the removal of all defective material. All necessary repairs not
covered by ASTM shall be subject to approval by SABIC.
5.1.3 When steam conditions exceed 8.7 MPa or 480 °C, any critical casting area exposed to internal
pressure shall be examined by radiography. Ultrasonic examination may be used in lieu of radiography,
with SABIC’s approval.
5.1.4 When magnetic particle inspection methods are required or otherwise used, all exterior and
accessible interior surfaces shall be tested in accordance with 4.4.c. Acceptability of defects shall be
based on a comparison with the photographs in ASTM E 125. For each type of defect, the degree of
severity shall not exceed the limits specified in Table
II
. Regardless of these generalized limits, it shall be
the vendor’s responsibility to review the design limits of all castings in the event that more stringent
requirements are specified. Defects that exceed the limits imposed in Table
II
shall be cleaned out to meet
the quality standards cited above as determined by additional magnetic particle inspection before repair
welding.
Table
II
Defect Severity Limits
5.1.5 When liquid penetrant examination is required or otherwise used, all exterior and accessible interior
surfaces shall be tested in accordance with 4.4.d.
5.1.6 Major welding repairs and all welding repairs to pressure containing parts shall be subject to the prior
approval of SABIC. Prior to welding, SABIC will check the extent and location of the defective part.
5.1.7 Minor welding repairs may be made at the discretion of the manufacturer without prior SABIC
approval.
5.1.8 Major repair welds in ferritic steel materials shall be given stress relief heat treatment. A magnetic
particle or liquid penetrant examination shall be performed on all repair welds in accordance with 5.1.4 or
5.1.5.
5.2 Weld Inspection
The welding of pressure containing parts shall conform to the following requirements:
a. Pressure containing castings made of wrought materials or combinations of wrought and cast
materials shall have all accessible weld surfaces inspected by a magnetic particle or liquid penetrant
examination after back chipping or gouging, and again after stress relieving or, for austenitic stainless
steel, after solution annealing
b. When the internal pressure exceeds 2 MPa, butt welded joints on pressure containing casings
shall be examined by spot radiography. The acceptable procedure for radiographic examination shall
conform to ASME Section VIII, Div 1, Subsection B, Paragraph UW 51.
5.3 Forged Steel Inspection
Casing and other pressure containing parts of forged steel shall be examined for critical areas by the
magnetic particle method after final machining.
6. Rotor Tests and Inspections
6.1 Forgings used for turbine shafts, discs and rotors with integrally forged discs shall be inspected by
ultrasonic methods.
6.2 If the normal steam inlet temperature exceeds 400 °C, a heat stability check shall be performed on the
rotor. The procedure and acceptance criteria for the heat stability check shall be in accordance with
ASTM A 472.
6.3 A magnetic particle or liquid penetrant examination shall be performed for shaft and discs after final
machining.
6.4 When specified, a blade shaker test shall be performed on special purpose turbines to measure the
actual natural frequency of a group of blades while static. If the blades are free standing without shroud or tie wires, the natural frequency of 25 percent of the actual number of blades shall be measured. The
vendor shall submit a proposal containing details of the test procedure.
7. Rotor Balance Test
7.1 Major parts of the rotating element, for example the shaft and disks, shall be dynamically balanced.The rotating element shall also be multi-plane dynamically balanced during assembly. The procedurebalancing, and the acceptance criteria used, shall comply with SES G06-S01 or G06-S02 as applicabl
7.2 After the final balancing of each assembled rotating element has been completed, a residual
unbalance check shall be performed and recorded in accordance with the residual unbalance worksheetin SES G06-S01 or G06-S02 as applicable.
7.3 High speed balancing (balancing in a high speed balancing machine at operating speed) using a
minimum of three balancing correction planes may be done in lieu of multi-plane balancing, with SABapproval. Details of the high speed balancing procedure and the acceptance criteria to be used shall be
submitted to SABIC for approval prior to the test.
8. Runout Check
8.1 Mechanical runout shall be measured on all shafts prior to installation in the casing, by rolling the
rotors in V-blocks and measuring the tolerances on the peripheral surfaces of the shaft with a dial
indicator, as described in SES G06-S01 or G06-S02.
8.2 For rotors using anti-friction bearings, the mechanical runout at the bearing or seal surfaces shallexceed 0.03 mm. The runout at all other shaft positions shall not exceed 0.06 mm.
8.3 For rotors using hydrodynamic bearings, the mechanical runout shall not exceed the following
tolerances:
8.4 Electrical and mechanical runout shall be determined in accordance with SES G06-S01 or G06-S02.
9. Hydrostatic Test
9.1 Pressure containing parts, including auxiliaries, shall be hydrostatically tested with a liquid in
accordance with SES G06-S01 or G06-S02 as applicable.
9.2 No coatings, primer or finish, shall be applied to any components prior to hydrotest.
9.3 The chloride content of liquids used to hydrotest austenitic stainless steel materials shall not exceed
50 parts per million. To prevent deposition of chlorides as a result of evaporative drying, all residual liquid
shall be removed from tested parts at the conclusion of the test.
10. Clearance Check
10.1 When mounting the rotor in the turbine casing, the following clearances shall be checked, if
applicable:
a. Turbine blade and nozzle clearances
b. Inter-stage shaft and labyrinth clearance
c. Shaft (drum) and packing labyrinth clearance
d. Radial bearing and shaft clearance
e. Thrust bearing and thrust collar clearance
10.2 The clearances measured shall be within the allowable range given in the manufacturer’s design, and
shall be recorded and furnished with the final unit documentation.
11. Mechanical Running Test
11.1 All turbines shall receive a mechanical (no-load) running test in accordance with SES G06-S01 or
G06-S02 as applicable.
11.2 Emergency overspeed trip systems test shall be required for all steam turbines.
11.3 During the mechanical running test of all steam turbines, the following data, as a minimum, shall be
recorded at 15 minute intervals:
Tabl e
III
Run Test Data
11.4 During the mechanical running test of all steam turbines, bearing temperatures shall be within the
following limits:
11.5 The following data shall be recorded for turbines that are specified with proximity type vibration
probes. Contract vibration probes, cables and oscillator-demodulators shall be used for the test, except as
specifically approved by SABIC:
a. The unfiltered and synchronous (filtered once per revolution) vibration amplitudes and phase
angle versus speed shall be recorded at speeds from zero to maximum continuous speed in
10 percent increments
b. Photographs or digital electronic copies of the vibration trace and shaft orbit of each bearing
shall be taken at the maximum continuous speed, minimum governor control speed, and the speeds
of plus and minus 10 percent of the estimated first lateral critical speed. Circular, elliptical, single dot,
‘banana’, or figure eight orbit shapes shall be acceptable as long as the maximum diameter or length
of the orbit is within the specified maximum vibration amplitude. An orbit consisting of a circular shape
with an internal loop or a straight line shall not be acceptable. Orbits with other irregular shapes shall
require review and specific approval by SABIC. All orbits shall be single phase and continuous.
c. Plots showing vibration amplitude and phase angle versus speed for acceleration and
deceleration shall be made before and after the 4 hour run. Plots shall be made of both the filtered
and unfiltered vibration levels. The speed range covered by these plots shall be zero to the specified
driver trip speed.
11.6 The partial stroke manual test device on combined trip and throttle valves shall be checked during
the mechanical run test.
11.7 The trip valve or combined trip and throttle valve shall be tested for seat steam leakage.
11.8 The contract speed control governor system shall be used for shop testing in accordance with
SES G06-S01 and G06-S02. Successful operation of the governor and speed control system within the
range of accuracy specified shall be demonstrated over the complete speed control range for all turbines.
12. Optional Tests
12.1 Optional tests as described in SES G06-S01 or G06-S02 shall be performed as specified on the data
sheets. See ASME PTC 6 if performance test is specified.
Note: Specification of optional tests, for example performance tests or complete unit tests, is usually
limited to very critical or unusual services.
12.2 If specified on the data sheets, turbines with hydraulically mounted shaft couplings shall be
inspected by comparing the hub/shaft match marks to ensure that the coupling hub has not moved during
the mechanical running or other tests.
13. Appearance and Dimensional Check
13.1 An appearance and dimensional inspection shall be performed after fully assembling the machine,
auxiliary piping and instruments, in accordance with the applicable specifications and drawings.
13.2 The location of all connections to other console units, and the size, type and rating of all connections
shall be checked in accordance with the outline drawings, other related drawings and the connection lists.
The location of the connections shall conform to the drawings in dimension within a tolerance of ± 3 mm.
13.3 Auxiliary piping, conduit and tubing shall be checked for adequate support and resistance to
vibration.
13.4 The foundation bolt holes shall be checked in accordance with the outline drawings. The allowable
tolerance of the distance between foundation bolt holes shall be ± 3 mm.
13.5 The coupling size, type and coupling end of the turbine shaft shall be checked. The match mark for
hydraulic fit couplings shall be checked.
13.6 The nameplate shall be checked for correct data.
13.7 The direction of rotation arrow shall be checked for correctness.
14. Inspection and Test Report
14.1 Inspection and test reports shall be submitted in accordance with Appendix A or B of this standard,
unless otherwise specified in the requisition and project specification.
14.2 All heat stability check reports, when specified, shall include the heating temperature record and the
runout of the rotor before, during and after heating the rotor.
14.3 Dynamic balancing reports shall, include:
a. The residual unbalance of each rotating element
b. The residual unbalance of the completed rotor assembly
c. Records of each step of multi-plane balancing
d. Calibration report of the rotor balancing machine
14.4 The mechanical running test record shall include the following data:
a. For all steam turbines:
(i) Test log sheet showing all data required by 11.3, and bearing metal temperatures if such
instrumentation is specified
(ii) Unfiltered vibration versus speed
(iii) Actual first critical speed observed during the test, if applicable
(iv) Actual trip speed checked during the test
(v) Speed governor response to control signal
b. For special purpose steam turbines built to SES G06-S02, or multi-stage general purpose
turbines with proximity vibration probes built to SES G06-S01:
(i) Synchronous vibration analysis, phase angle versus speed
(ii) Frequency analysis
(iii) Photographs or digital electronic copies of vibration wave and shaft orbit
(iv) Combined mechanical and electrical runout
(v) Plots required by 11.5
14.5 All the mechanical runout check, clearance check and dimension inspection records shall include
both the actual measured value and the allowable limit.
15. Appendices
15.1 The shop inspection and test requirements checklists in Appendices A and B shall be:
a. Appendix A for SES G06-S01 General Purpose Steam Turbines
b. Appendix B for SES G06-S02 Special Purpose Steam Turbines
15.2 Items marked ‘X’ in the ‘Inspection required’ column mean that the activity is required.
15.3 Items marked ‘X’ in the ‘Inspection record/report/document required’ column mean that in addition to
the inspection activity being carried out, a record/report/document giving the values measured and their
relationship to the range of normal accepted values shall be provided.
15.4 Items marked ‘X’ in the ‘Observed inspection’ column mean that SABIC shall be notified in advance of
the timing of the inspection or test, but the inspection or test shall be performed as scheduled with or
without the presence of SABIC or its representative.
15.5 Items marked ‘X’ in the ‘Witness inspection required’ column mean that a hold shall be applied to the
production schedule and the inspection or test shall only be carried out with SABIC or its representative in
attendance.
Shop Inspection and Test Requirement Checklist for
General Purpose Steam Turbines
Shop Inspection and Test Requirement Checklist for
Special Purpose Steam Turbines
