APPENDIX No. 5
TESTS AND PERFORMANCE PARAMETERS
测试和性能参数
APPENDIX No. 5
TESTS AND PERFORMANCE PARAMETERS
测试和性能参数
General Procedure of the Tests /
测试的一般程序/
No later than 1 month before the start of Hot Equipment Testing, the parties must agree on a program of Hot Equipment Testing. For this purpose, the Seller submits the draft of the Hot Test program no later than 2 months before the start of Hot Testing of the Equipment | |
Before starting the tests agreement should be reached regarding the format, structure and actual personnel of Buyer’s operation/maintenance crews to be used as well as the commencement date for the tests. | |
The tests include: Cold Tests (without load): Cold Tests of the section of induction furnaces for initial and final heating, components and assemblies on vertical and horizontal, hydraulic press, Cold tests of the output side. Hot Tests (under load): Hot Tests of the section of induction furnaces of the initial and heating cycle, components and assemblies on vertical and horizontal, hydraulic press, Hot tests of the output side. Performance Tests – confirmation of the operability of the Equipment supplied by the Seller and its achievement of Performance Parameters | |
After successful completion of the installation, the Parties sign the relevant certificates: Certificate on completion of installation of induction furnaces of the initial and heating cycles, assemblies and aggregate units of a hydraulic press with vertical expansion and a horizontal tube and Certificate on completion of installation of the refrigeration section. | |
Upon successful completion of the Cold Tests, the Parties sign the relevant Cold Tests Completion Certificate. | |
Upon successful completion of the Hot Tests, the Parties sign the relevant Hot Tests Completion Certificate. | |
Upon successful completion of the Performance Tests, the Parties sign the relevant Performance Tests Completion Certificate. | |
All important events at the Construction Site shall be registered in the Log Book of Works and Services. | |
If at the beginning of the tests it comes out that part of the erection work has not been completed, but this does not affect the plant functionality for beginning the tests, then the tests shall be carried out just by common consent. The above Log Book of Works and Services shall in this case specify who is supposed to complete any additional work and the relevant time for completion. | |
During the tests, the Buyer provides the Seller with everything necessary to carry out the tests (including repeated ones) in the quantities and quality assurance determined by the Seller, as well as appropriate materials and personnel. | |
The Seller shall attend the tests by means of its technicians, who shall supervise and instruct the Buyer’s personnel. | |
The tests are carried out during day shifts (one day shift per day), on any day of the six-day week, excluding Sundays and holidays. | |
During the tests, the Seller and the Buyer must keep detailed records of performance characteristics, failures, adjustments and approvals related to specific units of the press line equipment, as well as record operational data, parameters and test results. | |
Any remarks about the tests shall be reported in the Log Book of Works and Services. | |
The seller may also request an interruption of the pressing process, which may be necessary to adjust/optimize the settings for Hot and Performance Tests. | |
Equipment supplied by the Buyer must be operable in time, quality and function as required prior the starting of the test period. The Buyer shall fulfil all his preconditions for performing the tests as stated in this Appendix. | |
In case of a delay due to Buyer’s fault the duration of such delay shall be added to the total duration of the tests. |
Cold Tests (no-load test) /
After the completion of Equipment Installation (or during the Installation itself), the Seller shall carry out the Cold Tests. Such tests shall be performed following a schedule and procedure agreed 2 weeks prior to the commencement date of the relevant Cold Tests. | |
The test will be conducted under no-load and shall be aimed at checking the: Equipment functionality. Systems functionality (hydraulic, electrical, services, etc). Simulation of the automation sequences. | |
If at the beginning of the tests it comes out that part of the erection work has not been completed, but this does not affect the plant functionality for beginning the tests, then the tests shall be carried out just by common consent. The above Log Book of Works and Services shall in this case specify who is supposed to complete any additional work and the relevant time for completion. | |
Comments are indicated in the Punch List with an indication of the time frame for their elimination. |
Conditions for the Beginning of Cold Tests /
冷试验开始条件/
The condition for the start of Cold tests of the induction furnaces section of initial and final heating, components and assemblies on vertical expansion and horizontal pipe hydraulic press is a signed Act of completion of installation by the Parties, in accordance with the conditions of completion of installation (as written below) and the availability of operating instructions for the Equipment supplied by the Seller. Conditions for the equipment installation completion and the beginning of Cold Tests: All the equipment is assembled completely and fixed fully on foundations; The equipment is equipped with all necessary utilities (gas, water, lubrication, air), piping (e.g. for hydraulic systems, coolant-cutting fluids, grease, air, etc.) and is connected with appropriate operating media (including interconnecting piping systems); Systems for hydraulics, grease, coolant-cutting fluids, etc. are tested and filled with appropriate operating media; Complete electrical equipment including measuring devices and automation control equipment (electric wire) is installed and connected; All the safety devices, including fences, fixed and movable guards, safety sensors, interlocking devices, light alarms, emergency stop devices and all the other devices related to safety, have to be properly installed by Buyer in accordance with the information provided by the Seller and successfully tested, verified and accepted by the Seller. The Seller has programmed PLC and checked the operability of automated process control system (Levels 0 and 1). The operation of the automated process control system shall comply with technical specifications of the Contract; It is allowed to carry out Cold Tests of individual technological areas upon mutual agreement of the Parties without waiting for the installation completion of the whole Equipment. If the installation works are not performed completely at an individual technological area, but these uncompleted works will not influence the operability of a technological area and will not be an obstacle for the beginning of carrying out of Cold Tests for this technological area, the tests shall be carried out upon the mutual agreement of the Parties. In this case, it will be mentioned in the Log Book of Works and Services, which of the Parties is responsible to perform additional works in order to finish uncompleted works with indication of the terms of their completion. |
Conditions for the Successful Completion of Cold Tests /
成功完成冷试的条件 /
Cold Tests shall be considered to be successfully completed if the following conditions are fulfilled: Normal operation of mechanical, electrical, hydraulic equipment, automation systems in terms of data exchange between PLC (Level1 and HMI), to the extend which will enable to carry out Hot Tests; Continuous supply of all operating media is provided; Interaction of the Equipment as a whole system. Cold Tests Results: Checking the correctness of installation work after installation of the equipment of the press line, connection and supply of energy carriers. Checking the operability of the equipment components of the press line by scrolling in idle mode. The operability of security devices and locking mechanisms in the workflow. Based on the results of scrolling the equipment in idle mode, a decision is made on the readiness of the equipment for conducting Hot Tests. |
Hot Tests (on-load) /
热测试(负载)/
Conditions for the Beginning of Hot Tests /
热测试开始条件/
Conditions for the start of Hot Tests are: | |
Starting material (billets) in sufficient quantities, having the characteristics specified in this Appendix to the Contract. | |
All required utilities and auxiliary materials in sufficient quantities and qualities. | |
Properly trained personnel according to Seller’s instructions | |
It is allowed to carry out hot Tests of individual technological areas without waiting for installation and Cold Tests completion of the whole Equipment. | |
The Hot Tests shall verify: The capacity of the equipment to smoothly operate in "on-load" condition. The functionality of the Electro-mechanical systems under "on-load" condition. The conformity of the equipment with the functions stated in the Contract. The conformity of the operative sequences of the equipment to the technological process. | |
Conditions for the Successful Completion of Hot Tests /
成功完成热试的条件 /
The Hot Tests are considered to have been successfully completed during production in accordance with Table 1 below. |
Table 1. Products to be Produced during Hot Tests /
表 1. 热测试期间要生产的产品/
No. | Pipe Dimensions | Billet Diameter | Material | Geometric Parameters | Pressing Parameters Параметры прессования | No. of Pipes | ||
S min / | S max / | V pressing / | T pressing / | |||||
1 | Ø 89х8mm | 180 mm | 304\316 | 7.2 mm | 8.8 mm | 200-300mm\c | 1160-1180C | 100 |
2 | Ø 89х9mm | 180 mm | 304\316 | 8.1 mm | 9.9 mm | 200-300mm\c | 1160-1180C | 100 |
3 | Ø114,3 х 8,56mm | 220 mm | 304\316 | 7.7 mm | 9.4 mm | 200-300mm\c | 1160-1180C | 100 |
4 | Ø 114,3 х 11mm | 220 mm | 304\316 | 9,9 mm | 12,1 mm | 200-300mm\c | 1160-1180C | 100 |
5 | Ø 114,3 х 13mm | 220 mm | 304\321 | 11,7mm | 14,3 mm | 200-300mm\c | 1160-1180C | 100 |
6 | Ø 219х10mm | 325 mm | 304\316 | 9,0 mm | 10,0 mm | 200-300mm\c | 1160-1180C | 50 |
7 | Ø 273х10mm | 350mm | 304\321 | 9,0 mm | 10,0 mm | 200-300mm\c | 1160-1180C | 50 |
The pressing speed will be adjusted within the range in Table 1 depending on the thickness of the pipe wall/
压制速度根据管壁厚度在表1范围内调整/
The test sizes and grades may be changed by agreement between Buyer and Seller. In case of a delay in the course of Hot Tests due to Buyer’s fault the duration of such delay shall be added to the total duration of Hot Tests. | |
If some Performance Parameters are achieved during Hot Tests, such confirmed Performance Parameters shall be considered achieved and shall be excluded from Performance Tests program. | |
During Hot Tests Parties shall keep detailed records of performance, defaults, corrections and relevant conditions in the Log Book of Works and Services. | |
Upon completion of Hot Tests Seller shall transfer to the Buyer the right to operate the Equipment on its own. Hot Tests Results: Checking the operability of the equipment of the press line in Hot Tests conditions. Checking the correct operation of metal heating modes in induction furnaces. Compliance with the temperature parameters of the workpiece heating. Efficiency of transport mechanization of billets and pipes. Checking the correct operation of components and assemblies on the expansion and pipe press. Compliance of pressure measuring devices and pressing speed modes in accordance with Table 1. Checking the compliance of the geometric parameters of the pipe after pressing, as indicated in Table 1. The operability of security devices and locking mechanisms in the workflow. |
TRANSITION PHASE /
过渡阶段/
After the Hot Tests, the optimization of the Equipment operation process ("Transition Phase") will be performed. | |
The aim of the Transition Phase is to progressively ramp up Equipment so as to achieve the target Performance Parameters as soon as practical. During the Transition Period, the performance of the Equipment will be closely monitored. The Seller notifies the Buyer that the Equipment is ready for Performance Tests. Buyer will provide necessary raw material and manpower to guarantee the continuous production in the Transition Phase. |
Performance Tests /
性能测试 /
Parties shall record tests results in a protocol. Performance Tests are considered successfully completed when the contractually agreed Performance Parameters have been reached. Measurement of Performance Parameters’ values will be made by means of measuring devices provided by Buyer. | |
During the tests, the Buyer's operators shall work under the supervision of the Seller's supervisors that have the right to take the place of the operators to operate the Equipment. | |
One month before the Performance Tests the Seller shall provide to the Buyer Performance Tests Program, and Parties shall agree upon such program two weeks prior to the commencement of Performance Tests. This program shall include, but not be limited to production technology, procedure of Buyer’s personnel activities, parameters to be controlled and organization chart of the personnel of the Parties for the Performance Tests. Performance Tests shall include 3 attempts for each pipe performance parameter. In the course of a single attempt the Prime Yield and the Productivity for a Single Pipe Size performance parameters shall be verified. A single attempt shall cover one day work shift of 10 hours. The number of joints produced in a single performance test trial should be at least equal to the number of joints specified in the Number of Joints column of Table 2 below for each pipe size. | |
After each test attempt Parties shall draw up and sign the relevant tests certificate with the indication of all actual Performance Parameters values. |
No. | Pipe Dimensions | Diameter of the workpiece | Material | No. of Pipes |
1 | Ø 42 х 4 mm | 140 mm | 304\316 | 300 |
2 | Ø 57 х 4 mm | 180 mm | 304\316 | 300 |
3 | Ø 57 х 6 mm | 180mm | 304\321 | 300 |
4 | Ø 60,3х3,91 mm | 180mm | 304\316 | 300 |
5 | Ø 89х5 mm | 180mm | 304\321 | 300 |
6 | Ø 88,9х5,49 mm | 180mm | 304\316 | 300 |
7 | Ø 101,6х5,74 mm | 220 mm | 304\321 | 250 |
8 | Ø 114,3х6,02 mm | 220 mm | 304\316 | 250 |
9 | Ø 133х16 mm | 270mm | 304\321 | 200 |
10 | Ø 168,3х7,1 mm | 270mm | 304\316 | 200 |
11 | Ø 219,1х6,71 mm | 325 mm | 304\321 | 150 |
12 | Ø 245х9 mm | 325 mm | 304\316 | 150 |
13 | Ø 273х14 mm | 350 mm | 304\321 | 150 |
14 | Ø 273х16 mm | 350 mm | 304\316 | 150 |
Table 2 Pipes to be Produced during Performance Tests /
表 2 性能测试期间要生产的管道 /
Performance Parameter – Yield /
性能参数-产量/
Table 3/ Таблица 3
Yield of 95% with Wall and Pipe Diameter Tolerances of ± 10% of the Nominal.
成品率为 95%,壁和管道直径公差为标称值的 ± 10%。
Выход годной продукции 95% от общего объёма с допусками по стенке и диаметру трубы ±10% от номинальной.
合适产品的产量为总体积的 95%,管壁和直径公差为标称值的 ±10%。
/ Billet Parameters | / Pipe Parameters | Responsibility as Applicable to All Billet and Pipes Parameters | |||||
/ Wall Thickness | / Pipe Diameter | ||||||
/ Nominal OD[mm] | / Nominal [mm] | / Minimum [mm] | / Maximum [mm] | / Minimum [mm] | / Maximum [mm] | Yield Value (Y) | Penalty, % of the Contract Price |
57 | 4 | 3,6 | 4,4 | 56,4 | 57,6 | 100%≥Y≥95% | __% |
57 | 6 | 5,4 | 6,6 | 56,4 | 57,6 | ||
60,3 | 3,91 | 3,52 | 4,3 | 59,6 | 60,9 | ||
88,9 | 5,49 | 4,9 | 6,039 | 88,0 | 89,7 | ||
89 | 5 | 4,5 | 5,5 | 88,1 | 89,9 | 95%≥Y≥91% | __% |
42 | 4 | 3,6 | 4,4 | 41,8 | 42,21 | ||
101,6 | 5,74 | 5,16 | 6,31 | 100,5 | 102,6 | ||
114,3 | 6,02 | 5,4 | 6,62 | 113,1 | 115,4 | ||
133 | 16 | 14,4 | 17,6 | 131,6 | 134,3 | ||
168,3 | 7,1 | 6,39 | 7,81 | 166,6 | 169,9 | ||
219,1 | 6,71 | 6,039 | 7,38 | 216,9 | 221,2 | 91%>Y | Contract Termination / |
245,0 | 9,00 | 8,1 | 9,9 | 242,5 | 247,4 | ||
273 | 14 | 12,6 | 15,4 | 270,27 | 275,73 | ||
273 | 16 | 14,4 | 17,6 | 270,27 | 275,73 |
Table 4/
表4/
Yield of 3% with Wall and Pipe Diameter Tolerances of ±12.5% of the Nominal
产量为 3%,壁径和管道直径公差为标称值的 ±12.5%
/ Billet Parameters | Параметры трубы / Pipe Parameters | Responsibility as Applicable to All Billet and Pipes Parameters | |||||
/ Wall Thickness | / Pipe Diameter | ||||||
/ Nominal OD[mm] | / Nominal [mm] | / Minimum [mm] | / Maximum [mm] | / Minimum [mm] | / Maximum [mm] | Yield Value (Y) | Penalty, % of the Contract Price |
57 | 4 | 3,5 | 4,5 | 56,4 | 57,6 | 3%≥Y≥0% | __% |
57 | 6 | 5,25 | 6,75 | 56,4 | 57,6 | ||
60,3 | 3,91 | 3,42 | 4,4 | 59,6 | 60,9 | ||
88,9 | 5,49 | 4,8 | 6,17 | 88,0 | 89,7 | ||
89 | 5 | 4,3 | 5,62 | 88,1 | 89,9 | 5≥Y≥3% | __% |
42 | 4 | 3,5 | 4,5 | 41,8 | 42,21 | ||
101,6 | 5,74 | 5,022 | 6,45 | 100,5 | 102,6 | ||
114,3 | 6,02 | 5,2 | 6,77 | 113,1 | 115,4 | ||
133 | 16 | 14 | 18 | 131,6 | 134,3 | ||
168,3 | 7,1 | 5,59 | 7,9 | 166,6 | 169,9 | ||
219,1 | 6,71 | 5,87 | 7,54 | 216,9 | 221,2 | Y>5% | Contract Termination / |
245,0 | 9,00 | 7,87 | 10,12 | 242,5 | 247,4 | ||
273 | 14 | 12,25 | 15,75 | 270,27 | 275,73 | ||
57 | 4 | 3,5 | 4,5 | 56,4 | 57,6 |
Table 5/
表5/
Yield of 2% with Wall and Pipe Diameter Tolerances of ±15% of the Nominal
壁厚和管道直径公差为标称值的 ±15%,产量为 2%
/ Billet Parameters | / Pipe Parameters | Responsibility as Applicable to All Billet and Pipes Parameters | |||||
Толщина стенки / Wall Thickness | / Pipe Diameter | ||||||
/ Nominal OD[mm] | / Nominal [mm] | / Minimum [mm] | / Maximum [mm] | / Minimum [mm] | / Maximum [mm] | Yield Value (Y) | Penalty, % of the Contract Price |
57 | 4 | 3,4 | 4,6 | 56,4 | 57,6 | 3%≥Y≥0% | __% |
57 | 6 | 5,1 | 6,9 | 56,4 | 57,6 | ||
60,3 | 3,91 | 3,3 | 4,5 | 59,6 | 60,9 | ||
88,9 | 5,49 | 4,6 | 6,3 | 88,0 | 89,7 | ||
89 | 5 | 4,25 | 5,75 | 88,1 | 89,9 | ||
42 | 4 | 3,4 | 4,6 | 41,8 | 42,21 | ||
101,6 | 5,74 | 4,87 | 6,6 | 100,5 | 102,6 | ||
114,3 | 6,02 | 5,11 | 6,9 | 113,1 | 115,4 | Y>3% | Contract Termination / |
133 | 16 | 13,6 | 18,4 | 131,6 | 134,3 | ||
168,3 | 7,1 | 6,03 | 8,16 | 166,6 | 169,9 | ||
219,1 | 6,71 | 5,87 | 7,54 | 216,9 | 221,2 | ||
245,0 | 9,00 | 7,68 | 10,35 | 242,5 | 247,4 | ||
273 | 14 | 11,9 | 16,1 | 270,27 | 275,73 | ||
273 | 16 | 13,6 | 18,4 | 270,27 | 275,73 |
The procedure for measuring the geometry of the pipe to confirm the Warranty indicator "Yield" | |
Samples for dimensional measurements shall be retrieved every 20 to 25 joints starting with joint 3 or 4. Samples shall be obtain from the head and the tail ends of a joint. Sample length shall be 200 to 250 mm. The specimens shall be used for dimensional measurements Wall thickness and pipe diameter. The wall thickness of the pipe will be measured on the front and back of each cut piece of pipe. The minimum and maximum values of each end will be recorded. The diameter is measured on each cut piece of pipe. The minimum and maximum values of each end will be recorded. During tests, the pipe surfaces are also checked. The check is performed visually. Pipes shall be free of cracks, striations, bullies, gouges, tears, blisters, etc. The Prime Yield parameter shall be demonstrated alongside the Productivity parameter for each pipe size. |
Performance Parameter – Production Rate /
性能参数-生产率/
Table 6/
表6/
Billet Length [mm] / | Billet Size [mm] / | / Pipe Parameters | Performance Parameter Value / | Penalty, % of the Contract Price | |||
/ Nominal OD [mm] | / Wall Thickness | Extruded Tube length/ | Production Rate (p), pipes per hour | Production Rate Value (P), pipes per hour | |||
760 | 180 | 57 | 4 | 20,0 | 55 | P ≥ 55 55 ≥ p ≤50 50 ≥ p ≤40 40 > p | __% |
850 | 180 | 57 | 6 | 20,0 | 55 | __% | |
950 | 180 | 60,3 | 3,91 | 20,0 | 55 | __% | |
930 | 180 | 88,9 | 5,49 | 15,0 | 55 | Contract Termination / | |
940 | 180 | 89 | 5 | 12,0 | 55 | ||
350 | 140 | 42 | 4 | 12,0 | 50 | P ≥ 50 50 ≥ p ≤45 45 ≥ p ≤40 40 > p | __% __% ___% Contract Termination / |
600 | 220 | 101,6 | 5,74 | 12,0 | 50 | ||
760 | 220 | 114,3 | 6,02 | 14,0 | 50 | ||
900 | 270 | 133 | 16 | 10,0 | 40 | P ≥ 40 40≥ p ≤35 35 ≥ p ≤30 30 > p | __% __% __% Contract Termination / |
900 | 270 | 168,3 | 7,1 | 14,0 | 40 | ||
670 | 325 | 219,1 | 6,71 | 12,0 | 33 | P ≥33 33≥ p ≤28 28 ≥ p ≤23 23 > p | __% __% __% Contract Termination / |
980 | 325 | 245,0 | 9,00 | 12,0 | 33 | ||
1100 | 350 | 273 | 14 | 8,0 | 28 | P ≥28 28≥ p ≤23 23 ≥ p ≤18 18 > p | __% __% __% Contract Termination / |
1100 | 350 | 273 | 16 | 6,0 | 28 |
Production Rate verification tests shall be carried out in accordance with the following conditions: Each Performance Tests attempt shall be performed during one day shift lasting ten (10) hours per day shift The Prime Yield and the Productivity performance parameters shall be demonstrated and verified concurrently in any hour of continuous Equipment operation while manufacturing pipe for a single Performance test run. During Performance Tests, the Buyer's personnel maintains the line settings and carries out operations according to the Seller's instructions and under the supervision of the Seller's staff. | |