CCAMTG-2500 A04 — QA, Inspection & NDE

Volume 14 defines the complete quality-assurance, inspection and non-destructive examination architecture for the CCAMTG-2500 A04. It controls quality gates from incoming material and purchased-equipment receipt through fabrication, machining, welding, heat treatment, NDE, dimensional inspection, assembly release, pressure and electrical testing, preservation, Factory Acceptance Testing, Site Acceptance Testing and final as-built quality-record closeout.

Main Public Quality Baseline

Machine Class: 2.5 MW-Class Dual-Mode Compressed-Air Energy Storage / Recovery Magnetic Motor-Generator Machine
Net AC Generation Target: 2.50 MW
Nominal Rotor Speed: 12,000 rpm
Master Air Mass Flow: 12.2 kg/s
Compression Architecture: Three-Stage, 1.20 bara → ~31 bara
Expansion Architecture: Three-Stage Reheated, ~31 bara → 1.20 bara
DC Bus: 1,500 VDC

A04 Quality Basis: Quality verification is performed against the approved released requirements for each subsystem. Preliminary, analysis-dependent, supplier-dependent, code-dependent and site-dependent values are not automatically treated as fabrication-release acceptance values.

Quality Assurance Overview

Inspection and Test Plan control
Material traceability
Incoming inspection
Manufacturing inspection
Welding and special-process quality control
Non-destructive examination
Dimensional metrology
Rotating-equipment quality gates
Pressure-boundary quality gates
Electrical, controls and instrumentation quality
Calibration management
FAT and SAT quality readiness

Inspection & Test Plan

Approved design-input verification
Supplier qualification and quality-flow-down review
Incoming material and purchased-item inspection
Material identification and traceability transfer
Welding and special-process readiness
In-process fabrication and machining inspection
Heat-treatment and coating verification
NDE before irreversible manufacturing operations
Final component dimensional inspection
Rotor balance and rotating-equipment release
Pressure-boundary completion review
Electrical and functional testing
Subsystem assembly release
Integrated machine pre-FAT review
Factory and site acceptance release

Hold, Witness & Review Points

Hold points prevent work from proceeding without documented release
Witness points provide controlled inspection attendance opportunities
Review points verify controlled records and supporting evidence
Contract, code and jurisdiction requirements can add stricter quality points
Inspection status remains clearly identified throughout manufacture and assembly

Material Traceability

Unique A04 part identification
Controlling drawing and revision
Material specification and condition
Manufacturer, mill and supplier identity
Heat, melt, batch or lot traceability
Serial-number control where applicable
Material and supplier certification
Receiving inspection records
Manufacturing process history
Inspection and NDE report linkage
Installed-position traceability
Final acceptance or NCR disposition

Incoming Inspection

Purchase-order and specification verification
Part and serial-number verification
Material certificate review
Visual condition inspection
Dimensional and rating checks
Positive material identification where required
Supplier-documentation verification
Receipt acceptance before release to manufacture

Non-Destructive Examination

Visual testing
Liquid penetrant testing
Magnetic particle testing where material permits
Ultrasonic testing
Radiographic testing where required
Volumetric inspection of critical forgings and pressure welds
Surface inspection of critical rotating components
Repair-area re-examination

NDE Execution Control

Approved examination procedures
Qualified and certified NDE personnel
Calibrated examination equipment
Controlled reference standards and blocks
Defined examination coverage
Controlled sensitivity and recording thresholds
Traceable indication disposition
Final reports linked to the inspected part, weld or joint

Pressure-Boundary NDE

Pressure-vessel weld examination
High-pressure nozzle and attachment inspection
High-pressure process weld examination
Pressure-casing inspection
Code- and design-controlled examination extent
Required NDE completed before pressure testing
Pressure-boundary inspection results retained in the final quality dossier

Structural Weld Inspection

Primary structural skid weld inspection
Visual examination of fabricated joints
Surface NDE where required
Volumetric examination of designated critical welds
Structural distortion monitoring
Mounting-interface geometry verification
Inspection extent coordinated with the released structural design

Rotating-Component NDE

Rotor-shaft forging inspection
Compressor impeller inspection
Turbine wheel and blade inspection
Surface and volumetric examination where applicable
Inspection before and after critical manufacturing operations
Final inspection before rotor assembly
Repair controls tied to engineering disposition

Welding Quality Control

Approved welding procedures
Supporting procedure qualification records
Qualified welders and welding operators
Controlled welding consumables
Joint preparation and fit-up inspection
Preheat and interpass monitoring where applicable
Post-weld heat-treatment records where required
Stainless-steel contamination control
Controlled repair welding

Dimensional Inspection & Metrology

Coordinate measuring machine inspection
Laser-tracker dimensional inspection
Precision runout measurement
Concentricity verification
Flatness and coplanarity verification
Rotor and coupling interface inspection
Skid and machinery-datum verification
Final general-arrangement dimensional inspection

Measurement Equipment Control

Unique equipment identification
Current calibration status
Traceability to recognized standards
Measurement capability matched to the inspected characteristic
Environmental suitability for acceptance measurements
Measurement uncertainty considered near acceptance limits
Out-of-tolerance calibration findings receive documented impact review

Rotating-Equipment Quality Release

Compressor aerodynamic and structural release verification
Turbine aerodynamic and overspeed release verification
Material-certification review
Rotor and wheel NDE
Dimensional-profile inspection
Runout verification
Dynamic-balance verification
Coupling-interface inspection
Common rotor alignment verification

Active Magnetic Bearing & Touchdown Quality

AMB and TDB dimensional inspection
Rotor-position sensor verification
Electrical checks
Coil and insulation verification
Rotor levitation verification
Static and transient support verification
Touchdown fault-capability evidence
Integration with approved magnetic-bearing engineering

PMSM/PMG Quality Verification

Electromagnetic design-release verification
Rotor-retention evidence
Stator and rotor dimensional inspection
Winding resistance verification
Insulation testing
Sensor verification
Supplier test evidence
Balance and overspeed evidence where required

Pressure-Boundary Quality Gates

Approved pressure-design input
Pressure-boundary material traceability
Qualified fabrication procedures
Weld-map control
Required NDE acceptance
Dimensional inspection
Relief-device certification and installation verification
Controlled pressure and leak testing
Complete pressure-equipment quality dossier

Fastener, Joint & Seal Quality

Critical joint identification
Joint-specific preload verification
Controlled tightening method
Fastener material and lot traceability
Gasket and seal verification
Pressure-flange inspection
Bearing and AMB housing joint inspection
PMG structural-joint verification
Rotating-fastener independent inspection where designated

Electrical Quality Control

Electrical component-rating verification
Polarity and connection inspection
Insulation-system verification
Precharge and isolation testing
Contactor and interlock verification
Earthing and bonding continuity
Converter and PMSM/PMG supplier FAT review
Electrical protection coordination with approved design documents

Instrumentation Quality Control

Instrument tag verification
Measurement-range verification
Unit and process-connection verification
Calibration
Orientation and installation inspection
Impulse and tubing integrity checks
Loop checks to PLC, SIS and HMI
Trip-input simulation where safe and approved

PLC, SIS & HMI Quality

Software version and configuration control
Configuration checksum verification
I/O point-to-point verification
Permissive and interlock testing
Alarm and trip cause-and-effect verification
Network segregation verification
Backup and restore verification
Controlled software records retained in the quality dossier

BESS & PCS Quality

Supplier-certified BMS and PCS testing
DC-system compatibility verification
State-of-charge logic verification
Thermal and fire-interface checks
Isolation verification
Emergency-response interface testing
Supplier quality records incorporated into the machine dossier

Subsystem Quality Release

General arrangement dimensional release
Intake material and actuator verification
Compressor material, profile, NDE, runout and balance release
HP buffer pressure-equipment quality release
Turbine material, profile, NDE, runout and balance release
AMB/TDB dimensional, electrical and functional release
Thermal and cooling equipment quality release
Skid material, weld, dimensional and lifting verification
Electrical FAT and protection release
Joint and seal installation verification
Manufacturing-record completion
System-integration configuration verification

Nonconformance Control

Nonconforming items positively identified
Physical or electronic quarantine
Technical review of the nonconformance
Rework, repair, concession or scrap disposition
Design-authority review for safety-critical conditions
Controlled repair instructions
Repeat affected inspection and NDE
Final documented closure

Corrective & Preventive Action

Recurring quality issues receive root-cause investigation
Corrective actions are documented and controlled
Preventive measures applied where appropriate
Effectiveness review confirms corrective-action performance
Configuration impact is assessed where the design baseline is affected

Cleanliness & Foreign-Material Exclusion

Process-air internals protected from foreign material
Compressor and turbine internals protected during manufacture and assembly
HP vessel and heat-exchanger interiors protected from contamination
Openings capped or covered when unattended
Controlled foreign-material inventories used where loose-item risk exists
Final cleanliness acceptance documented before closure

Preservation Quality

Controlled corrosion protection
Moisture and environmental protection
Controlled packaging
Storage-condition monitoring
Shaft-restraint or rotation requirements where applicable
Preservation inspection before shipment
Preservation status transferred into site receipt and installation records

Factory Acceptance Quality Readiness

Calibration status confirmed
Mandatory safety guards installed
Critical inspection hold points closed
Subsystem quality-release records complete
Rotor and magnetic-bearing release evidence complete
Pressure-protection evidence complete
Electrical and controls verification complete
Approved FAT configuration established

Manufacturing Data Record & Quality Dossier

Released design and configuration records
Procurement and supplier records
Material certifications
Manufacturing process records
Welding qualifications and weld maps
NDE procedures and reports
Dimensional inspection records
Mechanical assembly records
Pressure-test records
Electrical and control records
Rotating-equipment quality records
FAT and SAT test records
NCR and corrective-action records
Preservation and shipping records

V14 Quality Documentation

Quality Plan / Inspection & Test Plan
NDE Matrix
Material Traceability Register
Incoming Inspection Report
Weld and Joint Inspection Record
Dimensional Inspection / FAI Record
NCR / Concession / Repair Record
Calibration and Test Equipment Register
Subsystem Quality Release Certificate
Manufacturing Data Record / Quality Dossier Index

Quality Release Philosophy

Every manufactured part is traceable to its controlling requirement
Every purchased critical item has defined supplier-quality acceptance
Every critical weld and joint has controlled qualification and inspection
Every safety-critical characteristic has objective verification evidence
Every critical instrument is tagged, calibrated and reconciled with controls documentation
No unresolved safety-critical NCR remains open at release
No expired acceptance calibration is permitted at release
No mandatory traceability record may be missing at final machine release