Reciprocating Compressors Inspection Checklist

IPE Engineering Practice IPE-EP-6-2-1C

Document number: IPE-EP-6-2-1C · Section: 6 — Rotating Equipment

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

THE MANUFACTURER OF EQUIPMENT PURCHASED BY REFINING COMPANY SHALL BE RESPONSIBLE FOR MEETING ALL APPLICABLE REQUIREMENTS OF THE ENGINEERING PRACTICES AND OTHER DOCUMENTS REFERENCED THEREIN REGARDLESS OF WHETHER THE ITEMS ARE INSPECTED BY A REPRESENTATIVE.

REFERENCES

THE LATEST EDITION OF THE FOLLOWING STANDARDS AND PUBLICATIONS ARE REFERRED TO HEREIN.

ENGINEERING PRACTICES

EP 6-2-1 RECIPROCATING COMPRESSORS

EP 10-2-3 MATERIALS HARDNESS REQUIREMENTS

API PUBLICATIONS

API 618 RECIPROCATING COMPRESSORS

FREQUENCY OF CONTACT BY THE INSPECTOR: (CHECK ONE)

LEVEL 1: ON CALL BY FABRICATOR LEVEL 2: ONCE EVERY TWO WEEKS LEVEL 3: EVERY WEEK

LEVEL 4: DAILY

LEVEL 5: OTHER, SPECIFY

LEVEL OF INSPECTION BY THE INSPECTOR:(CHECK ONE)

LEVEL 1: PREFABRICATION MEETING, DOCUMENT REVIEW, AND FINAL INSPECTION

LEVEL 2: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, AND FINAL INSPECTION

LEVEL 3: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, WITNESS POINTS, AND FINAL INSPECTION

LEVEL 4: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, WITNESS POINTS, HOLD POINTS, AND FINAL INSPECTION

LEVEL 5: OTHER, SPECIFY

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW):

NOTE: IF “X” IS IN PARENTHESES (X), THIS DENOTES “IF APPLICABLE.”

	DOCUMENT DESCRIPTION	INSPECTOR'S INITIALS (REVIEW COMPLETE)	DATE
1.	PURCHASE DOCUMENTS
2.	DRAWINGS AND SPECIFICATIONS
3.	INSTRUCTION MANUAL INCLUDED WITH COMPRESSOR
4.	QUALITY CONTROL MANUAL
5.	QUALITY CONTROL PLAN
6.	MATERIAL RECEIVING SIGN-OFF
7.	MATERIAL REQUISITIONS (EP 6-2-1, 2.11.1.4 EP 6-2-1 DATA SHEETS)
8.	IMPACT TEST REPORTS (API 610: 2.11.4.1 EP 6-1-1, 2.11.4)
9.	MATERIAL TEST REPORTS (API 610: 2.11.2, 3.11)
10.	MATERIAL HARDNESS TEST REPORTS
11.	UT REPORTS OF CASTINGS (API 610: 4.2.2.3)
12.	UT REPORTS OF FORGINGS (API 610: 4.2.2.3)
13.	TEST EQUIPMENT CALIBRATION CERTIFICATIONS (EP 6-2-1, 4.3.1.2)
14.	WELDING PROCEDURE SPECS.
15.	WELDER TRACEABILITY DOCUMENT
16.	NDE PROCEDURES
17.	NDE TEST REPORTS
18.	NDE PERSONNEL CERTIFICATION
19.	MFR. PLAN/SHOP TRAVEL
20.	IDENTIFICATION OF CRITICAL DIMENSONS
21.	SUB-CONTRACTOR Q/C REPORTS
22.	AS-BUILT DATA SHEET
23.	TEST PROCEDURES
24.	TEST PERFORMANCE CURVES
25.	SPECIAL TOOL LIST
26.	PRESERVATION, PACKAGING AND SHIPPING PROCEDURES (API 610: 5.2.5.8)
27.	RELIEF VALVE CERTIFICATION
28.	AUTHORIZED WAIVERS AND/OR DEVIATIONS REVIEW
29.	REVIEW OF SUBORDERS OF UNPRICED PURCHASE ORDERS TO SUBVENDORS FOR COMPLIANCE WITH ENGINEERING PRACTICES
30.	NAMEPLATE RUBBINGS AND/OR CODES
31.	LATERAL CRITICAL SPEED ANALYSIS REPORT
32.	TORISIONAL ANALYSIS REPORT (5.2.3.2.g)
33.
34.
35.
36.
37.
38.

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

GENERAL FABRICATION INSPECTION REQUIREMENTS (ALL FABRICATED EQUIPMENT)

R CHECK: THE SHOP INSPECTOR SHALL REVIEW DOCUMENTED RESULTS OF INSPECTION PERFORMED BY VENDOR'S INSPFCTOR OR SUBCONTRACTED INSPECTOR.

W CHECK: INDICATES THE SHOP INSPECTOR SHALL WITNESS ITEMS DURING FABRICATION SHOP SHALL NOTIFY INSPECTOR 2 DAYS IN ADVANCE OF FABRICATION POINT BUT NEED NOT HOLD PRODUCTION FOR INSPECTION.

H CHECK: INDICATES THE SHOP INSPECTOR SHALL INSPECT ITEMS DURING HOLD ON FABRICATION. SHOP SHALL NOTIFY INSPECTOR FIVE DAYS IN ADVANCE OF FABRICATION POINT AND SHALL NOT CONTINUE AFFECTED PRODUCTION UNTIL INSPECTOR PERFORMS AND IMPROVES FABRICATION AFTER INDICATED INSPECTION.

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
			PRESSURE VESSELS
			RT UPS OF WELD ROOTS AND BEVELS
			WELDING PROCEDURES
			-PLATE
			-STEEL CASTINGS
			UT OF WELDS
			RT OF WELDS
			-LOCATION SECTION
			-FILM REVIEW
			MPI RESULTS
			MPI/UT OF NON-RADIOGRAPHABLE NOZZLES
			UT OF NOZZLES IN CASTINGS
			PWHT PROCEDURES/REQUIREMENTS REVIEW & APPROVAL
			PWHT PREPARATIONS
			FLATNESS CHECK OF GASKET CONTACT SURFACES AFTER PWHT
			MPI AFTER PWHT
			RADIOGRAPH AFTER PWHT
			X-RAY PIPING WELDS
			-GAS
			-OIL
			WELDING REPAIR PROCEDURES
			PRESSURE TESTS (4.3.1)
			HYDROSTATIC TEST-CYLINDERS
			-PRESSURE VESSELS (4.3.1.1c)
			-FILTERS (4.3.1.2)
			CYLINDER HELIUM LEAK TEST (4.3.1.2
			CYLINDER COOLING WATER

			COMPARTMENT HYDROSTATIC TEST (4.3.1.1b)
			HYDROSTATIC TEST OF PIPING (4.3.1.1c)

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW):

NOTE: IF “X” IS IN PARENTHESES (X), THIS DENOTES “IF APPLICABLE.”

FABRICATION INSPECTION

	DOCUMENT DESCRIPTION (REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)	INSPECTOR'S INITIALS (REVIEW COMPLETE)	DATE
1.	IMPACT TEST REPORTS (2.14.2.b.1)
2.	MATERIAL TEST REPORTS (2.14.1.2, 2.14, 2.5, 2.14.4.1.6)
3.	NDE PROCEDURES (2.14.4.2, & 3)
4.	NDE PERSONNEL CERTIFICATION
5.	NDE REPORTS ON CASTINGS (CYLINDERS, DISTANCE PIECE, MAIN FRAME) 2.14.4.2
6.	NDE REPORTS ON FORGINGS (CRANKSHAFT, CONNECTING RODS, CROSSHEAD) 2.14.2
7.	TEST EQUIPMENT CERTIFICATION CALIBRATIONS
8.	WELDER QUALIFICATION RECORDS
9.	WELDER TRACEABILITY DOCUMENT ASME SECTION VIII COMPLIANCE
10.	FABRICATION PLAN/SHOP TRAVELER
11.	SUB CONTRACTOR Q/C REPORTS
12.	MATERIAL HARDNESS CHECK RESULTS 2.4.1.10 (MAX Rc 22 IN H2S EXPOSED AREAS)
13.	CASTING REPAIR PROCEDURES (2.14.3.1, 4.5)
14.	AUTHORIZED WAIVERS AND/OR DEVIATIONS REVIEW
15.	REVIEW OF SUBORDERS OF UNPRICED PURCHASE ORDERS TO SUBVENDORS FOR COMPLIANCE WITH ENGINEERING PRACTICES
16.
17.
18.
19.

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION
			DIMENSIONAL CHECKS (INCLUDES ID & OD SNAPS, LENGTHS & FACE PARALLELISM) (SEE DRAWINGS)
			* MAIN FRAME
			* DISTANCE PIECES
			* CYLINDERS LINERS
			* CRANKSHAFT
			* CONNECTING RODS
			* PISTON RODS
			* PISTONS
			* CROSS HEAD
			* MAIN BEARINGS
			* ROD BEARING
			* CROSS-HEAD BEARINGS
			* PULSATION DAMPERS
			* CYLINDER I.D. & PISTON O.D SURFACE FINISH (2.6.2.2)
			* FLYWHEEL



ASSEMBLY INSPECTION (PRIOR TO ASSEMBLY) (SEE DRAWINGS)	ASSEMBLY INSPECTION (PRIOR TO ASSEMBLY) (SEE DRAWINGS)	ASSEMBLY INSPECTION (PRIOR TO ASSEMBLY) (SEE DRAWINGS)	ASSEMBLY INSPECTION (PRIOR TO ASSEMBLY) (SEE DRAWINGS)	ASSEMBLY INSPECTION (PRIOR TO ASSEMBLY) (SEE DRAWINGS)	ASSEMBLY INSPECTION (PRIOR TO ASSEMBLY) (SEE DRAWINGS)
			CYLINDER-LINER INTEREFERENCE FITS & ID SURFACE FINISH (2.6.2.2)
			MAIN BEARING-SHAFT CLEARANCE (BRG. IN ROD)
			ROD BEARING-SHAFT CLEARANCE (BRG.IN ROD)
			CROSS HEAD PIN-CROSS HEAD CLEARANCE (BRG. IN ROD)
			CROSS HEAD PIN-CONNECTING ROD CLEARANCE
			PISTON-CYLINDER CLEARANCE
			PISTON RING & WEAR BAND CYLINDER CLEARANCES
			VALVE LIFTS
			MASTER PARTS LIST
			INSIDE PAINTING OF FRAME AND DISTANCE PIECES
			EQUIPMENT & PIPING CLEARANCES (4.2.6)

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
DURING ASSEMBLY	DURING ASSEMBLY	DURING ASSEMBLY	DURING ASSEMBLY	DURING ASSEMBLY	DURING ASSEMBLY
			MAIN FRAME IN-PLANE FLATNESS (SAG)
			MAIN FRAME MAIN BEARING TAUT WIRE TEST
			MAIN BEARING-CRANKSHAFT CLEARANCE
			CRANK TROW PARALLELISM
			CROSS HEAD BEARING CLEARANCE
			PISTON-PISTON ROD TORQUING (2.8.1)
			CYLINDER CRANKSHAFT SQUARENESS (TAUT WIRE TEST)
			DISTANCE PIECE-MAIN FRAME BOLT TORQUES
			CYLINDER DISTANCE PIECE BOLT TORQUES
			PISTON RING & WEARBAND RADIAL CLEARANCES
			MAIN BEARINGS AND CONNECTING ROD BOLT TORQUES
			ROD DROPS (RUNOUT) (2.6.2.1)
			PULSATION DEVICES & ALL ASSOCIATED GAS PIPING FIT-UP/CLEARANCES (4.3.3.2)
			VERIFY ALL PARTS INSTALLED
			VERIFY INTER CONNECTS AND LOCATION ON CERTIFIED OUTLINE DRAWING
			CORRECT VALVE INSTALLATION (2.7.3)




FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS
			LUBE OIL CONSOLE FUNCTIONAL TEST
			COOLING WATER CONSOLE FUNCTIONAL TEST
			RELIEF VALVE FUNCTIONAL TEST
			MECHANICAL RUN TEST OF COMPLETE COMPRESSOR WHEN APPLICABLE
			PERFORMANCE TEST OF THE COMPLETE COMPRESSOR WHEN APPLICABLE
			BAR OVER & CLEARANCE TEST OF THE COMPLETE COMPRESSOR
			CYLINDER LUBE OIL PUMPING RATE AND FLOW TO ALL CYLINDERS
			ADEQUATE CLEARANCE AREAS AND ACCESS FOR OPERATION AND MAINTENANCE (2.1.6, 2.6.1.3)
			VERIFY ALARMS AND SHUTDOWNS
			CHECK UNLOADER FUNCTION
			CHECK OUT CONTROL PANEL FUNCTION

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
PREPARATION TO SHIP	PREPARATION TO SHIP	PREPARATION TO SHIP	PREPARATION TO SHIP	PREPARATION TO SHIP	PREPARATION TO SHIP
			INSPECT MAIN BEARINGS
			FLUSH CRANKCASE & APPLY PRESERVATION (4.4.5.3)
			FLUSH DISTANCE PIECE & APPLY PRESERVATION (4.4.5.3)
			DRY OUT COOLING WATER PASSAGES AND APPLY PRESERVATION
			MATCH MARK ALL FLANGES
			BLOCK CRANKSHAFT (4.4.1)
			PAINT EXTERIOR NON-MACHINED SURFACES (4.4.5.1)
			COVER ALL OPENINGS WITH METAL CLOSURES (4.4.5.5. & 6)
			APPLY RUST PREVENTION TO EXTERIOR MACHINED PARTS

INSPECTOR SIGN-OFF	INSPECTOR SIGN-OFF	INSPECTOR SIGN-OFF	INSPECTOR SIGN-OFF
INITIALS	NAME	COMPANY	SOCIAL SECURITY NUMBER

EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

SUMMARY:

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