Packaged Integrally Geared Centrifugal Air Compressors Inspection Checklist

IPE Engineering Practice IPE-EP-6-2-3C

Document number: IPE-EP-6-2-3C · Section: 6 — Rotating Equipment

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 6-2-3 PACKAGED, INTEGRALLY GEARED AIR COMPRESSORS

EP 6-7-1 SPECIAL REQUIREMENTS FOR ROTATING EQUIPMENT

EP 10-3-1 SUPPLEMENTAL MATERIAL REQUIREMENTS FOR METALLIC MATERIALS

EP 10-2-3 MATERIAL HARDNESS REQUIREMENTS

EP 12-2-1 INSTALLATION AND TESTING OF INSTRUMENTATION AND CONTROL SYSTEMS

EP 15-1-4 POSITIVE MATERIALS IDENTIFICATION (PMI)

API PUBLICATIONS

API–672 PACKAGED, INTEGRALLY GEARED AND 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

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
PRE-FABRICATION MEETING ITEMS	PRE-FABRICATION MEETING ITEMS	PRE-FABRICATION MEETING ITEMS	PRE-FABRICATION MEETING ITEMS
1.	PURCHASE DOCUMENTS
2.	INSPECTION CHECKLIST
3.	VENDOR DRAWINGS
4.	APPLICABLE STANDARDS & SPECIFICATIONS
5.	AUTHORIZED WAIVERS AND/OR DEVIATIONS
6.	VENDOR'S QUALITY CONTROL MANUAL
7.	QUALITY CONTROL PLAN
8.	MAJOR WELD REPAIRS & REVIEW AND APPROVAL OF REPAIR PROCEDURES
9.	TESTING REQUIREMENTS AND TEST PROCEDURES
10.	PRELIMINARY TEST SCHEDULE
11.	PROCEDURE FOR NOTIFICATION OF WITNESSED (OR OBSERVED) TESTING AND INSPECTION ACTIVITIES
12.	SUB-VENDORS Q/C PLAN
13.
14.
15.
16.

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
DOCUMENT REVIEW (DURING MANUFACTURING PROCESS)	DOCUMENT REVIEW (DURING MANUFACTURING PROCESS)	DOCUMENT REVIEW (DURING MANUFACTURING PROCESS)	DOCUMENT REVIEW (DURING MANUFACTURING PROCESS)
1.	MATERIAL REQUISITIONS (EP 6-2-3: 2.3.9.1,2,4,5;2.2.2.1.10,11; EP 6-2-3DS)
2.	MATERIAL RECEIVING SIGN-OFF
3.	MATERIAL TEST REPORTS (2.3.9.1.3 )
4.	IMPACT TEST REPORTS ( 2.3.9.4 )
5.	MATERIAL HARDNESS TEST REPORT (2.3.9.1.3)
6.	PMI OF ALL APPLICABLE MATERIALS (EP 15-1-4)
7.	WELDING PROCEDURE SPECS.
8.	WELDER QUALIFICATION RECORDS
9.	WELDER TRACEABILITY DOCUMENT (ASME SECTION VIII COMPLIANCE)
10.	NDE PROCEDURES
11.	NDE TEST REPORTS (4.2.2.2.-5)
12.	- BUILT–UP IMPELLERS
13.	- GEARS
14.	- WELDS
15.	- CASTINGS
16.	- FORGINGS
17.	- REPAIRS
18.	NDE PERSONNEL CERTIFICATION
19.	MANUFACTURER PLAN/SHOP TRAVEL
20.	MAIN AND SPARE ROTORS – ASSEMBLY AND BALANCING RECORDS
21.	SUB-CONTRACTOR Q/C REPORTS
22.	AUTHORIZED WAIVER AND/OR DEVIATION REVIEW
23.	REVIEW OF SUBORDERS OF UNPRICED PURCHASE ORDERS TO SUBVENDORS FOR COMPLIANCE WITH ENGINEERING PRACTICES
24.
25.
26.
27.

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
FINAL DOCUMENT REVIEW (PRIOR TO RELEASE FOR SHIPMENT)	FINAL DOCUMENT REVIEW (PRIOR TO RELEASE FOR SHIPMENT)	FINAL DOCUMENT REVIEW (PRIOR TO RELEASE FOR SHIPMENT)	FINAL DOCUMENT REVIEW (PRIOR TO RELEASE FOR SHIPMENT)
28.	INSTRUCTION MANUAL INCLUDED WITH UNIT
29.	PRESSURE RELIEF VALVE CERTIFICATIONS
30.	HYDROTEST CERTIFICATIONS
31.	FINAL MECHANICAL INSPECTION RECORDS
32.	TEST PERFORMANCE CURVES
33.	AS-BUILT DATA SHEETS
34.	SPECIAL TOOL LIST (2.1.17)
35.	PRESERVATION, PACKING AND SHIPPING PROCEDURES
36.	COMPLETE SPARE PART LIST
37.	LUBRICATION REQUIREMENTS
38.	NAMEPLATE RUBBINGS AND/OR CODES
39.	CERTIFICATE OF COMPLIANCE
40.	LATERAL AND TORSIONAL ANALYSES (2.3.7.1.6, 2.3.7.2.1–2, 3.7.4.5–6)
41.
42.
43.

GENERAL FABRICATION INSPECTION REQUIREMENTS (ALL FABRICATED EQUIPMENT)

(REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)

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

O 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	R	O	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
MATERIALS INSPECTION	MATERIALS INSPECTION	MATERIALS INSPECTION	MATERIALS INSPECTION	MATERIALS INSPECTION	MATERIALS INSPECTION	MATERIALS INSPECTION
				CHARPY IMPACT TEST (2.3.9.4)
				PMI OF APPLICABLE MATERIALS (EP 15-1-4)
				- COMPRESSOR (CASING, SHAFT, IMPELLERS, ETC)
				- PIPING
				- IMPELLERS
				-LUBE OIL SYSTEM
				MATERIAL PROPERTIES – SHAFTS, GEARS, CASINGS & BEARINGS
				- CHEMICAL COMPOSITION
				…- PHYSICAL PROPERTIES
				- STRENGTH
				- HARDNESS
				MATERIAL PROPERTIES – COOLERS (EP 7-1-2)
				– SHELL, CHANNEL, TUBES & TUBE SHEETS



FABRICATION INSPECTION	FABRICATION INSPECTION	FABRICATION INSPECTION	FABRICATION INSPECTION	FABRICATION INSPECTION	FABRICATION INSPECTION	FABRICATION INSPECTION
				FIT UPS OF WELD ROOTS AND BEVELS
				PIPING JOINTS (2.2.2.2.1.1; 2.3.3.3.5)
				WELDER IDENTIFICATION & PERFORMANCE QUALIFICATION
				WELDING REQUIREMENTS (2.2.2.1.8)
				REPAIR PROCEDURE APPROVED
				WELDING REPAIR MAPS
				LT OF ACCESSIBLE AREAS OF WELDS ON BUILT–UP IMPELLERS (4.2.2.2)
				MT OF ACCESSIBLE AREAS OF WELDS ON BUILT–UP IMPELLERS (4.2.2.2)

R	R	O	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
				MT OF BULL–GEAR AND PINION TEETH (4.2.2.3)

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW): NOTE: IF “X” IS IN PARENTHESES (X), THIS DENOTES “IF APPLICABLE.” (REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
FABRICATION INSPECTION CONTINUED	FABRICATION INSPECTION CONTINUED	FABRICATION INSPECTION CONTINUED	FABRICATION INSPECTION CONTINUED	FABRICATION INSPECTION CONTINUED	FABRICATION INSPECTION CONTINUED
			ADDITIONAL SPECIFIED NDE (4.2.2.4, 5)
			– CASING
			– SHAFT
			– IMPELLERS
			– PIPING/CONNECTIONS
			– LUBE OIL SYSTEM
			– REPAIRS
			HYDROSTATIC TEST OF PRESSURE-CONTAINING PARTS (4.3.2)
			- CASING
			- LUBE OIL SYSTEM
			– INTERCONNECTING PIPING
			– INTERCOOLERS
			– AFTERCOOLER
			MT OF IMPELLERS AFTER OVERSPEED TEST (4.3.3)

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW):

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

(REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
MACHINING INSPECTION/DIMENSIONAL CHECKS (SEE DRAWINGS)	MACHINING INSPECTION/DIMENSIONAL CHECKS (SEE DRAWINGS)	MACHINING INSPECTION/DIMENSIONAL CHECKS (SEE DRAWINGS)	MACHINING INSPECTION/DIMENSIONAL CHECKS (SEE DRAWINGS)	MACHINING INSPECTION/DIMENSIONAL CHECKS (SEE DRAWINGS)	MACHINING INSPECTION/DIMENSIONAL CHECKS (SEE DRAWINGS)
			MACHINED FINISH OF COMPRESSOR'S MOUNTING SURFACES (2.3.1.7)
			STUDDED CONNECTIONS OF CASING (2.3.2.4,5)
			INTERSTAGE HOUSINGS (2.3.3.1)
			CASING CONNECTIONS (2.3.1.3;2.3.3.2-4)
			CASING FLANGES AND NOZZLES (2.3.3.6)
			SHAFT ENDS FOR COUPLING FITS (API 671)
			SHAFT RUNOUTS (SEE VENDOR DRAWINGS FOR TOLERANCES)
			MRO & ERO OF SHAFT SENSING AREAS OBSERVED BY VIBRATION PROBES(2.3.5.1.3)
			SURFACE FINISH OF SHAFTS (2.3.5.1.2)
			IMPELLERS (SEE VENDOR DRAWINGS)
			MATCHING OF RING AND PLUG GAUGES FOR COUPLING (2.5.2, API 671: APP.D)
			SURFACE FINISH AND RUNOUT OF THRUST COLLARS (2.3.8.4)
			SURFACE FINISH OF COUPLING HUB BORES (API 671: 2.1.8.2)
			COUPLING HUB'S TAPERED BORES CHECK (API 671: 2.1.9.1.4)
			BEARING PEDESTAL SURFACES AND BASEPLATE (2.2.3.1)
			LIFTING LUGS FOR BASEPLATE (2.2.3.11)
			GROUTING ACCESSIBILITY OF BASEPLATE (2.3.3.12)
			SHAFT ENDS FOR IMPELLER FITS

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW): NOTE: IF “X” IS IN PARENTHESES (X), THIS DENOTES “IF APPLICABLE.” (REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
PRE-ASSEMBLY INSPECTION/TESTING (SEE DRAWINGS AND TEST PROCEDURE)	PRE-ASSEMBLY INSPECTION/TESTING (SEE DRAWINGS AND TEST PROCEDURE)	PRE-ASSEMBLY INSPECTION/TESTING (SEE DRAWINGS AND TEST PROCEDURE)	PRE-ASSEMBLY INSPECTION/TESTING (SEE DRAWINGS AND TEST PROCEDURE)	PRE-ASSEMBLY INSPECTION/TESTING (SEE DRAWINGS AND TEST PROCEDURE)	PRE-ASSEMBLY INSPECTION/TESTING (SEE DRAWINGS AND TEST PROCEDURE)
			DYNAMIC BALANCE OF COUPLINGS (API 671: 2.5.2, COUPLING DRAWINGS)
			DYNAMIC BALANCE OF BARE SHAFT (2.3.7.5.1)
			DYNAMIC BALANCE OF EACH IMPELLER ON MANDREL ,PINIONS, AND BULL GEAR (2.3.7.5.1, 2)
			IMPELLER OVERSPEED TEST (4.3.3)
			DIMENSIONAL CHECK OF IMPELLERS AFTER OVERSPEED TEST (4.3.3)
			NDE OF IMPELLERS AFTER OVERSPEED TEST (4.3.3))
			ROTOR ASSEMBLY AND DYNAMIC BALANCING (2.3.7.5.2)
			FACE RUNOUTS ON THRUST COLLAR OF COMPLETELY ASSEMBLED ROTOR (2.6.13)
			IMPELLER/-SPACER GAP CHECK (SEE ASSEMBLY DRAWINGS FOR DIMENSIONS)
			RESIDUAL UNBALANCE CHECK OF ROTOR ASSEMBLY (2.3.7.5.3)
			GAUSS CHECK OF FINAL ROTOR ASSEMBLY)
			SHAFT END AND COUPLING HUB BLUING CONTACT CHECK (SEE DRAWINGS FOR TOLERANCE)
			VERIFY SHAFT-IMPELLERS INTERFERENCE FITS
			ROTOR HIGH-SPEED BALANCING (2.3.7.5.4)

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW): NOTE: IF “X” IS IN PARENTHESES (X), THIS DENOTES “IF APPLICABLE.” (REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
ASSEMBLY INSPECTION (SEE VENDOR’S ASSEMBLY DRAWINGS)	ASSEMBLY INSPECTION (SEE VENDOR’S ASSEMBLY DRAWINGS)	ASSEMBLY INSPECTION (SEE VENDOR’S ASSEMBLY DRAWINGS)	ASSEMBLY INSPECTION (SEE VENDOR’S ASSEMBLY DRAWINGS)	ASSEMBLY INSPECTION (SEE VENDOR’S ASSEMBLY DRAWINGS)	ASSEMBLY INSPECTION (SEE VENDOR’S ASSEMBLY DRAWINGS)

			CHECK SHAFT-BEARING CLEARANCES
			CHECK IMPELLER-CASING AXIAL CLEARANCES
			CORRECTLY APPLICATION OF CASING BOLTS TORQUING PROCEDURE
			JACKSCREWS, GUIDE RODS, DOWELS & LIFTING LUGS OPERATIONAL CHECK (2.2.3.9, 11; 2.3.1.6)
			MOUNTING OF COUPLING HUB ON SHAFT (SEE COUPLING DRAWINGS AND MANUALS)
			VERIFY ROTOR AXIAL CLEARANCE (COLD FLOAT)
			COMPRESSOR-DRIVER COUPLING ALIGNMENT
			VERIFY INTER-CONNECTIONS AND LOCATIONS ON CERTIFIED OUTLINE DRAWINGS
			VERIFY ALL PARTS INSTALLED (SEE DRAWINGS AND BILLS OF MATERIAL)
			CHECK IMPELLER SEAL RADIAL CLEARANCES
			CHECK IMPELLER SHAFT DIMENSIONAL FITS



INSTRUMENT AND CONTROL PANELS INSPECTION	INSTRUMENT AND CONTROL PANELS INSPECTION	INSTRUMENT AND CONTROL PANELS INSPECTION	INSTRUMENT AND CONTROL PANELS INSPECTION	INSTRUMENT AND CONTROL PANELS INSPECTION	INSTRUMENT AND CONTROL PANELS INSPECTION
			PIPING AND WIRING (2.2.4.3.3)
			TAGGING (2.2.2.4.3.3)
			THERMOMETERS AND TEMPERATURE GAUGES (2.2.4.4.1)
			PRESSURE GAUGES & PRESSURE SENSING ELEMENTS (2.2.4.4.2, 2.2.4.5.2.4)
			ELECTRICAL SYSTEMS (2.2.4.6)
			VIBRATION AND POSITION DETECTORS (2.2.4.7)
			VERIFY ALL PARTS INSTALLED (SEE DRAWINGS AND BILLS OF MATERIAL)

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW): NOTE: IF “X” IS IN PARENTHESES (X), THIS DENOTES “IF APPLICABLE.” (REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
PIPING AND APPURTENANCES INSPECTION	PIPING AND APPURTENANCES INSPECTION	PIPING AND APPURTENANCES INSPECTION	PIPING AND APPURTENANCES INSPECTION	PIPING AND APPURTENANCES INSPECTION	PIPING AND APPURTENANCES INSPECTION
			PIPING CONNECTIONS (2.2.2.1.4 – 6, 13)
			OIL PIPING (2.2.2.2)
			INSTRUMENT LINES (2.2.2.3)

DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW): NOTE: IF “X” IS IN PARENTHESES (X), THIS DENOTES “IF APPLICABLE.” (REFERENCES ARE TO API 618 UNLESS OTHERWISE NOTED)

R	W	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
FUNCTIONAL CHECKS AND TESTING	FUNCTIONAL CHECKS AND TESTING	FUNCTIONAL CHECKS AND TESTING	FUNCTIONAL CHECKS AND TESTING	FUNCTIONAL CHECKS AND TESTING	FUNCTIONAL CHECKS AND TESTING
			INSTRUMENT AND CONTROL PANEL FUNCTIONAL TEST (2.2.4.3)
			VERIFY ALARM AND SHUTDOWN SETTINGS (2.2.4.5)
			LUBE OIL CONSOLE FUNCTIONAL TEST (API 614)
			ADEQUATE CLEARANCE AREAS AND ACCESS FOR OPERATION AND MAINTENANCE
			JACKSCREWS, GUIDE RODS, DOWELS & LIFTING LUGS FUNCTIONAL CHECK (2.3.1.6)
			COMBINED MECHANICAL AND PERFORMANCE TEST (4.3.4)
			SHOP VERIFICATION OF UNBALANCED RESPONSE ANALYSIS (2.3.7.3)
			OPTIONAL PERFORMANCE TEST (4.3.5.1)
			GUIDE–VANE TEST (4.3.5.2)
			SOUND–LEVEL TEST (4.3.5.3, 2.1.15)
			SPARE–ROTATING–ELEMENTS TEST (4.3.5.4)
			DRIVER MEETS REQUIREMENTS OF ATTACHED INSPECTION CHECKLIST
			FINAL INSPECTION AND APPROVAL BEFORE SHIPPING



PREPARATION FOR SHIPMENT	PREPARATION FOR SHIPMENT	PREPARATION FOR SHIPMENT	PREPARATION FOR SHIPMENT	PREPARATION FOR SHIPMENT	PREPARATION FOR SHIPMENT
			PLUGS FOR TAPPED OPENINGS (2.3.3.5)
			NAMEPLATE REQUIREMENTS (2.3.10)
			CLEANING (4.4.3.3, EP 6-7-1: 6.2.1, 6.2.18)
			PAINTING, COATING & PRESERVATION (4.4.3.1., 2 & 4; EP 6-7-1: 6.2.4,5)
			PACKING & PROTECTION (4.4.3.5-9; EP 13-7-1: 6.2.6 ,7,12)
			PARTS TAGGING & IDENTIFICATION (2.1.17.2, 4.4.3.11, 4.4.4–5; EP 6-7-1: 6.2.15,17)
			SPARE ROTATING ELEMENTS PREPARATION (4.4.3.12)
			INSTALLATION, OPERATION & MAINTENANCE MANUALS (4.4.6)

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

SUMMARY:

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