General Purpose Steam Turbines Inspection Checklist

IPE Engineering Practice IPE-EP-6-3-1C

Document number: IPE-EP-6-3-1C · 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 6-3-1 GENERAL PURPOSE STEAM TURBINES EP 6-3-2 SPECIAL PURPOSE STEAM TURBINES EP 10-2-3 MATERIAL HARDNESS REQUIREMENTS

API PUBLICATIONS

API 611 GENERAL PURPOSE STEAM TURBINES

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):

	DOCUMENT DESCRIPTION	INSPECTOR'S INITIALS (REVIEW COMPLETE)	DATE
PREFABRICATION MEETING	PREFABRICATION MEETING	PREFABRICATION MEETING	PREFABRICATION MEETING
1.	PURCHASE DOCUMENTS
2.	SPECIFICATIONS, APPROVED DRAWINGS, PARTS LISTS AND ASSEMBLY PROCEDURES (EP 6-3-2, 5.2.3.4, 5.2.3.5, 5.2.5.5)
3.	VENDOR QUALITY CONTROL MANUAL
4.	VENDOR QUALITY CONTROL PLAN
5.	IDENTIFICATION OF CRITICAL DIMENSIONS (APPENDIX E. PARAGRAPH #41)
6.	SUB-CONTRACTOR Q/C REPORTS
7.	AUTHORIZED WAIVERS AND/OR DEVIATIONS REVIEW
8.	CUSTOMER INSPECTION SCHEDULE (4.1.4.1)
9.	REVIEW OF SUBORDERS OF UNPRICED PURCHASE ORDERS TO SUBVENDORS FOR COMPLIANCE WITH ENGINEERING PRACTICES
10.	WELDING PROCEDURES SPECS -PIPE (2.11.3.1, 3.6.1.1, AND 2.1.1.3.6. 3)
11.	WELDING PROCEDURES SPECS -STEEL CASINGS AND PLATE (2.11.3.1 AND .3)
12.	REPAIR PROCEDURES (2.11.2.3, 2.11.3.2)
FABRICATION DOCUMENTATION REVIEW	FABRICATION DOCUMENTATION REVIEW	FABRICATION DOCUMENTATION REVIEW	FABRICATION DOCUMENTATION REVIEW
13.	MATERIAL REQUISITIONS (2.11.1.1 & .2)
14.	MATERIAL RECEIVING SIGN-OFF
15.	NDE PROCEDURES (4.2.2)
16.	NDE PERSONNEL CERTIFICATION
17.	IMPACT TEST REPORTS ( 2.11.1.15 AND 16 )
18.	MATERIAL TEST REPORTS (5.2.5.2.a)
19.	MATERIAL HARDNESS TEST REPORTS (5.2.5.2.)
20.	WELDER TRACEABILITY DOCUMENTATION
21.	MANUFACTURING PLAN/SHOP TRAVELER
22.	PRESSURE CASING
23.	FIT-UPS OF WELD ROOTS AND BEVELS
24.	UT OF WELDS (4.2.2.1.2)
25.	RT OF WELDS - PRESSURE CASING (4.2.2.1.1)
26.	- PIPING, STEAM (3.5.1.1)
27.	- PIPING, OIL (3.5.1.1)
28.	MPI RESULTS (4.2.2.3)
29.	MPI/UT OF NON-RADIOGRAPHABLE CASING CONNECTIONS
30.	UT OF COMPLETED CASING CONNECTIONS
31.	POST WELD HEAT TREAT (PWHT) PROCEDURES/REQUIREMENTS REVIEW AND APPROVAL (2.11.3.5.4 AND 2.11.3.6.4)
32.	PWHT PREPARATIONS
33.	AFTER PWHT
34.	-MPI
35.	-WELDING HEAT AFFECTED ZONE (HAZ) HARDNESS CHECK (2.11.3.)
36.	-UT
37.	-RADIOGRAPH
38.	HYDROSTATIC TEST -CASINGS (4.3.2)
39.	-PIPING (4.3.2)
40.
41.
42.

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	R	W	W	H	H	INSPECTION/TESTING ACTIVITY	INSPECTOR'S INITIALS (REVIEW COMPLETE)	DATE
MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION	MACHINING INSPECTION
1.						DIMENSIONAL CHECKS (INCLUDING ID AND OD SNAPS, LENGTHS AND FACE PARALLELISM, SEE DRAWINGS)
2.						PRESSURE CASING
3.						SHAFT (INCLUDING RADIAL RUNOUTS) (APP. E. PAR. 31.a)
4.						DISC(S) (APP. E. PAR. 31.b)
5.						BEARINGS (APP. E, PAR. 31.d AND e)
6.
7.
8.
9.
PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY	PRIOR TO AND DURING ASSEMBLY
10.						ASSEMBLED ROTOR RADIAL AND AXIAL RUNOUTS
11.						FINAL ROTOR RESIDUAL UNBALANCE AMPLITUDE AND PHASE ANGLES
12.						BEARING RADIAL CLEARANCES (5.2.4.2.k)
13.						ROTOR AXIAL CLEARANCES (5.2.4.2.k)
14.						THRUST DISC AXIAL RUNOUT (5.2.4.2.k)
15.						ROTOR END FLOAT (WITH THRUST DISC INSTALLED) (5.2.4.2.k)
16.						SHAFT SEAL CLEARANCES (5.2.4.2.k)
17.						VERIFY BEARING ATTACHMENT BOLT TORQUES (VENDOR SPECS)
18.						CASING SPLIT LINE BOLT TORQUES (VENDOR SPECS)
19.						VERIFY INLET AND OUTLET PIPE FLANGE INTERFACE LOCATIONS (APP. 3.PAR.1a)
20.						VERIFY ALL PARTS ARE INSTALLED PER PARTS LIST (5.2.4.3)
21.						COUPLING HUB BLUING CHECK
22.						OBTAIN DIMENSIONAL RECORD OF OIL RING SIZE AND PLACE IN OWNER'S FILE. VERIFY THAT ALL DIMENSIONS ARE PER DESIGN. VERIFY CONCENTRICITY AND PROPER CHAMFER ON ALL EDGES
23.
24.

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.

R	R	W	W	H	H	INSPECTION/TESTING ACTIVITY	INSPECTOR’S INITIALS (REVIEW COMPLETE)	DATE
FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS	FUNCTIONAL CHECKS
1.						OIL RINGS ARE TURNING
2.						ROTOR OVERSPEED TRIP (DO 3 TIMES) (4.3.3.3.5)
3.						GOVERNOR SPEED CONTROL STABILITY AND RANGE (4.3.3.3.6 AND 7)
4.						HORIZONTAL (VERTICAL) SPLIT LINE LEAK TEST (4.3.3.1.8)
5.						MECHANICAL RUNNING TEST (COMPLETE UNIT) (4.3.3 AND 5.2.4.2.c)
6.						PERFORMANCE TEST (COMPLETE UNIT, WHEN SPECIFIED) (4.3.4.1)
7.						MECHANICAL TEST OF THE SPARE ROTOR ASSEMBLY (4.3.3.4.3)
8.						SENTINEL VALVE (3.4.5.2)
9.
10.
11.
12.
PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION	PREP TO SHIP – INSPECTION
13.						INSPECT BEARINGS (4.3.3.4.1)
14.						INSPECT SHAFT SEALS
15.						FLUSH PRESSURE CASING, SUPPLY AND DISCHARGE SECTIONS AND APPLY PRESERVATIVE (4.4.3.3)
16.						FLUSH BEARING HOUSINGS AND APPLY PRESERVATIVE (4.4.3.4)
17.						DRY OUT COOLING WATER PASSAGES AND APPLY PRESERVATIVE
18.						MATCH MARK ALL MATING FLANGES
19.						PAINT EXTERIOR NON-MACHINED SURFACES (4.4.3.1)
20.						COVER ALL OPENINGS WITH METAL CLOSURES (4.4.3.5)
21.						APPLY RUST PREVENTIVE TO EXTERIOR MACHINED PARTS (4.4.3.2)
22.						VERIFY PROPER BRACING TO AVOID DAMAGE DURING SHIPPING (4.4.1)
23.
24.
25.
26.
27.

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.

PREP TO SHIP -DOCUMENTATION REVIEW	PREP TO SHIP -DOCUMENTATION REVIEW	PREP TO SHIP -DOCUMENTATION REVIEW	PREP TO SHIP -DOCUMENTATION REVIEW	PREP TO SHIP -DOCUMENTATION REVIEW	PREP TO SHIP -DOCUMENTATION REVIEW	PREP TO SHIP -DOCUMENTATION REVIEW
28.				INSTRUCTION MANUAL INCLUDED WITH TURBINE
29.				PRESSURE RELIEF VALVE(S) CERTIFICATION
30.				HYDROGEN CERTIFICATIONS
31.				FINAL MECHANICAL INSPECTION RECORDS
32.				TEST PERFORMANCE CURVES
33.				AS-BUILT DATA SHEETS
34.				SPECIAL TOOL LIST (3.6)
35.				PRESERVATION, PACKING AND SHIPPING PROCEDURES
36.				COMPLETE SPARE PARTS LIST
37.				LUBRICATION REQUIREMENTS
38.
39.
40.

EQUIPMENT ID	JOB NO.	DOCUMENT NO.	REV.

SUMMARY:

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