Special Purpose Steam Turbines Inspection Checklist

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

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

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

REFERENCES

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

EAGLE POINT REFINERY ENGINEERING PRACTICES

EP 6-3-2 SPECIAL PURPOSE STEAM TURBINES EP 10-2-3 MATERIAL HARDNESS REQUIREMENTS

API PUBLICATIONS

API-612 SPECIAL 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: RESIDENT

LEVEL 6: 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.	EAGLE POINT REFINERY 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 EAGLE POINT REFINERY ENGINEERING PRACTICES
10.	WELDING PROCEDURES SPECS - PIPE (2.11.3.1, 3.6.1.1, AND 2.11.3.6. 3) - STEEL CASINGS AND PLATE (2.11.3.1 AND .3)
11.	REPAIR PROCEDURES (2.11.2.3, 2.11.3.2)
FABRICATION DOCUMENTATION REVIEW	FABRICATION DOCUMENTATION REVIEW	FABRICATION DOCUMENTATION REVIEW	FABRICATION DOCUMENTATION REVIEW
12.	MATERIAL REQUISITIONS (2.11.1.1 & .2)
13.	MATERIAL RECEIVING SIGN-OFF
14.	NDE PROCEDURES (4.2.2)
15.	NDE PERSONNEL CERTIFICATION
16.	IMPACT TEST REPORTS ( 2.11.1.15 AND 16 )
17.	MATERIAL TEST REPORTS (5.2.5.2.a)
18.	MATERIAL HARDNESS TEST REPORTS (5.2.5.2.)
19.	WELDER TRACEABILITY DOCUMENTATION
20.	MANUFACTURING PLAN/SHOP TRAVELER
21.	PRESSURE CASING
22.	FIT-UPS OF WELD ROOTS AND BEVELS
23.	UT OF WELDS (4.2.2.1.2)
24.	RT OF WELDS - PRESSURE CASING (4.2.2.1.1)
25.	- PIPING, STEAM (3.5.1.1)
26.	- PIPING, OIL (3.5.1.1)
27.	MPI RESULTS (4.2.2.3)
28.	MPI/UT OF NON-RADIOGRAPHABLE CASING CONNECTIONS
29.	UT OF COMPLETED CASING CONNECTIONS
30.	POST WELD HEAT TREAT (PWHT) PROCEDURES/REQUIREMENTS REVIEW AND APPROVAL (2.11.3.5.4 AND 2.11.3.6.4)
31.	PWHT PREPARATIONS
32.	AFTER PWHT
33.	-MPI
34.	-WELDING HEAT AFFECTED ZONE (HAZ) HARDNESS CHECK (2.11.3.)
35.	-UT
36.	-RADIOGRAPH
37.	HYDROSTATIC TEST -CASINGS (4.3.2)
38.	-PIPING (4.3.2)
39.
40.
41.

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 INSPECTOR 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
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 APP. E, Par. 2 AND 3)
2.				PRESSURE CASING
3.				SHAFT (INCLUDING RADIAL RUNOUTS) (APP. E. PAR. 41.a)
4.				DISC(S) (APP. E. PAR. 41.d AND e)
5.				BEARINGS (APP. E, PAR. 41.d AND e)
6.
7.
8.
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
9.				ASSEMBLED ROTOR RADIAL AND AXIAL RUNOUTS
10.				FINAL ROTOR RESIDUAL UNBALANCE AMPLITUDE AND PHASE ANGLES
11.				BEARING RADIAL CLEARANCES (5.2.4.2.k)
12.				ROTOR AXIAL CLEARANCES (5.2.4.2.k)
13.				THRUST DISC AXIAL RUNOUT (5.2.4.2.k)
14.				ROTOR END FLOAT (WITH THRUST DISC INSTALLED) (5.2.4.2.k)
15.				SHAFT SEAL CLEARANCES (5.2.4.2.k)
16.				VERIFY BEARING ATTACHMENT BOLT TORQUES (VENDOR SPECS)
17.				CASING SPLIT LINE BOLT TORQUES (VENDOR SPECS)
18.				VERIFY INLET AND OUTLET PIPE FLANGE INTERFACE LOCATIONS (APP. E. PAR.1a)
19.				VERIFY ALL PARTS ARE INSTALLED PER PARTS LIST (5.2.4.3b)
20.				COUPLING HUB BLUING CHECK
21.
22.
23.

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	W	H	INSPECTION/TESTING ACTIVITY	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
1.				VERIFY OIL FLOW IS EVIDENT IN EACH DRAIN LINE SIGHT FLOW INDICATOR	VERIFY OIL FLOW IS EVIDENT IN EACH DRAIN LINE SIGHT FLOW INDICATOR
2.				ROTOR OVERSPEED TRIP (DO 3 TIMES) (4.3.3.3.5)	ROTOR OVERSPEED TRIP (DO 3 TIMES) (4.3.3.3.5)
3.				GOVERNOR SPEED CONTROL STABILITY AND RANGE (4.3.3.2.4)	GOVERNOR SPEED CONTROL STABILITY AND RANGE (4.3.3.2.4)
4.				HORIZONTAL (VERTICAL) SPLIT LINE LEAK TEST (4.3.3.3.1)	HORIZONTAL (VERTICAL) SPLIT LINE LEAK TEST (4.3.3.3.1)
5.				MECHANICAL RUNNING TEST (COMPLETE UNIT) (4.3.3)	MECHANICAL RUNNING TEST (COMPLETE UNIT) (4.3.3)
6.				PERFORMANCE TEST (COMPLETE UNIT, WHEN SPECIFIED) (4.3.4.1)	PERFORMANCE TEST (COMPLETE UNIT, WHEN SPECIFIED) (4.3.4.1)
7.				MECHANICAL TEST OF THE SPARE ROTOR ASSEMBLY (4.3.3.4.3)	MECHANICAL TEST OF THE SPARE ROTOR ASSEMBLY (4.3.3.4.3)
8.				SENTINEL VALVE (2.3.2)	SENTINEL VALVE (2.3.2)
9.
10.
11.
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
12.				INSPECT BEARINGS (4.3.3.4.1)	INSPECT BEARINGS (4.3.3.4.1)
13.				INSPECT SHAFT SEALS	INSPECT SHAFT SEALS
14.				FLUSH PRESSURE CASING, SUPPLY AND DISCHARGE SECTIONS AND APPLY PRESERVATIVE (4.4.3.3)	FLUSH PRESSURE CASING, SUPPLY AND DISCHARGE SECTIONS AND APPLY PRESERVATIVE (4.4.3.3)
15.				FLUSH BEARING HOUSINGS AND APPLY PRESERVATIVE (4.4.3.4)	FLUSH BEARING HOUSINGS AND APPLY PRESERVATIVE (4.4.3.4)
16.				DRY OUT COOLING WATER PASSAGES AND APPLY PRESERVATIVE	DRY OUT COOLING WATER PASSAGES AND APPLY PRESERVATIVE
17.				MATCH MARK ALL MATING FLANGES	MATCH MARK ALL MATING FLANGES
18.				PAINT EXTERIOR NON-MACHINED SURFACES (4.4.3.1)	PAINT EXTERIOR NON-MACHINED SURFACES (4.4.3.1)
19.				COVER ALL OPENINGS WITH METAL CLOSURES (4.4.3.5)	COVER ALL OPENINGS WITH METAL CLOSURES (4.4.3.5)
20.				APPLY RUST PREVENTIVE TO EXTERIOR MACHINED PARTS (4.4.3.2)	APPLY RUST PREVENTIVE TO EXTERIOR MACHINED PARTS (4.4.3.2)
21.				VERIFY PROPER BRACING TO AVOID DAMAGE DURING SHIPPING (4.4.1)	VERIFY PROPER BRACING TO AVOID DAMAGE DURING SHIPPING (4.4.1)
22.
23.
24.
25.

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
1.				INSTRUCTION MANUAL INCLUDED WITH TURBINE
2.				PRESSURE RELIEF VALVE(S) CERTIFICATION
3.				HYDROTEST CERTIFICATIONS
4.				FINAL MECHANICAL INSPECTION RECORDS
5.				TEST PERFORMANCE CURVES
6.				AS-BUILT DATA SHEETS
7.				SPECIAL TOOL LIST (3.6)
8.				PRESERVATION, PACKING AND SHIPPING PROCEDURES
9.				COMPLETE SPARE PARTS LIST
10.				PICTORIAL RECORD SHOWING SHOP ASSEMBLY AND DISASSEMBLY SEQUENCES WITH 100 TO 200 PHOTOS EACH. THE PICTORIAL RECORD SHALL: IDENTIFY CREW SIZE (I.E. MANPOWER REQUIREMENT) SEQUENTIALLY TRACK THE TIME IT TAKES FOR EACH STEP TO BE COMPLETED TRACK TOTAL ELAPSED TIME SINCE COMMENCEMENT OF ASSEMBLY/DISASSEMBLY
11.
12.

EQUIPMENT ID	JOB NO.	DOCUMENT NO.	REV.

SUMMARY:

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