f.sq-p-009 rev. 0 procedure for inspection of rotating equipment

8/19/2019 F.sq-p-009 Rev. 0 Procedure for Inspection of Rotating Equipment

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PROCEDURE FOR INSPECTION OF ROTATINGEQUIPMENT

DOCUMENT NUMBER REV DATE SHEET

F.SQ-P-009 0 26 Sep 2011 1 of 13

F.SQ-P-009 Rev. 0 Procedure For Inspection of Rotating Equipment.doc

PROCEDURE AUTHORIZATION

This procedure have been generated and implementedto identify the control that shall be applied by members ofstaff in the department when carrying out their duties

Department Authorization

Signed:

Date:

This confirms that this procedure has been approved forofficial issue and that members of staff shall complete thetasks assigned in accordance with the mechanismsdefined herein

Corporate Authorization(Company Director)

Signed:

Date:

The procedure forms part of a formal system within thecompany which ensure that this document is handled in acontrolled manner in accordance with documentedprocedures.

This procedure will be subject to audit as part of thecompany policy towards quality

Quality Authorization

Quality Manager

Signed:

Date:

PROCEDURE REVISION

Rev. Date Section Outline of Changed Authorization

0 26 Sep 2011 First Issue

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STATEMENT OF CONFIDENTIALITY

This procedure is for controlled circulation unless stamped "Uncontrolled Copy”. The documents orextracts from documents must nor be passed or copied to other companies, agents or persons without

the permission of the relevant Company Directors.


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TABLE OF CONTENT

Page

1.0 PURPOSE 3

2.0 SCOPE 3

3.0 DEFINITIONS 3

4.0 REFERENCES 4

4.1 GENERAL 4

4.2 TECHNICAL STANDARDS 4

5.0 RESPONSIBILITIES 4

6.0 PROCEDURES 5

6.1 INTRODUCTION 5

6.2 PRE-INSPECTION MEETING 5

6.3 DOCUMENT REVIEW 5

6.4 INSPECTION 6

6.5 HYDROSTATIC AND PERFORMANCE TEST 8

6.6 REPORT AND RECORDS 12

7.0 ATTACHMENT 12


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1.0 PURPOSE

a. The purpose of this document is to ensure that the rotating equipment is insafe condition, both prior to and during in service.

b. To provide guideline for surveyor to perform inspection, testing, reviewingand verifying of rotating equipment comply with quality requirements.

2.0 SCOPE

a. This procedure shall be applied for quality verification during design,

fabrication, installation, testing, and reporting of rotating equipment.

b. This procedure covers the minimum requirement of International Code orClient's requirement.

c. This is the Company approved procedure and shall be adhered to at alltimes except where Client or Contract Document specifies otherrequirement.

3.0 DEFINITIONS

a. Company - PT. Sertco Quality

b. Client - Those Companies, Organizations orIndividuals to which the Company iscontracted to provide services

c. Contract Document - The form of agreement for the provision ofthe Services to the Client by the Company

d. Services - All things provided under the ContractDocument including all activities to be carried

out by the Company for the Client

e. Line Management - Operation Director, Department Heads,Engineering

f. Manufacturer - The Company responsible for fabrication orPressure Vessel(s), either in its facilities or onsite

g. General Definitions - For the purpose of this procedure thedefinitions given in references referred toshall apply


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h. Surveyor - The personnel who perform the inspectionactivities under employed by company.

4.0 REFERENCES

4.1 GENERAL

This list of standards is provided for guidance only and is not intended to becomprehensive. It is included to assist the Inspector in selecting relevantsources of information where client's specific requirements do not exist.

4.2 GOVERNMENT REGULATION AND TECHNICAL STANDARDS

a. Undang Undang Republik Indonesia Nomor 22 Tahun 2001: MinyakDan Gas Bumi

b. Mijn Politie Reglement Sb.1930 No. 341: Peraturan KepolisianPertambangan

c. Peraturan Pemerintah Nomor 19 Tahun 1973: Pengaturan DanPengawasan Keselamatan Kerja Di Bidang Pertambangan

d. Peraturan Pemerintah Nomor 17 Tahun 1974: PengawasanPelaksanaan Eksplorasi Dan Eksploitasi Minyak dan Gas Bumi Di

Daerah Lepas Pantaie. Peraturan Pemerintah Nomor 11 Tahun 1979: Keselamatan Kerja Pada

Pemurnian Dan Pengolahan Minyak dan Gas Bumif. Peraturan Menteri Pertambangan dan Energi Nomor

06P/0746/M.PE/1991: Pemeriksaan Keselamatan Kerja Atas Instalasi,Peralatan Dan Teknik Yang Dipergunakan Dalam PertambanganMinyak Dan Gas Bumi Dan Pengusahaan Sumber Daya Panas Bumi

g. Keputusan Direktur Jenderal Minyak dan Gas Bumi No.84.K/38/DJM/1998: Pedoman Dan Tata Cara PemeriksaanKeselamatan Kerja Atas Instalasi, Peralatan, dan Teknik YangDipergunakan Dalam Usaha Pertambangan Minyak dan Gas Bumi Dan

Pengusahaan Sumber Daya Panas Bumih. API Std 610 : Centrifugal Pump for General Refinery Servicesi. API Std 613 : Special Purpose Gear Units for Refinery Services j. API Std 616 : Combustion Gas Turbines for General Refinery

Servicesk. API Std 617 : Centrifugal Compressors for General Refinery

Servicesl. API Std 670 : Vibration and Bearing Temperature Monitoring

Systems.m. API Std 671 : Couplingsn. ASME-PTC 10 : Power Test Code – Compressors and Exhausterso. ASME B16.5 : Pipe Flanges and Flanges Fittings


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p. NFPA 37 : Installation and Use of Stationary CombustionEngine and Gas Turbineq. NFPA 72 E : Automatic Fire Detectorr. I.E.C. 34 : International Standard for Rotating Electrical

Machiness. ANSI. C.50 : American National Standard for Rotating Electrical

Machineryt. NEMA - MG1 : Rotating Electrical Machines

5.0 RESPONSIBILITIES

a. The Company Management shall be responsible for ensuring that thenecessary resources are made available for the requirements of thisprocedure to be carried out in a safe manner

b. Line Management shall be responsible for ensuring that the requirements ofthis procedure are fully implemented at all times.

c. All employees involved in the implementation of this procedure shall beresponsible for adherence to the requirements stated within.

6.0 PROCEDURES

6.1 INTRODUCTION

The inspection services setup in this procedure is a general guidance thatshall be performed by the inspection personnel. The detail inspection andthe acceptance criteria shall refer to applicable code and standard used thatstated in contract document or client specification.

The inspection personnel shall be qualified by training and experience, suchpersonnel shall be capable of performing the inspection services mentionedbelow.

6.2 PRE-INSPECTION MEETING

Prior to manufacturing and installation of the rotating equipment take inplace, a pre-inspection meeting shall be hold, to setup an inspection andtest plan, getting information regarding to schedule of fabrication, and otherthings that necessary required in performing inspection. The pre-inspectionmeeting should be held between Company, Client and Manufacturer. If nosuch meeting held then requirement shall be established.

The inspection and test plan should contain item to be inspected andverified, which more detailed in section 6.4 Inspection below, acceptancecriteria, verifying document, verifying material, etc.


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The agreed inspection and test plan shall be as a reference of in performinginspection for all parties who involved in construction of Pressure Vessel.

6.3 DOCUMENT REVIEW

The Inspector assigned to this work must be provided with the following;

a. Client's purchase order and specification (if applicable);

b. Complete set of drawings approved by client;

c. Latest or specified edition of the relevant specification and standardmaterial specifications as required for the construction;

d. Confirmation that the client has approved drawings, test proceduresetc;

e. Review of test procedure and arrangements for witnessing ofperformance tests, also Operating Manual of the rotating equipment.Note:

Instances will arise when all of the above cannot be made available atthe time the order is assigned to an Inspector. The Inspector mustthen obtain the information from the Vendor and particular care mustbe taken that drawings/specifications are the latest editions and havebeen approved by the Client.

6.4 INSPECTION

6.4.1 Final and Surface Inspection Only

a. Internal Cleanliness

The Inspector should assure himself that the Vendor takes carethat all rotating equipment casings, bearing housings etc. arecompletely clean prior to assembly. Surfaces of castings mustbe completely free from molding sand, machinery swarf or anyother dirt.

b. Balancing

Balancing of the rotating components is always important andbecomes increasingly so as diameter, weight and runningspeed increase. The rotating equipment specification should be


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consulted to check whether static or dynamic balancing isrequired. The inspector should by observation, confirm that theVendor's standard practice conforms to the specificationrequirements.

c. Clearance

Does the Vendor have a satisfactory system for checking thatcorrect running clearances are achieved on assembly.

d. Performance Tests

Does the Vendor conscientiously carry our tests according toSpecification.

6.4.2 Visual and Dimensional Inspection

a. Painted Surfaces

Rotating Equipment casings and bearing housings that arcpainted before they are inspected are to be rejected. It ispossible, in priming a surface for painting, to deliberately cover

up casting defects. Hydrostatic and performance testing mustalways be completed prior to painting.

b. Visual Examination and Dimensional Check

The surface inspection should consist of a visual examination,check of overall dimensions, including location of mountingholes, flange drilling, flange thickness, facings, shaft height,shaft diameter etc. The casing should be examined, and if thecasing is not opened for internal examination, the inside of thesuction and discharge nozzles should be visually inspected to

ensure that they are smooth and free from any excrescencewhich would restrict flow. If the casing has vents and drains, theorder must be checked to see if they are authorized.

c. Flange Thickness

Some Vendors assign a rotating equipment case a series ofpressure ratings with the flange thickness and casing thicknessbeing based on the highest rating. When the casing is used fora lower rating the flange faces are drilled accordingly but theflange thickness is often left at their original thickness, thus theyare excessively thick. In the absence of an order limitation, thisextra thickness would not be considered a cause for rejection.


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d. Casing Thickness

When required by the order, the rotating equipment casingthickness should be measured at several points to establish thatthe nominal thickness is not under the minimum shown on therotating equipment manufacturer's drawings. These thicknesswould normally be obtained before the rotating equipment isassembled as only a limited amount of measuring can be donethrough open nozzles If the casing is open for this propose, aninternal surface examination should be made as described in

Para . It is the responsibility of the Manufacturer to specify thecasing thickness and furnish sketches showing actual readings,or a certification that thickness are as specified.

e. Oil Levels

Check that oil levels are clearly marked on bearing housingsexcept on rotating equipments which will have oil mistlubrication.

f. Nameplate

Data on the nameplate and nameplate material must conformwith all the requirements of the specification. If possible, thenameplate should be examined before mounting. Units must bethose specified in the order.

6.5 HYDROSTATIC AND PERFORMANCE TEST

6.5.1 Witnessed Hydrostatic Test

6.5.1.1 Casing

The casing surface should be examined as soon aspossible after full test pressure is applied and periodicallythrough the test period. The surface should be dry andfree from dirt, oil or grease.

All permanent connections, threaded into the casingproper, should be checked to see if they require sealwelding. Seal welds may leak on the first application ofpressure and require repair. If vent and drain connectionsare in, the purchase order should be checked to see ifthey are permitted the client should be contacted.


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The rotating equipment case should be hydrostaticallytested at the pressure given in the order, specification ordata sheet. If a case contains bowls.. such as in amultistage vertical rotating equipment, which develop adifferential head across them, the above mentionedhydrostatic test refers to the test on the outer case. Bowlsare tested out of the case. The maximum allowablecasing pressure should be used in computing the testpressure.

Check that calibration of pressure gauges. Ensure thatno air pockets exist before applying pressure. Thestuffing box must be tested with the casing. The casing issometimes hydro-tested after the rotating equipment isassembled. Unless specifically required in the order,mechanical seals should not be installed during hydro-test.

6.5.1.2 Pedestals etc.

Cooling passages and jackets for bearings, stuffingboxes, pedestals, etc. must be tested as required byspecification. These tests are only witnessed whenspecified on the Purchase Order/Data Sheets.

6.5.1.3 Duration of Test

Hydrostatic test pressure should be held for a minimumof 30 minutes unless otherwise specified or approved bythe client.

6.5.1.4 Auxiliary Equipment

The Inspector must ensure that all auxiliary equipment -coolers pipe work etc. included in the rotating equipmentsupply is hydro-statically tested as required by thespecification. These tests may or may not be required tobe witnessed dependant on the order requirements.

6.5.2 Performance test

The Inspector must clearly establish that the Vendor's testprocedure, and method of recording results will provide all the


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pipe work, valves etc. or from the shop test driver orcoupling.

A Vendor's claim that the excessive vibration woulddrop to an acceptable level if the rotating equipmenthad been property mounted, should not be acceptedunless it drops to an acceptable level whenremounted. Other problems causing high vibrationmust be corrected before the rotating equipment isreleased.

On rotating equipments fitted with anti-frictionbearings, readings should be made on the bearingshousings. An anti-friction bearing is one that containsrolling elements - balls or cylindrical rollers. When thebearing is in the motor on a vertical rotatingequipment, the vibration should be measured on therotating equipment frame adjacent to where to motoris bolted down. Shaft readings can be taken but it isstandard practice in the field to read on the bearinghousing. This picks up looseness in the bearing fit.

Vibration readings must be taken on the shaftadjacent to the bearing housing.

b. Bearing Check

If the bearings overheat, the cause should beinvestigated and corrected by the Manufacturer.Clients may specify varying acceptable maximumtemperatures for the shop test depending on theambient conditions of the site location. As a generalrule, if bearing housings become too hot to touch the

Inspector should check to see that specifiedtemperatures are not being exceeded.

c. Mechanical Shaft Seal

The Inspector should check that the seal circulationsystem used for the performance test with water is thesame as that required on site. If a flow restrictingorifice is required, check that it has not been omitted.

d. Stuffing Box Leakage

If the rotating equipment has a packed stuffing box,some leakage through the packing is necessary and


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normal. It lubricates the packing and also prevents itfrom over-heating.

e. Shaft Sleeve Leakage

Leakage between the shaft sleeve and shaft is notpermitted.

f. Distress

Any signs of distress, such as noise caused bycavitations or rubbing should be investigated and the

cause determined and corrected.

6.5.2.3 Hydraulic Performance

a. Data Recording

During the running, test data must be recordedthrough the operating range of the rotating equipment.Reading must be taken of capacity, brake horsepowerinput and speed.

For various reasons it may not be possible to carry

out the performance test at the correct rated speed.The Inspector must only accept such deviation whenapproval has been received from the client.

b. Performance Test Data and Curves

The Inspector must review the performance test dataand rotating equipment test curve to satisfy himselfthat the rotating equipment meets the requirements ofthe order. This applies for both witnessed and non-

witnessed performance test.

c. Alarm and Trip Operation

Large rotating equipments are usually provided withprotective alarm and/or trip devices and the operationof these should be simulated at the Vendor's works.

They may include:

Low inlet pressure

High discharge pressure

Excessive vibration High journal bearing temperature

High thrust bearing temperature


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F SQ-P-009 Rev 0 Procedure For Inspection of Rotating Equipment doc

Seal leakage etc.

6.6 REPORT AND RECORDS

During performing inspection, the inspection personnel shall makeinspection records use company standard form.

7.0 ATTACHMENTS

F.SQ-F-009.1 rev 0 Form for Pump Certificate of InspectionF.SQ-F-009.2 rev 0 Form for Compressor Certificate of Inspection

f.sq-p-009 rev. 0 procedure for inspection of rotating equipment

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