1、SGS Ref No.:14Rev.:0Page:1 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:18/03/04INSPECTION GUIDELINESRECIPROCATING COMPRESSORSFORGENERAL SERVICES0 For Approval 18/03/2004 J.C.Brotton B.Tremain B.Tremain June 2004Rev.Description Date Prepared Checked Approved DateSGS Ref N
2、o.:14Rev.:0Page:2 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:18/03/04CONTENTS1 PURPOSE2 SCOPE3 PROCEDURE4 DOCUMENTS5 INSPECTION PROCESS6 SHIPPING7RECIPROCATING COMPRESSORS DATADOSSIER8 INSPECTION CHECK LISTSGS Ref No.:14Rev.:0Page:3 of 9INSPECTION GUIDELINESRECIPROCATIN
3、GCOMPRESSORSFORGENERAL SERVICESDate:18/03/041.0 PURPOSE This instruction covers the inspection,test and verification activities required to validate thesupply,manufacture and test of a Reciprocating Compressor for general use.2.0 SCOPE This instruction covers all necessary stages in the production o
4、f the Reciprocating Compressorfrom the examination of certification from procurement sources to the final inspection,preservation and packing to despatch to site.Although the methodology in compiling this instruction is to systematically progress through theconstruction of a typical Reciprocating Co
5、mpressor.Experienced,inspectors may interpret theintent of the instruction to accommodate local or novel practices or to utilise the instruction for aone-off,or alternative design of compressor.The design having been approved by the client.Any such variations should be noted on the inspectors report
6、.3.0 PROCEDURE3.1 GENERALThis instruction together with the associated check sheet may be used on any contract or order.It is intended to act as a guide to the inspector in the course of the inspection programme.Anypart of the document may be invoked and the sections to be used and the level of insp
7、ectionrequired will be as specified on the check list.All tests and inspections will be carried out against the approved drawings,purchase orderspecifications,purchasers or company standards,and within the practices and rules of thecountry,state or province and any government decrees,laws,ordinance
8、or regulation as mayapply.If any conflict or contradictions should be apparent in any of the above then the more onerousrequirement will apply unless the purchaser or client directs otherwise in writing.3.2 REFERENCE DOCUMENTS Applicable codes and specifications.Design code(to be stated on inspectio
9、n report)Purchase order specification Purchasers standards Approved drawings SGS company standardsApplicable codes and standards(sample only)API 618 JIS B83414.0 DOCUMENTS TO BE RECEIVED/AVAILABLE AT INSPECTIONPurchase Order or ContractInspection and Test plansData sheetSub-assembly drawingsSGS Ref
10、No.:14Rev.:0Page:4 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:18/03/04Material test certificatesWeld procedures and Procedure Qualification RecordsList of qualified welders or welding operatorsWelders qualificationsCalibration of measuring and test equipmentNDE procedur
11、es,(appropriate to material of construction)List of qualified NDE operators/inspectorsNDE/inspectors qualificationsHydrostatic testing procedurePreparation and painting procedurePreservation,packing and shipping procedureSupply list(packing list)5.0 INSPECTION PROCESS5.1 MATERIAL5.1.1 REVIEW OF CERT
12、IFICATIONOriginal or authenticated copies of certificates should be available at the manufacturerspremises.These should be examined for compliance with specifications and where appropriate,drawings:The review will include checks on:-Manufacturers name and location Certificate No Material Specificati
13、on Heat or cast No Makers No or Plate No Chemical composition Mechanical properties Heat treated condition NDE applied and results Surface finish5.1.2 VISUAL AND DIMENSIONAL VERIFICATIONMaterial identification on certificates against product markings.Material supplied against drawing,material list a
14、nd specification as appropriate.Visual and dimensional compliance with specification.5.1.3 ADDITIONAL/SPECIAL REQUIREMENTSMay apply on special components.Check to ensure specification contract requirements havebeen met.Witness NDE examinations as necessary.5.1.4 REPORTINGReporting on the material ch
15、ecks should include:Conformation of satisfactory document review Record of endorsement of certification reviewed/witnessed Record of all non-conformities Record of any tests witnessed and the result SGS Ref No.:14Rev.:0Page:5 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:1
16、8/03/045.2 RECIPROCATING COMPRESSOR MANUFACTURE After clearance of the above points to the satisfaction of the inspector,the fabricator will proceedwith the manufacture of the sub assemblies and components for a reciprocating compressor.5.2.1 FABRICATION INSPECTIONFollowing the completion of welding
17、 and machining operations the compressor parts will beinspected as required by the specification or contract.The inspection will consist of:Visual inspection for damage Dimensional check to drawing requirement Inspection of parts,particularly cast in passages and piping for cleanliness Visual examin
18、ation of welded on connections Review of welder qualifications Review of weld procedure record Confirmation of satisfactory NDE5.2.2 HYDROSTATIC TESTSThe compressor and other pressure containing parts will be hydrostatically tested.The main items being:Cylinder Cooling Jackets Piping Pressure vessel
19、s Filters CoolersThe inspector must verify that the correct test pressure has been applied to the relevant partsdepending on specification requirements.5.2.3 PRESSURE TESTIn addition to the hydrostatic test it may be necessary to carry out a pressure test using heliumas the test medium.The inspector
20、 will:Witness pressure test as required Review test method to ensure it is acceptable to the code/specificationrequirement.5.2.4 ASSEMBLY INSPECTIONDuring compressor assembly and when required by the Purchase order or contract inspectionwill be carried out paying particular attention to the followin
21、g items:Piston end clearanceCrankshaft deflectionRun-out checkProper match markingProtection of machined surfacesSGS Ref No.:14Rev.:0Page:6 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:18/03/045.2.5 MECHANICAL RUNNING TESTCertain types of compressor may be subjected to a
22、mechanical running test.This particularlyapplies to skid mounted units.Where required by the purchase order the inspector will check forthe following attributes during the test period.Lubricating oil-temperature,pressure flow rate Cooling water-temperature,pressure flow rate Critical speed Bearing t
23、emperatures Vibration Gasket condition/leakage Proper operation of pressure relief valves speed governors and overspeedshutdown devices5.2.6 DISMANTLING INSPECTIONSome purchasers may require a strip down inspection after testing.Where there is aninspection the following points will be checked as a m
24、inimum:Visual condition of cylinder liner Surface condition of cross head guide piston rods and bearings Valve plates Valve springs Pistons5.2.7 FINAL VISUAL AND DIMENSIONAL INSPECTIONAfter completion of all manufacture and test the inspector will undertake final inspection of thecompressor paying p
25、articular attention to:Main dimensions to drawing requirements Skid dimensions Match marks for re-assembly Position of outside connection points Inspection of workmanship Direction of rotation marked correctly5.3 NAME PLATEContents to be checked in accordance with the approved drawings and specifica
26、tions andstamped/marked in accordance to clients requirements.5.4 PAINTING/COATING INSPECTIONSurface preparation for painting will be checked for the following attributes according to thespecification:Cleaning method Preparation grade Freedom from weld spatter,blow holes and other defects.Humidity a
27、nd Steel Temperature checks prior to painting Paint manufacture,type and colour of paint to clients specification Dry film paint thickness to be checked according to specification.SGS Ref No.:14Rev.:0Page:7 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:18/03/04 Painted sur
28、face condition to be free from pin-holes,runs,damage or otherdiscontinuity5.5 SPARE PARTS,LOOSE ITEMS AND ACCESSORIESSpare parts,loose items and accessories will be checked visually and for dimensions materials,workmanship and quantity according to purchase order specification test marks and tags wi
29、ll bechecked for correct identification.5.6 REPORT AND RELEASE5.6.1 REPORTINGA final report summarising the activities carried out will be issued in accordance with the contractrequirements and circulated within the time limits laid down in the contract.The report will be ina format approved by the
30、client and must clearly indicate the final acceptance or rejection of thepump.5.6.2 RELEASE NOTEWhere required by the contract a release document will be issued to the manufacturer when thepumps have been finally accepted.6.0 SHIPPING6.1 PREPARATION AND PACKINGThe following points must be checked:Al
31、l exterior machined surfaces must be coated with rust preventative All internal surfaces which are susceptible to corrosion must be coated with rustpreventative All flanged openings should be fitted with metal protectors in accordance withthe specification All threaded connections must be provided w
32、ith steel plugs Check manuals and instructions are included are included as the specificationrequirements Packing style and suitability for overseas shipment Shipping marks are correct Pre-assembled systems are marked as required by the specification7.0 RECIPROCATING COMPRESSORS DATA DOSSIER The fol
33、lowing final documents will be reviewed and endorsed as necessary.Manufacturers data reportsMaterial certificationDimensional recordNDE reportsHydrostatic test reportsPerformance test requirementsNPSH reportsRun-test reportsStrip down reportsFinal inspection reportMarkingsPacking listSGS Ref No.:14R
34、ev.:0Page:8 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:18/03/04Spare partsSGS Ref No.:14Rev.:0Page:9 of 9INSPECTION GUIDELINESRECIPROCATINGCOMPRESSORSFORGENERAL SERVICESDate:18/03/04 8.0 INSPECTION CHECK LISTINSPECTION CHECK LIST(1)VISUAL INSPECTION/WITNESSING BY BUYER
35、REPRESENTATIVE(2)CERTIFICATES/RECORDS TO BE CHECKED BY BUYER REPRESENTATIVE(3)CERTIFICATES/DATA TO BE PROVIDED BY VENDOR/SUPPLIER/MANUFACTURERPre-Fabrication/Production Requirements Specification Details/NotesPurchase Order RequirementsInspection&Test Plan(ITP)Approved Drawings P.W.H.T ProceduresWel
36、d Procedures Specification(WPS)&Procedure Qualification Records(PQR)Welder Qualification RecordsNDT Personnel Records and ProceduresCompressor Performance ProceduresIn-Process Inspection&Testing RequirementsMaterial Test Certificates&IdentificationCompressor Casing Inspection&Hydro TestComponents In
37、spection Prior to AssemblyHydrostatic Pressure TestsAssembly Inspection(Piping&Electrical)Mechanical Running TestDismantling Inspection(if specified by client)Visual&Dimensional InspectionElectric MotorSteam Turbine Drivers(if applicable)Diesel Engine(if applicable)InstrumentationFinal Inspection&Testing RequirementsVisual&Dimensional CheckNameplate&Identification MarkingPainting/Coating InspectionSpare Parts,Loose Items&AccessoriesShippingDocumentation PackageAdditional/Supplementary RequirementsPreparation&Packing
