Guide for Source Inspection and Quality …

1 Guide for Source Inspection and Quality surveillance of Rotating Equipment Foreword This Guide has been developed to provide information for Source inspectors for the purpose of providing a consistent method of Supplier/Vendor (S/V) Quality surveillance for the oil, petrochemical and gas industries. It is intended as a resource for individuals studying to take the API Source Inspector Certification examination. Other references contained herein and in the published Body of Knowledge (BOK) will also be necessary for individuals to become familiar with in order to pass the examination and to perform satisfactorily in the Source Inspection job. This study Guide is also intended as a draft from which an API Recommended Practice for Source Inspection could eventually be formulated and published utilizing the ANSI standardization process. iii Table of Contents Scope/Purpose.

2 6 Introduction .. 7 References .. 7 Definitions, Abbreviations and Acronyms .. 8 Training .. 21 General .. 21 Source Inspection Management Program .. 21 Employers or Inspection Agencies .. 21 Source Inspection Management Programs .. 22 These Management Programs May Reference .. 22 Project Specific Source Inspection Planning Activities .. 22 General .. 22 Equipment Risk Assessment .. 23 Development of a Source Inspection Project Plan .. 24 Development of Inspection and Test Plans .. 24 Selection of an Inspector .. 24 Coordination of Inspection Events .. 25 Report Review .. 25 Source Inspection Performance .. 25 Inspector Conduct and 25 Review of Project Documents .. 25 Performing the Source Inspection .. 32 Source Inspection Work Process Scheduled Planning Events .. 32 Report Writing .. 33 Nonconformance/Deviations .. 34 Source Inspection Project Continuous Improvement.

3 35 Source Inspector Continuous Improvement .. 35 Examination Methods, Tools and Equipment .. 35 General .. 35 Review and Confirmation of Materials of Construction .. 36 Dimensional Inspections .. 37 Visual Inspections .. 38 Nondestructive Examination (NDE) Techniques .. 38 Destructive Testing .. 39 Pressure/Leak Testing .. 40 Performance/Functional Testing/Mechanical Run Test .. 41 Equipment Disassembly Inspection .. 42 Surface Preparation/Coatings Inspections .. 42 Final Acceptance .. 43 Prior to Final Acceptance of Rotating Equipment .. 43 Shipping Preparations .. 43 Reviewing Final S/V Data .. 43 Manufacturing and Fabrication Processes .. 44 General .. 44 Welding Processes and Welding Defects .. 44 Casting .. 45 Forging .. 45 Machining .. 46 Assembly .. 47 Metallurgy Issues Associated with Manufacturing and Fabrication Processes .. 47 250 to 1,000 Horsepower Pumps (Centrifugal Pumps).

4 48 General .. 48 Design and Construction Standards .. 51 Materials of Construction/Pump Components .. 51 Testing .. 60 Final Inspection .. 62 Drivers .. 63 General .. 63 Design and Construction Standards .. 63 Materials of Construction .. 63 Tests and Inspections .. 63 Final Inspection and Shipping Preparations .. 64 Gears: Reducers and Increasers .. 64 General .. 64 Design and Construction Standards .. 66 Materials of Construction .. 66 Internal Component Inspections .. 67 Testing of Gears Increasers and 67 Final Inspection and Shipment .. 68 General Purpose Turbines .. 68 General .. 68 Design and Construction Standards .. 69 Materials of Construction .. 70 Internal Component Inspections .. 72 Testing of Steam Turbine .. 72 Final Inspection .. 72 Lube Oil Systems .. 73 General .. 73 Design and Construction Standards .. 74 Materials of Construction.

5 74 Inspection and Testing of Lube Oil System .. 76 Final Inspection and shipment .. 77 Reciprocating Compressors .. 78 General .. 78 Design and Construction Standards .. 78 Materials of Construction .. 79 Internal Component Inspections .. 80 Testing of Reciprocating Compressors and Associated Equipment .. 81 Final Inspection and Preparation for Shipment .. 81 Rotary-Type Compressors .. 82 General .. 82 Design and Construction Standards .. 83 Materials of Construction .. 83 Internal Component Inspections .. 84 Testing of Rotary Screw Compressors and Associated Equipment .. 84 Final Inspection and Preparation for Shipment .. 85 Axial/Centrifugal Compressors .. 85 General .. 85 Design and Construction Standards .. 87 Materials of Construction .. 87 Component Inspection .. 88 Testing of Axial/Centrifugal Compressors .. 90 Final Inspection and Preparation for Shipment.

6 93 Guide for Source Inspection and Quality surveillance of Rotating Equipment Scope/Purpose This study Guide covers the process of providing Quality surveillance of materials, equipment and fabrications being supplied for use in the oil, petrochemical and gas Industry, including upstream, midstream and downstream segments. This Guide may be used as the basis for providing a systematic approach to risk-based Source Inspection in order to provide confidence that mechanical rotating equipment being purchased meet the minimum requirements as specified in the project documents and contractual agreements. The activities outlined in this study Guide do not intend to replace the manufacturer s own Quality system, but rather are meant to Guide Source inspectors acting on behalf of purchasers to determine whether manufacturers own Quality systems have functioned appropriately, such that the purchased equipment will meet contractual agreements.

7 This study Guide focuses primarily on Mechanical Rotating Equipment including but not limited to: pumps, gears, compressors, turbines, etc. and associated appurtenances. This document assumes that suppliers/vendors (S/V) have been pre-qualified by a systematic Quality review process of their facilities and Quality process to determine if the facility has the ability to meet the requirements of the contractual agreements. That process generally leads to a list of pre-approved S/V s deemed acceptable to the supply chain management of the purchaser and capable of meeting the requirements of the contract prior to it being placed. S/V s on such a list will normally have an acceptable Quality process already in place that meets the requirements of the contract. The purpose of Source Inspection in such a case is simply to verify that the S/V Quality process is working as it should and to verify that certain vital steps in the Inspection and test plan (ITP) have been satisfactorily accomplished prior to manufacturing completion and/or shipping.

8 The primary purpose of this study Guide is to assist candidates intending to take the API Source Inspection examination to become certified Source inspectors for mechanical rotating equipment. The study Guide outlines the fundamentals of Source Inspection and may be useful to all personnel conducting such activities to perform their jobs in a competent and ethical manner. For more information on how to apply for Source Inspection Certification, please visit API website at and follow the links as shown in chart below. The Source Inspector Examination contains 100 multiple-choice questions targeting core knowledge necessary to perform Source Inspection of mechanical rotating equipment. The focus of the exam is on Source Inspection issues and activities rather than design or engineering knowledge contained in the reference standards.

9 The exam is closed book and administered via computer based testing (CBT). The bulk of the questions address mechanical rotating equipment Inspection / surveillance which are typically known by persons who have experience working as Source inspectors or persons intending to work as Source inspectors who have studied the material in this study Guide and the associated reference materials. Study Guide for the Source Inspection of Rotating Equipment October 2015 Page 6 API website ( ) Certification Programs ICP Programs Source Inspector CertificationExam Introduction Like most business processes, the Source Inspection work process follows the Plan Do Check Act circular process first popularized in the 1950 s by Edward Deming. The Planning part of Source Inspection is covered in Sections 6 and 7 of this study Guide and involves the Source Inspection management systems, Source Inspection project plan and the Inspection and Test Plan (ITP).

10 The Doing part is covered in Sections 8 and 9 and involves implementing the ITP, participating in scheduled Source Inspection work process events, filing nonconformance reports and Source Inspection report writing. The Checking part, covered in Section , involves looking back at all the Source Inspection activities that occurred in the Planning and Doing segments to see what went well and what should be improved based on the results of that look-back. And finally the Act part (sometimes called the Adjust part) covered in Section involves implementing all the needed improvements in the Planning and Doing process before they are implemented on the next Source Inspection project. References The following standards or other recommended practices are referenced in this study Guide and are the documents from which the SI exam has been developed. API - American Petroleum Institute No.