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.

2 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 .. 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.

3 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.

4 32 Report Writing .. 33 Nonconformance/Deviations .. 34 Source Inspection Project Continuous Improvement .. 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 .

5 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) .. 48 General.

6 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.

7 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 .. 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.

8 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.

9 87 Materials of Construction .. 87 Component Inspection .. 88 Testing of Axial/Centrifugal Compressors .. 90 Final Inspection and Preparation for Shipment .. 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.

10 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.