BN-G-UP-202 Guide for Qualification of Inspection Personnel

Details: Last Updated: 17 September 2013

Table of Contents

Scope
General
Requirements
Qualifications
Education and Experience
Minimum Levels of Capability for Inspection Functions
Questionnaire for the Technical Interview of Inspection Candidates
Records
References
Attachments

1. Scope

This guide applies to every member of the Inspection Group and every assigned Inspection Engineer to a project or any other employee who will perform or assist in inspection, examination or testing duties during fabrication prior to receipt of item at the construction site, during construction on site. This guide does not apply to construction personnel.

The requirements of this guide are optional, at the discretion of the employer, for application to personnel who perform quality control/inspection.

This guide also provides requirements and guidance for the qualification of individuals (see paragraphs 3.0 and 4.0), who participate in an inspection, such as technical specialists, management representatives, and inspectors-in-training.

The requirements apply to personnel of Company equipment suppliers, outside testing agencies and consultants. The ASME Boiler and Pressure Vessel Code, as well as other ANSI Standards, have been considered in development of this guide which is intended to be compatible with their requirements.

This guide provides requirements and guidance for the qualification of an Inspection Engineer (see paragraph 7.0), who organizes and directs inspection work, reports inspection findings, and evaluates corrective action.

The suitability of an individual for the position of Inspector or Inspection Engineer will decide whether or not will be assigned on a project.

2. General

In the project execution the Project Manager has the overall responsibility for implementation of the applicable requirements of this guide. He may, however , delegate this work to the Project Engineering Manager, the Manager Inspection (Company administrative organization) or the Project Inspection Supervisor.

It is Company’s responsibility to assure that only those personnel within the respective departments who meet the requirements of this guide are permitted to perform inspection, examination, and testing activities covered by this guide that verify conformance to quality requirements.

The work of establishing selection and training practices and qualification procedures and of providing the resources in terms of personnel, equipment, and services necessary to implement the requirements of this guide, may be delegated to other qualified personnel. It is the responsibility of each department using authorized personnel to conform to the requirements of this guide.

It is the responsibility of the department performing these activities to specify the detailed methods and procedures for meeting the requirements of this guide.

Personnel selected for inspection, examination, and testing assignments shall have experience or training (see paragraph 7.0) commensurate with the scope, complexity, or special nature of the activities to be inspected. Inspectors shall have, or be given, appropriate training or orientation to develop their competence for performing required inspections. Competence of personnel for performance of the various inspection functions shall be developed by appropriate training methods.

3. Requirements

3.1 Planning

Plans shall be developed for staffing, indoctrination, and training of an adequate number of personnel to perform the required inspections, examinations and tests, shall reflect the schedule of project activity so as to allow adequate time for assignment or selection and training of the required personnel (reference 9.1).

3.1.1 Indoctrination

Previsions shall be made for the indoctrination of personnel as to the technical objectives of the project, the codes and standards that are to be used, and the quality assurance elements that are to be employed.

3.1.2 Training

The need for formal training programs shall be determined, and such training activities shall be conducted as required to qualify personnel who perform inspections, examinations, and testes. On-the-job participation shall also be included in the program, with emphasis on first-hand experience gained through actual performance of inspections, examinations, and testes. Records of training, when used as the basis for certification, shall be maintained (reference 9.1).

3.2 Determination of Initial Capability

The capabilities of a candidate for certification shall be initially determined by a suitable evaluation of the candidate’s education, experience, training, test results, or capability demonstration. The questionnaire (see Attachment 1 ) may be used for evaluation of the candidate’s technical know-how.

3.3 Performance Evaluation

The job performance of inspection, examination, and testing personnel shall be re-evaluated at yearly intervals (reference 9.2). Re-evaluation shall be by evidence of continued satisfactory performance or redetermination of capability in accordance with § 3.2.

If, during this evaluation or at any other time, it is determined by the responsible organization that the capabilities of an individual are not in accordance with the qualifications specified for the job, that person shall be removed from that activity until such time as the required capability has been demonstrated.

Any person who has not performed inspection, examination, and testing activities in his qualified area for a period of one year shall be re-evaluated by a redetermination of required capability accordance with § 3.2.

3.4 Written Certification of Qualification

The qualification of personnel shall be certified in writing in an appropriate form, including the following information:

(1) identification of person being certified. (2) level of capability. (3) activities certified to perform. (4) basis used for certification, including:: (a) records of education, experience, training and, verbal and written ability in the necessary language(s);
(b) test results, were applicable;
(c) results of capability demonstration.

(5) results of yearly evaluations.
(6) results of physical examinations, when required.
(7) signature of Company’s Manager of Inspection and Inspection Supervisor.
(8) date of certification and date of certification expiration.

3.5 Physical

Company shall identify any special physical characteristics needed in the performance of each activity. Personnel requiring these characteristics shall have them verified by examination at intervals not to exceed one year.

4. Qualifications

4.1 General

The requirements contained within this section define the minimum capabilities that qualify personnel to perform inspections, examinations, and tests which are within the scope of this guide.

There are three levels of qualification. The requirements for each level are not limiting with regard to organizational position of professional status, but rather, are limiting with regard to functional activities which are within the scope of this guide.

4.2 Level I - Personnel Capabilities

A level I person shall be capable of performing the inspections, examinations, and tests that are required to be performed in accordance with documented procedures and/or industry practices. The individual shall be familiar with the tools and equipment to be employed and

shall have demonstrated proficiency in their use. The individual shall also be capable of determining that the calibration status of inspection and measuring equipment is current, that the measuring and test equipment is proper condition for use, and that the inspection, examination, and test procedures are approved.

4.3 Level II - Personnel Capabilities

A level II person shall have all of the capabilities of a Level I person for the inspection, examination or test category or class in question. Additionally, a Level II person shall have demonstrated capabilities in interpreting codes and specifications, planning inspections, examinations, and tests; in setting up tests including preparation and setup of related equipment, as appropriate; in supervising or maintaining surveillance over the inspections, examinations, and tests; in supervising and certifying lower level personnel; in reporting inspection, examination, and testing results; and in evaluating the validity and acceptability of inspection, examination, and test results.

4.4 Level III - Personnel Capabilities

A level III person shall have all of the capabilities of a Level II person for the inspection, examination or test category or class in question. In addition, the individual shall also be capable of evaluating the adequacy of specific programs used to train and test inspection, examination, and test personnel whose qualifications are covered by this guide and be able to effectively coordinate with other Engineering disciplines in resolving problems.

5. Education and Experience

The following is the recommended personnel education and experience for each level. These education and experience recommendations shall be treated to recognize that other factors may provide reasonable assurance that a person can competently perform a particular task. Other factors which may demonstrate in a given job are previous performance or satisfactory completion of capability testing.

5.1 Level I

(1) Two years of related experience in equivalent inspection, examination, or testing activities, or
(2) MTS (ONC) degree and six months of related experience in equivalent inspection, examination, or testing activities, or
(3) HTS (HNC) degree in a related discipline plus three months of related experience in equivalent inspection, examination, or testing activities.

5.2 Level II

(1) One year of satisfactory performance as Level I in the corresponding inspection, examination, or test category or class, or
(2) MTS (ONC) degree plus three years of related experience in equivalent inspection, examination, or testing activities, or
(3) HTS (HNC) degree in a related discipline plus one year related experience in equivalent inspection, examination, or testing activities, or
(4) TH (MSc) degree plus six months of related experience in equivalent inspection, examination, or testing activities.

5.3 Level III

(1) Six years of satisfactory performance as a Level II in the corresponding inspection, examination, or test category or class, or
(2) MTS (ONC) degree plus ten years of related experience in equivalent inspection, examination, or testing activities; or MTS (ONC) degree plus eight years experience in equivalent inspection, examination, or testing activities, with at least two years as Level II, and with at least two years associated with refinery/chemical facilities - or if not, at least sufficient training to be acquainted with the relevant industrial quality assurance aspects.
(3) HTS (HNC) degree and seven years of related experience in equivalent inspection, examination, or testing activities, with at least two years of this experience associated with refinery/chemical facilities - or if not, at least sufficient training to be acquainted with the relevant industrial quality assurance aspects, or
(4) TH (Msc) degree plus five years of related experience in equivalent inspection, examination, or testing activities, with at least two years of this experience associated with refinery/chemical facilities - or if not, at least sufficient training to be acquainted with the relevant industrial quality assurance aspects.

6. Minimum Levels of Capability for Inspection Functions

Personnel who are assigned the responsibility and authority to perform functions covered by this guide shall have, as a minimum, the level of capability shown in this paragraph. When a single inspection or test requires implementation by a team or group, personnel not meeting the requirements of this guide may be used in data-taking assignments or in plant or equipment operation provided they are supervised or overseen by a qualified individual participating in the inspection, examination, or test.

		LEVEL
INSPECTION FUNCTION	L I	L II	L III
Recording inspection, examination, and testing data	X	X	X
Implementing inspection, examination, and testing procedures	X	X	X
Planning inspections, evaluations, and tests; setting up tests including preparation and setup of related equipment		X	X
Evaluating the validity and acceptability of inspection, examination, and testing results and correctly interpret codes and specifications		X	X
Reporting inspection, examination, and testing results		X	X
Supervising equivalent or lower level personnel		X	X
Qualifying lower level personnel		X	X
Evaluating the adequacy of specific programs used to train and test inspection, examination and testing personnel			X
Qualifying same level personnel			X

7. Questionnaire for the Technical Interview of Inspection Candidates

The questionnaire for the technical interview of inspection candidates (see Attachment 1) covers the following subjects:

A. Valves
B. Inspection of Base Materials
C. Inspection of Pipe Materials
D. Elbows-Fittings-Flanges
E. Welding
F. Pressure Vessels
G. Heat Exchangers
H. Hydrotesting
I. Non-destructive Testing
J. Pumps
K. Instrumentation (Later)
L. Electrical (Later)
M. Special Requirements

8. Records

A file of records of personnel qualification shall be established and maintained by the Department Head. Collection, storage, and control of records required by this guide shall be in accordance with Company QA Manual (QAM-021).

9. References

Document

	Number	Title	Level
9.1	CM-MA-800	Training	II
9.2	CM-MA-838	Performance Evaluation	II
9.3	BN-IN-001	Inspection Schedules - not available	III
9.4	ANSI/ASME N45.2.6-1978	Qualifications of Inspections Examination and Testing Personnel for Nuclear Power Plants	-

10. Attachments

1. Standard Questionnaire for the Technical Review of Inspection Candidates

Standard Questionnaire for The Technical Interview of Inspection Candidates

Index

A. Valves
B. Inspection of Base Materials
C. Inspection of Pipe Materials
D. Elbows-Fittings-Flanges
E. Welding
F. Pressure Vessels
G. Heat Exchangers
H. Hydrotesting
I. Non-Destructive Testing
J. Pumps
K. Instrumentation
L. Electrical
M. Special Requirements

A. Valves

1. Which type of valves do you know ?

gate valve
globe valve
ball valve
plug valve
check valve
motor operated valve
butterfly valves
twin seal valves
hammerblind valves
control valves (CV)

2. How are the following tests performed and what information do they provide ?

body pressure test
seat pressure test
backseat pressure test
high pressure closure test
functional tests
tests for remote controlled valves
tests for control valves (CV)

3. Which dimensions important for checking on valves ?

face-to-face dimensions
assembly height
rating of flanges
thickness of flanges
orientation of bolt holes
number and diameter of bolt holes
bolt hole circle
casing thickness
stem clearance (special requirement)
actuator size, type, air failure action, shut-off pressure (for CV)

4. What will you be looking for during visual inspection ?

valve casting (what defects are unacceptable?)
what is shrinkage?
valve type in full accordance with PO?
material identification
what for in case of cast steel valves
what for in case if valves fabricated by welding
valve function
speed of travel (for CV)

5. Could you say something about types of gaskets and required gasket faces finishes and stem packings?

CAF
spiral wound
all metal
stock finish
smooth finish
RMS
what types of packing for stuffing boxes

B. Inspection of Base Materials

What type of certificates are common in Europe?
Which European certificates are roughly equivalent to an American mill certificate?
Which type of European certificates is roughly equivalent to a certificate of conformity?
What shall be stated in a material certificate?
How are certificates identified against the material being inspected?

plate material
pipe material
forgings
castings

C. Inspection of Pipe Materials

What would you for during visual inspection of tubes and pipes?
identification
roundness weld bevel if ordered
surfaces inside and out
How would you check the wall thickness?
What do you know about eddy current testing?
What is, in your opinion, the main purpose of the hydrotest on mill fabricated tubing and piping?
What is, in your opinion, the best test to check tubing and piping for small leaks?

D. Elbow-Fittings-Flanges

Explain the difference between material certificates and fabricator’s certificates.
Does an elbow fabricator’s certificate give adequate proof that the material of final product is in accordance with what is required in the Purchase Order?
What are the critical dimensions on:

elbow (where would you check the wall thickness?)
flanges
tees
caps

4. Do you know various fabricating methods for:

elbows
flanges (forged, cast, plate)
nipples (forged or machined from stock)

5. Can you mention some of the defects specific for the above-mentioned fabrication methods?

E. Welding

1. What is the difference between

WPS
WPQ (PQR)
performance Qualification
production Welding Test Plate

2. Which are in Europe the most common Codes for testing, welding and welding procedures?

Stoomwezen
ASME
British Standard
TÜV

3. Could you identify some typical differences in these Codes. 4. Mention the tests mostly used in qualifying welding procedure qualifications and welder’s performance qualifications.

tensiles (two types)
bends (two types)
hardness
macro
X-ray
for testing hardness in the HAZ what would you choose: Poldi Hammer or Vickers?
what are the differences between transverse and longitudinal weld tensiles?
what are the differences between transverse and side weld bend tests?

5. If a piece of equipment is built, for example, to ASME and Stoomwezen requirements, is it necessary to duplicate specific tests, or can we, for example, use the tensile test from one qualify for the other code as well?

6. What are the often used welding processes?

OFW (gas welding)
SMAW (manual with coated electrodes)
SAW (automatic with flux)
(GMAW) (automatic with flux)
GTAW (TIG)
FCAW
PAW (plasma)
ESW (electroslag)
overlay welding
back cladding

7. What are the ASME welding position for

groove welds in plates (1G, 2G, 3G, 4G)
groove welds in pipes (1G, 2G, 5G, 6G)
fillet welds in plates (1F, 2F, 3F, 4F)
fillet welds in pipes (1F, 2F, 2FR, 4F, 5F)

8. What can you say about the limits of acceptability in accordance with the ASME Code, Stoomwezen, TÜV, British Standards for:

bend tests of welds
tensile tests of welds

9. What is the purpose of impact tests?

10. What type of impact tests do you know of, which ones give the more “average” values, which ones the more “localized” values?

key-hole groove
U-groove
Sharpy V-groove

11. What is important and must be watched during impact testing?

the type of specimen
the surface finish of the groove
the radius of the groove
the cross-sectional area of the specimen
the depth of the groove
the temperature of the specimen during testing
the calibration of the testing machine and thermometer
the positioning of the impact specimen on the machine
with cold specimen, the time interval between taking the specimen from the cooling bath, placing it on the impact machine and testing
checking the “free swing” of the machine

12. What various heat treatments do you know?

stress relief
normalizing
annealing
quench and temper

13. What do you look for when you check a heat treatment chart or heat treatment record?

heating up time
holding time
cooling down rate

14. If a piece of equipment is too large to place it completely in a furnace and the heat treatment is done in sections, what do you look out for?

15. What do you look for when checking heat treatment furnaces?

method of heating, maximum temperature fluctuations from “given” temperature
location and number of thermal couples
recording of temperature and calibration charts
calibration of recording instruments and thermocouples
uniform and smooth heating up and cooling down
cooling facilities

16. Mention the most important points to be watched when welding.

plain carbon steel over 30 mm thickness
low alloy carbon molybdenum and carbon manganese steels
ferritic high alloy chromium steel
austenitic high alloy chromium steel
low temperature high alloy nickel steel
welds between materials of different chemistry
under conditions of strain

17. What do you know about distortion and residual stresses?

are they related to one another?
what is their main cause?
what can we do in general to prevent them?

18. What do you look for when visually inspecting completed welds?

groove welds filling, “o” size of fillets
contour
undercut
starts and stops

19. Mention at least two reasons for the removal of a welder from the job.

missing performance qualification
invalid performance qualification (date, process)
repetition of welding defects

20. What do you know about the areas to be radiographed and the moment of testing for spot radiography ?

21. What is the difference between shrinkage and hot tears?

F. Pressure Vessels

1. Mention some specific points to be watched when assembling pressure vessels.

circumferential seams, heads to shells
longitudinal seams
skirt to shell attachments

2. What methods of attaching nozzles to pressure vessels do you know?

set on
set in
integral

3. What are the most important dimensions to be checked on the shell of a pressure vessel?

diameter
roundness
bow
length
wall thickness, shell plates, heads, knuckles

4. What are the most important checks , dimensionally, on nozzles?

orientation
elevation
stand-out
diameter
flange rating
flange bolt holes
flange facing
flange angulation
thickness of nozzle necks

5. State some critical dimensions for site erection.

the base ring or supports
nozzle pairs for instrumentation or for connecting up to other equipment
nozzle elevation, orientation, stand-out andangulation

6. What are the checks to be made on tray support rings and how would you make these?

elevation
levelness
flatness
welding
down-comer

G. Heat Exchangers

1. What type of heat exchangers do you know?

fixed tube sheet exchangers
U-type, loose bundle exchangers
floating type, loose bundle exchangers
reboiler type exchangers (Kettle type)

2. What do you check on tube sheets prior to tubing up? Give examples.

3. What do you check on tube sheets after the tube to tube sheet connections have been completed? Give examples.

4. Which points will get your attention when inspecting a completed loose bundle?

the tube to tube sheet connections
the baffle orientation, diameter and number of
tube sheet thickness, diameter, flatness, gasket faces
presence of impingement plates

5. What are important dimensions to check on a heat exchanger shell prior to bringing in the bundle?

inside diameter and roundness
the straightness
the nozzle dimensions in the case of stacked exchangers.

6. What do you check on “stacked” exchangers? Give examples.

7. How many pressure tests do you have in the following cases, with the tube side pressure above the shell side pressure?

heat exchanger with fixed welded on tube sheets
heat exchanger with a loose bundle with U-tubes
heat exchanger with a loose bundle with floating head

8. Mention some points which you would check when a stainless steel bellow is fitted into an exchanger shell.

circumference of welding joint
overlap internal sleeve
pre-tension

9. Is there any specific method for bolting up the flanges between the channels and the covers with shell of heat exchangers?

H. Hydrotesting

1. What do you look out for when witnessing hydrotests?

water temperature
position of the equipment, horizontal or vertical
supporting the equipment
bleeding the air from the equipment
location of the gauges
calibration of the gauges
removal of the connection between the pressurizing equipment and the unit under test
the chloride content of the water in the case of austenitic stainless steel equipment
anything to watch when leaving on the test pressure over longer periods, say 12 hours?
if a pressure recorder indicates a small but continuous pressure drop, can this be caused by temperature difference between day / night?

I. Non-Destructive Testing

1. Which points do you have to watch when witnessing dye penetrant testing ?

2. How can you check with magnetic particle testing that you have sufficient magnetic field within the area under examination ?

3. What should be the direction of magnetic field in relation to the defects to be expected ?

4. What type of defects do you expect to find with magnetic particle examination ?

5. Can you execute magnetic particle examination on all steels ?

6. When checking radiographs how do you check the quality of the film ?

density, contrast, definition
image quality indicator
scatter
projection, distortion

7. What exposure techniques are used to radiograph circumferential welds in pipes?

straight shot single wall technique
oval shot single wall technique
oval shot double wall technique
panoramic shot single wall technique

8. In case of 100% radiography, which technique would you prefer for:

2-inch pipe welds
4-inch pipe welds
6-inch pipe welds and over

9. Which type of image quality indicators do you know

10. What is the purpose of the image quality indicator ?

measure the quality of the radiograph as such
measure the thickness of the defect
indicate the seriousness of defects

11. What acceptance codes for RT do you know ?

12. Is the IIW collection of radiographs an acceptance code ?

13. What radiographic film types do you know ?

14. Do digital US wall thickness meters have to be frequently calibrated? Is this dependent upon material type ?

15. What is (as a guide) the minimum and what the maximum material thickness for ultrasonic and for radiographic testing ?

16. How could you check that an ultrasonic testing operator can be relied upon ?

17. Which data would you as a minimum expect to find in an US test report ?

part and location identification
material type and thickness
cross-sectional geometry
type of equipment and probes used
codes used
method of scanning, from one/two surfaces, from one/two sides on same surface, frequency, surfaces conditions
calibration means and settings
findings and diagnosis

18. Which data would you as a minimum expect to find in an RT Report ?

part and location identification
material type and thickness
exposure data
film/screen continuation
codes references
interpretation

19. What minimum data would you expect in NDT reports other than UT and RT?

20. What is the best moment and method of positive material identification?

J. Pumps

1. Mention some types of pumps

centrifugal pumps
positive displacement pumps
screw pumps

2. Mention some specific characteristics

suction pressure
discharge pressure
rated capacity
rated power consumption
rated efficiency

3. The specific gravity, of the liquid pumped, influences:
the differential pressure, rated capacity, the power consumption, the efficiency.

The viscosity influences:
differential pressure, rated capacity, power consumption, efficiency.

4. The maximum allowable casing pressure shall be greater than:

suction pressure
discharge pressure
differential pressure

5. Cavitation is caused by:

too high discharge pressure
too high suction pressure
too low discharge pressure
too low suction pressure
smooth impeller
rough impeller

6. What do the following abbreviations mean?:

NPSHA
NPSHR

7. NPSH changes with:

viscosity of liquid pumped
temperature of liquid pumped
vapor pressure of liquid pumped
condition of discharge piping
condition of suction piping
internal condition of pump
diameter of the impeller

8. NPSHA is measured

at top suction part of casing
at bottom of suction part of casing
at support level in suction line
at center of suction inlet

9. NPSHA is determined

by throttling discharge line
by throttling suction line
by spectacle blinds
by drawing from a special tank

10. How are the following characteristics determined?

flow
pressure
energy absorbed
energy given in liquid flow and pressure

11. What is critical speed?

12. A stiff rotor assembly has its first critical speed

below the operating range
within the operating range
above the operating range

13. Overhung horizontal pumps have the impellers

between bearings
outside the bearings
have flexible shafts
have stiff shafts

14. Pump vibrations is a matter of

rotor only
rotor and pump
rotor and pump and piping

15. Vibrations can be measured

on the shaft
on the bearing
in one, two or three directions?

16. What is meant by

mechanical run out
electrical run out

17. Wear rings

where are these located
what purpose do they serve
the hardness of both elements must differ or be the same?

18. Running clearances usually become larger or smaller in the following cases:

temperature rise
increase in viscosity
increased galling danger
“contaminated” fluids
diameter increase of rotating element
diameter increase of stationary element

19. Shaft sleeves

serve what purpose
are of what material type
how far do they have to extend?

20. Water injection into a stuffing box containing conventional packing serves:

to provide the sealing
to cool the packing

21. Liquid circulation in a mechanical seal serves:

to provide the sealing
to cool the seal

22. Pressure and Temperature rating of the seal piping shall at least equal those of

the maximum suction pressure
the maximum discharge pressure
the maximum differential pressure

23. Pressure at the seal surfaces shall be

above atmospheric pressure
protect pump against atmospheric pressure in case of stationary pump in vacuum service
above suction pressure in case of liquids near their boiling points

24. During following tests mechanical seals shall or shall not be used

hydrostatic test
performance test
mechanical running test

25. Points to be watched in case of conventional stuffing boxes/glands seals are:

number of packing rings and size
material of packing rings
presence of seal cage and connections
case of replacing packing
gland bolts

26. A running rotor may have a deflection from its center line. The maximum allowance deflection is related to which pump parts:

the wear rings
the seals
the seal bushings

27. Can a conventional seal be regarded as additional support for the shaft?

28. What are the main bearing types

radial bearings
thrust bearings
anti-friction
hydrodinamic?

29. What are “B-10 rating life” and “DN” factor of bearings?

30. Maximum allowable oil temperatures shall not exceed:

180°F on specific operating conditions
110°F on ambient operating conditions

31. What to check on bearing houses

sealed against water & dirt
drain plug provided
lubrication as per PO requirements and specifications?

32. Auxiliary Piping shall be checked for:

material
diameter and wall thickness
couplings and connections as ordered?
support
completeness and schematics
seal welding, if required, shall have a throat of minimum 9 mm and cover all threads
cleanliness

33. When does auxiliary piping have to comply with piping fabrication codes, and when to be hydro tested:

when inflammable and toxic
when subject to process fluid

34. How to repair casings in case of

small leaks in C. Steel
small leaks in high alloy
major repairs
what is a major repair?
peening or plastic fillers allowed?

35. How are materials certified and identified?

plain C. Steel casings
alloy casings
plate for welded casings
flanges for welded casings
shafts
impeller discs
what are optional requirements?

36. What should inspection of a completed pump casing consist of:

identification
surfaces inside and out
examination of “hidden” services
examination of machined surfaces
wall thicknesses at “critical” spots
cleanliness, especially at “hidden spots”

37. Welding on pump casings

what type of filler material
“mixed” welds allowed, yes/no
main nozzle welds must be full penetration, yes/no
piping attachments to the casing may or may not be of different composition as of the casing
piping attachments can or cannot be welded to the casing after PWHT?

38. Hydrostatic test pressures are for:

radial and axial split case pumps
barrel and multistage horizontal pumps
auxiliary equipment subject to process fluids
cooling systems

39. What to watch when witnessing hydrotests:

calibration of gauges
bleeding of air
surfaces coated, greased, oiled, painted
bolt holes
minimum time 30 minutes

40. What are the main check points when witnessing a shop performance test:

performance over full range
vibrations
bearing temperatures
cavitation and other noises

41. When does a performance test not have to be repeated?

K. Instrumentation

Later

L. Electrical