BN-G-UP-201 Guide for Vendor Inspection and Tests

Details: Last Updated: 17 September 2013

Purpose
General
Availability of Forms and Procedures
Basic Inspection Duties
Other Inspection Duties
Inspection Procedure - General
Welding
Non Destructive Testing
Hydrotest
Coating
Final Inspection
Static Process Equipment
Rotating Process Equipment.
Piping Fabrication and Valves
Structural Steel.
Electrical Equipment
Instruments
References

1.Purpose

The purpose of this guide is to inform the Inspector regarding the extent of his reporting in relation to the assigned inspection level for purchase orders and requisitions in general, and assist in the performed inspections and tests by giving guidelines and specific information per type of equipment and materials.

2. General

Company requisitions for materials and equipment are prepared by the engineering departments.

2.1 Based on the requisition, the purchase order and the available Vendor information, the Manager Inspection assigns the inspection level, and prepares the inspection schedule for the project. (See Reference 18.1)

2.2 This inspection schedule reflects all purchase orders for the project and its assigned inspection levels.

The inspection level shall be one of the following:

R - Resident Inspector

IPC - Close prgressive inspection

IP - Progressive inspection

F - Final inspection

N - No inspection

2.3 When necessary, the inspection level can be modified. This change can be initiated by the Inspector, the Manager Inspection or the Project Manager.

2.4 For all inspections the procedure for inspection activities shall be followed. See Reference 18.1.

2.5 The inspection level gives details regarding the scope of inspection. The following Table (2.6) is a guideline for the scope of inspection and the different reports in relation to the assigned inspection level. Regarding the levels and the timing of inspection the following should be considered:

R - Resident Inspection. All intermediate inspection steps shall be monitored closely for the duration of residence. Residence Inspection is implemented for the whole or only part of the manufacturing period, when required contractually or when in the opinion of the Manager Inspection:

- the workload in one location warrants it;
or when it is necessary to ensure specified quality requirements are met.

IPC - Close progressive inspection. Selected intermediate inspection steps shall be followed according to the inspection and test plan.

IP - Progressive inspection. Limited intermediate inspections shall be witnessed according to the inspection and test plan. Other inspection points will be monitored.

F - Final inspection. Only final inspection shall be carried out.

N - No inspections carried out.

2.6 Inspection Level and Required Reports

	Required reports	Form No.	R	IPC	IP	F
2.6.1	Inspection/Expediting Assignment	25013	*	*	*	*
2.6.2	Pre-inspection meeting	25009	*	*	*
2.6.3	Progressive inspection	25009	*	*	*
2.6.4	Final inspection	25009	*	*	*	*
2.6.5	Non Conformance Report	25010	*	*	*	*
2.6.6	Quality Control Memorandum	25012	*	*	*	*
2.6.7	Inspection Release Note	25011	*	*	*	*

Notes:

Inspection/Expediting Assignment is only used when an outside agency is employed.
A common form 25009 is used to report the various types of inspection visits to the Vendor, the section headings in the text being adjusted accordingly.
Each type of form used shall be numbered 001, 002 etc. per purchase order, the number being followed by the inspectors initials.

3. Availability of Forms and Procedures

All existing reports/forms and applicable procedures can be found in Reference 18.1.

Additional copies can be made available.

4. Basic Inspection Duties

Normal Q.C. (inspection) duties for projects are outlined in par.6, but will also include the following:

4.1 Check the Vendor's understanding of the Purchase Order requirements concerning materials, fabrication testing and inspection by the means of a pre-inspection meeting (See Reference 18.1)

4.2 Check if Vendor furnished documents according to requisition and procedures have been approved by Company Home Office.

4.3 Check, witness or monitor fabrication and testing according the inspection and test plan, in particular respecting holdpoints.

4.4 Check all relevant documentation such as certificates, test reports etc.

4.5 Check manufacturing data books.

4.6 In case of deviations contact the procurement and or engineering department(s) for formal decisions.

5. Other Inspection Duties

Inspectors will carry out surveys on Vendors' shops when required in order to determine Vendors' capabilities, experience and acceptability for work on Company projects, or re-surveys of Vendors shops if a considerable time has elapsed since the last experience with a particular shop.

This is one aspect of the overall assessment of Vendor capabilities and performance conducted by several Company departments. See Reference 18.2.

Inspectors will also continuously advise Company's Home Office on shop-loading developments in Vendors plants, trends in quality of workmanship, performance, etc. to assist buyers in selection of Vendors for new work.

6. Inspection Procedure - General

This section covers basic activities for inspection of all equipment, parts of equipment or parts of package units covered by Company purchase orders. Additional information regarding specific inspections can be found in the following sections, where possible requirements inspections and test are split up per type of equipment and materials.

It must be remembered that it is the Vendor himself who is in the first place responsible for the quality of his work using his own quality system. The inspector works through the Vendor system and would only assume a more pro-active role in case of necessity, and in agreement with the Manager Inspection.

Inspector’s visits to sub-Vendors shall only normally be carried out accompanied by a representative of the Vendor. The Inspector shall not give direct instructions to the sub-Vendor.

Each inspector has a personal rubber stamp with his name and boxes marked “witnessed” and “checked”. He shall use this on each quality record, ticking in one or other box, signing and dating it.

6.1 Acceptance Criteria/Governing Documents for Inspection

6.1.1 The basis of acceptance or rejection is defined by the purchase order requirements including the purchase order itself, the requisition, in combination with referenced codes, standards, specifications and drawings.

6.1.2 In case of contradiction in or incompleteness of the requirements, the inspector shall contact the Manager Inspection.

6.1.3 Vendors' shop drawings are only valid for details and dimensions not included in Company documents.

6.1.4 In the event of contradiction between Company and Vendor documents, Company documents govern unless specified by Company in writing.

6.1.5 Authority requirements shall prevail over Company general and project specifications, unless Company or project specifications are more stringent than the authority requirements.

6.2 Pre-Inspection Meeting (PIM) with Vendor

6.2.1 When applicable a complete review shall be made of the Purchase Order and its attachments, in order to confirm Vendor's proper understanding of all design, fabrication, inspection, and document requirements.

Every effort shall be made to eliminate questions in the earliest possible stage in the execution of the purchase order.

A PIM shall be held in accordance with reference 18.1, and reported on form 25009.

6.3 Material Delivered to Vendor's Shop

6.3.1 For major suborders the Inspector shall check in the first place that they have been placed with previously Company approved sub vendors. He shall then check that relevant requirements expressed in the Purchase Order have been mentioned on the sub-order. These could include:

Company Purchase Order number and item number
material specification and any special test requirements
certification requirements
critical minimum dimension
excess materials for tests
inclusion of clause concerning the Contractor's and Client's inspection rights
marking requirements

The Inspector will receive the relevant unpriced copies of suborders together with the Manager Inspection's recommendation for inspection coverage at source.

6.3.2 The type of materials shall be checked if required by PMI, marking of materials shall be identified against certificates as early as possible after arrival of materials at the Vendor's works.

6.3.3 The dimensions and appearance shall be checked, paying particular attention to:

critical minimum dimensions
radii of bending, forging and pressing on manufactured parts
fabrication and handling damage to surfaces and edges

6.3.4 The material certificates shall be legible and suitable for xerox copying and shall specify the test results in accordance with the specified material standard. Normal expected statements are the following:

name of manufacturer and factory symbol. (as on material)
purchase Order number and date of revision
manufacturer's order number
certificate registration number and date of issue
material specification
dimensions
quantity and/or weight in kg
surface examination statement
charge number, batch number or heat-lot number
chemical composition from test results
mechanical properties from test results
when applicable, NDT methods and results
when applicable, heat treatment procedure, furnace charge number and heat treatment records
signatories and function
supplementary or additional requirements as specified in the material specification, project specification purchase order as applicable.

Certificates checked and accepted by the Inspector shall be marked with his personal stamp and noted "checked" together with his signature and the date. Unless otherwise instructed the inspector shall only mark his stamp on the first page of the certificate.

6.4 Fabrication Procedures and Qualifications

6.4.1 The Inspector shall verify that all necessary approvals from Company's Home Office and Authorities have been obtained on Vendor furnished procedures and other documents. This can include the following:

vendor drawings/data sheets
welding procedures and qualifications
stress relief and other heat treatment procedures;
all forming operations, either hot or cold, on materials other than plain carbon steel
tube rolling procedures and rolling sequences
non-destructive testing procedures.

6.4.2 The Inspector shall ensure that welders are qualified to the used welding procedures and qualifications.

6.5 Intermediate Inspections

Basically all intermediate inspections either from Vendor, Company or Independent Authority are laid down in the inspection plan. The inspector shall incorporate the assigned inspection level when marking up the hold points in the inspection plan. The advised legend for marking up the inspection plan is as follows:

R - Review
W - Witnesses
H - Holdpoint

This legend can also be used when completing the inspection report.

Examples of hold points in the manufacturing stage are the following:

receipt material inspection;
location and dimensions of cut-outs before cutting;
fit-up of nozzles or other connections;
full dimensional and visual inspection before heat-treatment and/or pressure testing, including acceptance of NDE;
witness insert of bundle for heat-exchangers;
pressure testing; leak testing; PMI on final fabricated equipment and any other special NDE method;
shotblasting/coating/lining;
final inspection; manufacturing data book including shipping provisions or any other transport requirements;
witness transport and/or reloading of equipment.

Regarding possible holdpoints the next chapters (6.6 thru 6.16) give keywords as a reference for use during the inspections. For welding see Chapter 7.

6.6 Receipt Inspection

suborder
special tests
certification
minimum wall thickness
marking
storage

6.7 Location and Dimensions on Cut-outs

approved drawings
reference lines
shell course marking
hand or machine cutting
restamping material on cut-out for tests
weld configuration
template available
start points of cutting.

6.8 Fit-up of Nozzles/Shell Courses

applied welding procedure
proper grinding and cleaning
NDE for surface defects
NDE for weld edge (U.S.)
high-low
distortion prevented
orientation, elevation and stand-out
material for fit-up
cladding.

6.9 Dimensional and Visual Inspection

approved drawings
tolerances
level indicators; fixed tolerances
base plate template on jobsite required in advance
proper measuring equipment
PWHT to be carried out
field connections
flange facings and protection
internals to be installed
sharp edges on nozzles and clips
clip dimensions
trial fit up of vessels shipped in two or more parts for site welding
trial fit up of attachments (ladders; platforms etc.).

6.10 Insert of Bundle

dimensions of shell (straightness and ovality)
dimensions of bundle
proper tackwelding
number of baffle plates
dummy available
grease allowed
internal grinding
internal cleaning

6.11 Heat Treatment

procedure available
type of oven, fuel type, avoid direct flames
No. of thermocouple and temperature registration
calibration of used equipment
distortion prevented
method of support, expansion is approximately
CS 1,1 mm/m/100°C
SS 1,55 mm/m/100°C
sign of chart at start of cycle
heating up/cooling down rates
open oven at which temperature

6.12 Pressure Testing

Procedure available:
test medium, pressure and duration
flange facings check
used gaskets type
bolt tensioning equipment required
proper blinding off
correct bolts/nuts in relation to flanges
original bolts/nuts available
number of pressure gauges and correct ranges and calibration
correct venting
block valve
environment temperature
temperature of test medium
use of pressure recorder
method of support; position for testing
air test reinforcements
correct emptying (avoid vacuum!)
NDE after pressure testing.

6.13 Leak Testing

procedure available
equipment and calibration
work method
false indications
medium
acceptance criteria.

6.14 Positive Material Identification (PMI)

procedure available
Company standard specification
equipment available
detection ranges and identified elements
incoming materials and final product
welds to be checked/electrodes
cladding restoring.

6.15 Shotblasting/Coating/Lining

testing methods for profile
coating manufacturer data sheets
environmental conditions (temperature, dewpoint
coating thickness (wet, dry)
recoating time (curing of zinc silicates)
corners etc. not reached with shotblasting
sparktesting of lining (general rule = 9 Volts/micron).

6.16 Final Inspection

manufacturing Data Book, early list of contents
check Vendor furnished documents list and/or job specification for total contents
packing/marking/shipping instructions
internal cleanliness
anti-corrosion measures (silica gel, nitrogen purge etc.)
flange protection
marking of "North" line or arrow
marking of "Centre of Gravity" (COG)
method of lifting (slings or chains etc.)
method of transport
inform Company traffic department and/or jobsite.

7. Welding

When welding is involved on materials or equipment the following topics have to be taken into account:

code or non-code items
specifications with additional requirements to code
availability of WPS and PQR or requalify?
welder and welding operator qualifications
materials
weldability
thickness
post weld heat treatment and/or soaking
welding processes
cladding
joining unequal materials
vendor experience with welding process
in or outdoor welding
welding consumable handling
environmental conditions (temperature; humidity)
cutting process
pre-heating
proposed non-destructive examinations
weld configurations
fit-up materials
distortion prevention
dimensional control.
· REQUIRED WELD TEST PLATES + PWHT + TESTING !!

7.1 Basically the requisition and/or job specifications are the documents where the requirements for welding are laid down. For code items Company will normally require that the Vendor transmits the Welding Procedure Specification (WPS) and the applicable Procedure Qualification Record (PQR).

Note:

WPS - Weld configuration + position + consumable + equipment etc. as proposed for welding.

PQR - Record of tests done to prove WPS meets code requirements.

The WPS/PQR will be reviewed by Company Home Office using the same system as for drawings.

7.2 Review Codes

F - Final approved

1 - Approved without comments
2 - Approved with comments (production may start when comments are incorporated)
3 - Not approved (resubmit before start production).

7.3 It should be noted that sometimes Vendors do not have the required PQR to cover the proposed WPS and propose to qualify the WPS on a weld coupon which is attached to the longitudinal seam.

7.4 It is always the duty of Inspector to check whether welders are qualified in accordance with approved procedures (validity qualification records).>

7.5 Except when otherwise stated in the job specifications Company Inspectors do not normally witness welding tests. It is the sole responsibility of the Vendors and the applicable authorities.

7.6 It is the duty of the Inspector to ensure that all welding procedures and their qualifications are strictly adhered to by the Vendor. Note changes in geometry, position and welding process or consumable. For example: a Vendor had his WPS/PQR. approved for the welding of circumferential seams using SAW in 1 G position (on rollers), but is in fact welding with SMAW (hand electrode) in the 2 G position (side). The applicable WPS/PQR should be transmitted to the Company home office, and if necessary be requalified in accordance with the required code.

In the following chapters some keywords are given per subject related to welding in general.

7.7 Fit-up for Welding

reference lines for dimensional control
joint alignment; high/low
root gaps
shrinkage (= +/- rootgap)
fit up material
tackwelds in bevel or external (bridge plates)
removal of backwelds
NDE of tackwelds
pre-heating for tackwelds thick materials.

7.8 Distortion Prevention

proper stiffening/supporting by spiders, strongbacks etc.
number of passes
symmetrical welding
backwelding
pre-setting to reach desired dimension after shrinkage
large + heavy nozzle on edge of plate
large + heavy nozzle in relatively thin shell plate.

7.9 Pre-heating

flame cutting on air hardening materials
used method - electric or gas
area of pre-heating
heating up time
minimum and maximum pre-heat temperature
minimum interpass temperature
cooling method (environment)
method of checking temperature.

7.10 Visual Weld Examination

porosity
starts/stops
old tackwelds
unequal a-height
incomplete filling
overfilling
run out length
weld spatter
cracks
weld cap finish
weaving (max. 2,5 x d electr.)
arc - strikes
marks from lifting clamps.

7.11 Joints in Clad Material

approved welding procedure and qualification
bonding of clad material
sufficient cut away of cladding
transition electrode type
clad restoring
surface finish
PMI on electrodes
possible NDE (transition of U/S waves causing misinterpretations).

7.12 Post Weld Heat-Treatment

type of heat-treatment
min/max temperature for material according to specification
Method of support
CS: elongation = 1,1 mm/100°C
SS: elongation = 1,6 mm/100°C
visual and dimensional already 100% accepted
type of oven
max. temperature variation through whole oven
type of fuel and availability
position of burners
calibrated thermocouples and recorder
method of attaching thermocouples
minimum:
1 x on thickest piece
1 x on thinnest piece
1 x on test plate
1 x extra
hand or remote controlled oven
oxidation of materials
any stiffening required
heating up time/holding temperature/cooling down time
complete recording chart available ( mind the scales )
re-check critical dimensions after PWHT.

7.13 Welding Consumables

acceptable list applicable (controlas etc.)
storage
handling procedure
quivers required
holding ovens
special electrodes for project.

8. Non Destructive Testing

separate procedure required
acceptance criteria
type of ndt possible
qualification of operators
subcontracted NDT
NDT after visual acceptance of welds
minimum "setting time" after last welding before NDT
PWHT involved or not
any NDT specified after pressure testing
are all welds accessible after fabrication
up to date NDT lists
own qualified film interpreters or rely on Vendor’s.

9. Hydrotest

Regarding the hydrotest, the following topics have to be considered:

hydrotest procedure available/required
all NDE completed
visual and dimensional acceptable
method of support
testing liquid temperature
testing liquid contamination (chlorides stainless steel)
correct gaskets installed (hydrotest gaskets or specified type)
bolt tensioning equipment required/applied
correct bolting in relation to flanges (DIN flanges with DIN bolting as they are less stiff than ANSI flanges)
airpockets prevented
correct calibrated pressure gauges and ranges
minimum 2 pressure gauges
pressure recorder required (calibration)
block valve between pump and vessel
first pressurise to operating pressure then after setting rise to hydrotest pressure
test pressure and minimum holding time
pressure difference in two or more compartments
during testing note any deformation
proper venting after test (vacuum!)
drying and cleaning
any NDE specified after hydrotest.

10. Coating

Regarding coating and lining following topics should be considered.

10.1 General

coating system according to requisition/specification
in-house or subcontracted
approved manufacturers of paint
coating procedure necessary
applicable data sheets available
maximum operating temperature of equipment in relation to maximum temperature allowable for paint
approved coating system on drawings
all NDE/PWHT etc. carried out
visual and dimensional accepted
corners rounded off.

10.2 Shot-Blasting

type of grit in relation to material or equipment
type of grit in relation to required blasting profile
method of checking blasting profile
cleanliness of blasting (SA 2; 2-1/2; etc.) standard on site.
temperature of surface minimum 5 degrees above dewpoint
grit recycled or not (mean particle size)
flange facings suitably protected
method of support.

10.3 Coating Application

correct equipment/nozzle type
all dust from shotblasting removed
coating consistency
coating contamination
maximum wet film thickness applied (drips, sags)
pre strike difficult areas
overspraying time
temperature of surface.

10.4 Coating Inspection

calibrated coating thickness equipment
uniform application
proper illumination
check minimum 5 points per square metre
drips/sags/holidays
intermediate thickness
total thickness.

10.5 Lining and Lining Inspection

applicable specification
applicable procedure
corner rounded off (min: r = 3 mm)
manufacturer’s data sheets available
minimum surface temperature
method of application
check thickness with calibrated equipment
spark testing minimum voltage = 9V per micron when no spec. etc. available
repair procedure

11. Final Inspection

nameplate
as built drawing available
all possible deficiencies cleared
flange facings re-check
packing/marking/shipping and invoicing instructions for project issued and complied with
all drawings final approved
all calculations final approved
all procedures final approved
transport drawings approved
transport/lifting marks on equipment
spare parts and interchangeability records and/or cards filled in and transmitted to Company Home Office
any other outstanding documents according to vendor furnished documents list from requisition
traffic department informed
expediting department informed
site informed.

12. Static Process Equipment

12.1 Pressure Vessels

12.1.1 Specified code to be applied.

12.1.2 Check requisitions for:

applicable code(s) and additional requirements
used materials and certification
welding procedures and qualifications
dimensional tolerances
non destructive examinations
post weld heat treatment
authority inspection
pressure testing
surface preparation
service conditions

12.1.3 Points of specific importance during fabrication:

skirt-head connections
reinforcement plates
clips and supports
level and indicators etc.
weld test plates
rounding off nozzles internally
insulation rings
davits
aligning of internals (tray support rings)
welds in heads
flange facings
marking of tangent-line ( in- and outside )
base ring template required?
saddle fixed and sliding point
positive material identification
internal dimensional control " straightness
O- thickness measurements.

12.2 Heat Exchangers

Shell and tube-exchangers, double pipe exchangers.

12.2.1 Specified code to be applied.

12.2.2 Check requisitions for:

applicable code (s) and additional requirements
used materials and certification
welding procedures and qualifications
dimensional tolerances
non-destructive examinations
post-weld heat treatment
authority inspection
pressure testing
surface preparation and or lining
service conditions

12.2.3 Points of specific importance during fabrication:

tube to tube-sheet connections
reinforcing plates
dimensional control of bundle
tackwelds and tie-rods
check tie-rods for intermediate welds ( if so:NDE )
bundle dummy
rounding off nozzles internally
ovality of shell
jack-bolts
pulling of bundle
lifting of bundle
impingement plates
partition plate welding
weld test plates
drilling of tubesheets
dimensions stacked exchangers
expanding percentage
welding and rolling or rolling and welding
internal sealing strips for longitudinal baffle type exchangers
flange facings
positive material identification.

12.3 Airfin Coolers

Airfin coolers with headers of various designs such as plugged with loose covers fully enclosed, welded headers, cast headers with various air control systems etc.

12.3.1 Specified national/international specifications to be applied.

12.3.2 Check requisitions for:

applicable codes and additional requirements
used materials and certification
welding procedures and qualifications
dimensional tolerances
fin type and manufacturing (tightness and length)
non-destructive examinations
post weld heat treatment
authority inspection
pressure testing
surface preparation and coating
service conditions.

12.3.3 Points of specific importance during fabrication:

tube to tubesheet connections
welding and rolling or rolling and welding
drilling of tubesheet
expanding " access for NDE
plug type material and plug hole type
restamping of tubes (prior to finning)
prevent fin damage
for structural steel see separate section 15.0
fit-up of header boxes
welding sequence of header boxes
positive material identification
O measurements
grooving of fin to end 15 mm after tubesheet
gasket surface finish for cover type header boxes
fabrication of swaged nozzles.

12.4 Heaters

Fired heaters for refinery service.

12.4.1 Specified national/international specification to be applied.

12.4.2 Check requisition for:

applicable code(s) and additional requirements
used materials and certification
welding procedures and qualification
dimensional tolerances
non destructive examination (castings)
post weld heat treatment
authority inspection
lining requirements
pressure testing
surface preparation
fin type (studs)
service conditions.

12.4.3 Points of specific importance during fabrication:

welding of hairpins and pipes
restamping of pipes
postweld heat treatment, supports etc
casting technology and pilot castings
positive material identification
RT acceptance criteria.

Note: for structural steel see section 15.0

12.5 Atmospheric Tanks

Shop and Field fabricated with fixed roof, floating roof etc.

12.5.1 Specified national/international code to be applied.

12.5.2 Check requisitions for:

applicable code(s) and additional requirements
used materials and certification
welding procedures and qualifications
dimensional tolerances
authority inspection
non destructive examination
pressure testing procedure
surface preparation
service conditions.

12.5.3 Points of specific importance during fabrication (for sake of completeness site erection points included):

soil survey
soil consistency
welding sequences
lining " continuous dimensional survey(s) due to settlements
automated RT examination
fire monitoring system(s)
seal for floating roof
internal pipes and supports (heaters)
trial assemblies
gasket surfaces/flange facings
internal hoses for draining (roof)
skimmers applicable or not
floor configuration (cone-down; cone-up; slope)
any fixing with anchor bolts
clips and structural steel.
For structural steel see section 15.

12.6 Trays

Trays for site and for shop installation in pressure vessels, reactors etc.

12.6.1 National/international specifications - not applicable.

Manufacturers' standards, e.g. Koch, Glitsch Metawa.

12.6.2 Check requisition for:

used materials and certification
welding procedures and qualifications
dimensional tolerances
non-destructive examinations
surface preparation such as; (pickling, passivating etc)
installation procedure
hold down clamps etc
filling of loose internals such as balls, catalyst etc
service conditions.

12.6.3 Points of specific importance during fabrication and /or installation:

dimensional control (especially flatness)
trial assembly
tray holes, bubble caps, chimneys
overlapping edges
downcomers
bolting down devices
marking of tray numbers
contamination with other materials
positive material examination
gaskets between tray and support rings
installation through manhole possible
spargers.

13. Rotating Process Equipment

13.1 Centrifugal Pumps

Single and Multistage.

13.1.1 Specified national/international specification to be applied.

13.1.2 Check requisitions for:

applicable code(s) and additional requirements
used materials and certification
any welding involved
dimensional tolerances
seal system
accessories
used driver
baseplate type
NPSH and performances
service condition.

13.1.3 Point of specific importance during fabrication:

balancing of impeller(s)
dimensional control
installation of seal(s)
flange facings finish
testing procedure
positive material identification
non destructive examination results
repairs carried out
hydrotest procedure and liquid type
head/flow testcurve from water calculated to specified liquid
aligning pump and driver on base plate
protection of couplings etc (coupling guard)
grouting of baseplate on site involved
vibration measurements
flange facings.

13.2 Screw Pumps

13.2.1 Specified national/ nternational specification to be applied.

13.2.2 Check Requisitions for:

applicable code(s) and additional requirements
used materials and certification
any welding involved
dimensional tolerances
seal system
accessories
used driver
baseplate type
performance and other testing requirements
service conditions.

13.2.3 Points of specific importance during fabrication:

welding of casing
machining
dimensional control
seal installation
testing procedure
non destructive examination (access!)
aligning pump and driver on baseplate
baseplate grouting involved on site
coupling guards
testcurve from water calculated to specified liquid
state and/or dynamic balancing
vibration measurements
flange facings.

13.3 Centrifugal Compressors

Single and Multistage.

13.3.1 Specified national/international specification to be applied.

13.3.2 Check requisition for:

applicable code(s) and additional requirements
used materials and certification
any welding involved
dimensional tolerances
seal system
driver
testing requirements
seal system
accessories
baseplate type
casting requirements
service conditions.

13.3.3 Points of specific importance during fabrication:

welding and/or repair by welding
casting
static and/or dynamic balancing
pressure test requirements
non-destructive examination
aligning compressor and driver on baseplate
grouting of baseplate involved on site
coupling guards etc.
positive material identification
testing procedure for impellers overspeed etc
record of clearances
shop/performance/string test
vibration measurements
internal examination after
flange facings.

13.4 Reciprocating Compressors

13.4.1 Specified national/international specification to be applied.

13.4.2 Check requisition for:

applicable code(s) and additional requirements
used materials and certification
any welding involved
dimensional tolerances
driver
seal system
testing requirements
seal system
accessories
base plate
service conditions.

13.4.3 Points of specific importance during fabrication:

welding and /or repair by welding
casting
static and/or dynamic balancing
pressure testing
non-destructive examination
grouting involved on site
coupling guards
positive material identification
performance testing procedure
alignment of crank shaft
other alignments driver/compressor etc.
stripping test
flange facings
"rod run-out" prior to test run.

13.5 Steam/Gas Turbines

13.5.1 Specified National/International Specification to be Applied.

13.5.2 Check requisition for:

applicable code(s) and requirements
used materials and certification
any welding involved
dimensional tolerances
used as driver for:
seal systems
testing requirements
accessories
baseplate
service conditions.

13.5.3 Points of specific importance during fabrication:

welding and/or repair by welding
casting
static and/or dynamic balancing
pressure testing
non-destructive examination(s)
performance testing procedure
dimensional control/clearances
alignments
stripping test
installation of rotor
vibration measurements
complete testing procedures:

14. Piping Fabrication and Valves

14.1 Pipespools

14.1.1 Specified national/international code shall be applied.

14.1.2 Check Requisitions for:

applicable code(s) and additional requirements
used materials and certification
welding procedures and qualifications
dimensional tolerances
non destructive examination
post weld heat treatment
pressure testing
surface preparation
authority inspection
service conditions

14.1.3 Points of specific importance during fabrication:

fit up materials
compliance with welding procedures
marking, restamping authority
keep iso's up to date
maintain traceability
tracking of NDT records
marking of fieldwelds
welding of branch fittings and correct fit up
flange facing protection
O-thickness measurements
threaded connections
positive material identification:

14.2 Piping Materials

Pipe, fittings, flanges, O-lets, bolts, nuts.

14.2.1 Check requisition for:

applicable code and/or specification and additional requirements
non destructive examination
welding involved
heat treatments
hardstamping requirements
dimensional tolerances
service conditions.

14.2.2 Other important notes:

approved manufacturers involved to meet code or authority requirements
O-lets manufactured in accordance with approved drawings
tolerances.

14.3 Valves

Gate, Globe, Check, Butterfly etc.

14.3.1 Specified national/international specifications shall be applied.

14.3.2 Check Requisitions for:

applicable codes and additional requirements
material and certification
welding involved/casting involved
non-destructive examination tolerances
special packing materials
flange facing finish
special testing requirements
positive material examination
any auxiliaries
service conditions.

14.3.3 Points of specific importance during fabrication:

material marking/tracebility
testing procedure
control valve settings
pilot castings.

15. Structural Steel

15.1 Specified national/international specification shall be applied.

15.1.1 Check requisition for:

applicable code(s) and additional requirements
materials and certification
welding procedures/qualifications
non destructive examination
tolerances
service conditions.

15.1.2 Points of specific importance during fabrication:

keep track of all activities
(any partial subcontracting for ladders, handrailing etc.)
compliance with welding procedures
mind large size trusses; nodes (lifting eye etc)
inspection per defined lot (shipping lists etc) which is required also for next activities such as galvanising and then arrival at site.

16. Electrical Equipment

16.1 Electric Motors

Three phase, squirrel cage, induction type.

16.1.1 Specified national/international specification shall be applied.

16.1.2 Check requisitions for:

applicable code(s) and additional requirements
used materials and certification
classification zone
approved manufacturers
specified tests
service conditions
accessories.

16.1.3 Points of specific importance during fabrication/testing:

winding resistance (temperature)
insulation resistance
bearings
vibration tests
high voltage test
performance test efficiency/power factor/slip

Note: when Cos ø< 0.8 always contact Home Office Engineer

thermal constant time (Te time)
running up time (Art)
pull-up torque
rotor inertia (GD²)
cooling fan material
motor enclosure
certification (validity)
test of windings
terminal box (location and classification).

16.2 Generators

AC 3 phase, air cooled, rotating.

16.2.1 Specified national/international specification shall be applied.

16.2.2 Check requisitions for:

used materials and certification
service conditions
power factor/voltage/frequency
accessories (heater, cooling system)
bearings.

16.2.3 Points of specific importance during fabrication and testing:

temperature rise of stator winding
cooling air temperature
efficiency
momentary excess current
overload
short circuit requirements
voltage variations during operation
unbalanced loads
wave form
overspeed
subtransient reactance
noise level
vibration
critical speeds
rating plate
testing procedure.

16.3 Transformers

Single phase/three phase power and distribution transformers:

up to 100 KVA
· above 100 KVA.

16.3.1 Specified national/international specification shall be applied.

16.3.2 Check requisition for:

applicable code(s) and/or additional requirements
used materials and certification
classification
approved manufacturers
specified tests.

16.3.3 Points of specific importance during fabrication and/or during fabrication:

full load test for temp, rise of oil 14 quid and HV ILV windings
separate source voltage tests
overvoltage test (+ increased frequency)
no load test
winding transformation and polarity test
calculation of impedance voltage
calculation of iron losses
calculation of copper losses
calculation of efficiency
short circuit impedance
dielectric strength of oil or synthetic liquid in transformer
earthing.

16.4 Switchgear Switchgear for use in distribution of electrical energy:

low voltage switchgear
high voltage switchgear

16.4.1 Specified national/international specification shall be applied.

16.4.2 Check requisitions for:

specified materials and certification
approved manufacturers of components
service conditions.

16.4.3 Points of specific importance during fabrication and/or testing:

testing procedure
circuit breakers
protective relays
current and voltage transformers
fuses
draw-out units
metering devices
inspection of busbars and earthbars, size, connections and hole sizes
marking of components (busbars, terminals etc)
dielectric test
insulation resistance test
mechanical interlocks (doors etc)
mechanical and electrical operation test
interchangeability of components
high voltage test for main circuits; control and auxiliary circuits/secondary circuits
insulation resistance test
grounding continuity test for metal parts of switchboard to main earth bar and switching devices/busbar chambers to main earth bar.
shutters test
operation test
security (screening) for live parts
short circuit capacity test
impulse test
voltage drop test
nameplate(s).

17. Instruments

17.1 General

Generally specific test and inspection requirements are stated in the requisitions and/or its applicable documents. Basically the inspection of the instruments will contain a full detailed review of the requisition with applicable documents and a performance test.

This performance test shall be executed for a selected number of instruments, preferably minimum one instrument of each type. The results shall be compared with the calibration/test reports of the Vendor.

17.2 Scope

17.2.1 The following types of instruments will only be inspected if required by the terms of the Purchase Order and its attachments. In this event, the extent of inspection will be agreed between Inspection and Engineering in advance of request for quotation.

(a) Conventional and miniature pneumatic and electronic receiver-indicators, recorders and controllers.
(b) Electronic potentiometer instruments.
(c) Locally mounted indicators, recorders, controllers and transmitters, excluding displacement type level instruments.
(d) Thermocouples and other temperature measuring primary elements.
(e) Minor instruments such as pressure gages, thermometers, rotameters, pressure and level switches etc.

17.2.2 For the above categories of instruments, the Vendor will normally only be requested to furnish certificates of conformity with the specification, unless otherwise specifically mentioned in the Purchase Order.

17.2.3 Prior to release of any instrument for shipping all test calibration and other certificates as required per requisition shall be checked and approved, whether they have been inspected or not.

17.3 For certain specialised instruments as analysers, sample conditioning systems, control panels, auxiliary cabinets etc., inspection (where called for in the requisition) may be jointly with a control systems engineer. In these circumstances the proposed inspection dates, as advised in expediting reports, will be communicated in advance to Engineering.

In some cases it might be requested by Engineering to send instruments which are supplied by others, but actually forming a part of the system, to the Vendor of the system for an integral performance test.

17.4 In-Line Instruments as control valves, orifice flanges, turbine meters etc. shall, in addition to the specific instrument inspection procedure as described in this chapter, be inspected as described elsewhere in this guide.

17.5 Instruments on Package Units The inspection procedure for instruments on package units is identical to the inspection procedure as described above. In addition special attention shall be given to:

make and type of instrument
range of instruments
scale of instruments
location
visibility/accessibility
durability of installation
material certification
enclosures.

If the instruments are wired/piped by Vendor:

type of cable/tubing:
armoured/unarmoured
thermocouple extension cable
size and type of cable glands/unions
durable fastening of wiring/tubing

17.6 In some cases relevant Authorities require certain tests and inspections of safety and relief valves or bursting discs. A combination of Company's and Authority inspection shall be considered to improved co-ordination and to facilitate Authority approval.

18. References

	Document number	Title	Level
18.1	BN-IN-005	Vendor Inspection Procedure	3
18.2	CM-PE-711	Vendor Quality System Requirements	2