Third Party Inspection for Reciprocating Compressor article provides a sample procedure for reciprocating compressor testing and reciprocating compressor inspection in manufacturing shop. The draft compressor inspection and test plan should be reviewed with this article.
This content guides you through all the necessary stages in the production of the reciprocating compressors, including the examination of material, casing hydrostatic testing, performance test, mechanical run test, final inspection, preservation and packing and dispatch to site.
You need to take this point into account: this article is written for a typical reciprocating compressor and might not be detailed for special cases.
All reciprocating compressor inspections and testing are carried out against the approved drawings, purchase order specifications, purchasers or company standards, and within the practices and rules of the country, state or province and any government decrees, laws, ordinance or regulation as may apply.
Reciprocating compressors are among the most critical items of equipment on a process plant and do not normally have stand by units as is the norm with process pumps.
In consequence absolute integrity of all components is essential. The driver may or may not feature in assembly/tests at the compressor supplier's plant.
The applicable codes and specifications for a reciprocating compressor that is under the construction process is:
And the applicable codes and standards are:
The applicable codes and standards may be based on other international standards such as BS 7322, etc. This content is general and can be useful even if the design code is different from the API Code.
The list of documents normally is agreed upon in the Pre-Inspection meeting, which is held several weeks before the actual commencement of the inspection work.
The parties that participate in this meeting are the manufacturer, purchaser and third party inspection agency representatives.
These are the list of documents that are normally agreed upon to be presented to the inspector:
The first actual inspection
work in the reciprocating compressor is the raw materials inspection.
The original or authenticated copies of mill certificates of material normally are available at the manufacturer's premises.
The third party inspector examines these certificates for compliance with specifications, and where appropriate, drawings.
The review includes checks on:
Then the inspector witnesses the materials identification on the certificates against materials marking. It is also necessary to check with reciprocating compressor drawing datasheet, material list and other specification as appropriate.
Visual inspection for surface finish and probable defects is done and dimensional compliance with specification need to be controlled, as well.
When third party inspector carries out the material inspection, then provides the inspection visit report (IVR), the report contains the following items:
When the reciprocating compressor raw material inspection is carried out, and the results were satisfactory or non-conformities were closed by remedial action, then the compressor manufacturer will start fabrication.
The third party inspector checks the following points on the reciprocating compressor based on the inspection and test plan (ITP), which has already been agreed upon between the purchaser and the Compressor manufacturer.
The inspection scope is determined in the ITP. Some purchasers prefer to have stringent controls and assign the TPI for more “hold or witness points” for inspection and test activities, and some others prefer less “hold or witness points” and assign the TPI much more work in the “review document.”
This depends in the inspection budget, which purchasers assign for inspection. Much more inspection will have a much larger cost and less risk, and conversely, less inspection will have less cost but more risks.
The third party inspector checks the following items in the reciprocating compressor fabrication inspection process:
If the third party inspector is not in the hold or witness point in the ITP for this inspection stage, then he/she will review the reciprocating compressor manufacturer quality control report in his/her coming visit or on the final inspection day.
The compressor and other pressure containing parts are hydrostatically tested. The main items are:
The third party inspector verifies that the correct test pressure has been applied to the relevant parts depending on specification requirements.
During compressor assembly and when required by the Purchase order or contract inspection is carried out paying particular attention to the following items:
Detailed information can be found on reciprocating compressor testing article.
Certain types of compressor may be subjected to a mechanical running test. This particularly applies to skid mounted units.
Where required by the purchase order, the third party inspector checks for the following attributes during the test period:
For more details, review the Reciprocating Compressor Testing article.
Some purchasers may require a strip down inspection after testing. Where there is an inspection the following points are checked as a minimum by third party inspector:
Similarly, If the third party inspector is not in the hold or witness point in the ITP for this inspection stage, then he/she will review the reciprocating compressor manufacturer quality control report in his/her coming visit or on the final inspection day.
After completion of all of the manufacturing and tests, the third party inspector carries out a final inspection of the compressor with paying particular attention to:
The third party inspector checks the content in accordance with the approved drawings and specifications and make sure it is stamped in accordance with the code requirements.
Surface preparation for painting is checked for the following points, according to specification by third party inspector:
It is necessary that surface condition is free from pin-holes, runs damage and other discontinuity.
Third Party Inspection for Reciprocating Compressor Spare Parts, Loose Items and Accessories
Spare parts, loose items and accessories need to be checked visually for their dimensions, materials, workmanship and quantity, according to the purchase order specification.
Test marks and tags are checked for correct identification.
The third party inspector provides an Inspection Visit Report (IVR) after each visit, as well as a final report summarizing the activities carried out during the compressor production in accordance with the contract requirements and circulated within the time limits specified in the contract.
The report is in the format required by the client and clearly indicates final acceptance or rejection of the reciprocating compressor.
When required by the contract or purchase order, a release note is issued by the third party inspection agency and given to the manufacturer when the compressors have been accepted.
The following points are checked by the third party inspector:
The following final documents are reviewed and signed off by the third party inspector:
Manufacturer's data reports, Material certification, Dimensional record, NDE reports, Hydrostatic test reports, Run-test reports, Strip down reports, Final inspection report, Markings, Packing list, Spare parts
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