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Third Party Inspection for Reciprocating Compressor - Procedure

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Third Party Inspection for Reciprocating Compressor article provides a sample

procedure for reciprocating compressor testing and 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:

Design code
Purchase order specification
Purchaser's standards
Approved drawings

And the applicable codes and standards are:

API API 618

Other Related API Recommendation Practices

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.

Required Documents for Third Party Inspector Review:

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:

Reciprocating Compressor Purchase Order or Contract

Reciprocating Compressor Manufacture Quality Control Plan
Reciprocating Compressor Inspection and Test Plan
Reciprocating Compressor Data Sheet
Reciprocating Compressor Approved Drawings
Reciprocating Compressor Material Test Reports
Reciprocating Compressor Welding Specification Procedures (WPS) and
Reciprocating Compressor Procedure Qualification Records(PQR)
Reciprocating Compressor Welders Qualifications Reports
 Reciprocating Compressor N D E Procedures (Radiography, Ultrasonic, Magnetic
Particle, Dye Penetration, PMI, etc.)
Reciprocating Compressor NDE Personnel Qualifications Reports
Reciprocating Compressor Heat Treatment Procedure
Reciprocating Compressor Calibration Certificates for Test Equipment
Hydrostatic Testing Procedure and Water Quality Document
Reciprocating Compressor Mechanical Running and Performance Test Procedures
Reciprocating Compressor Preparation and Painting Procedure
Reciprocating Compressor Preservation, Packing and Shipping Procedure
Reciprocating Compressor Packing List

Third Party Inspection for Reciprocating Compressor - Material

Inspection

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:

Certificate No.
Heat or cast No.
Chemical Composition
Mechanical Properties
Heat treated Condition
NDE Applied and Results
Surface Finish

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.

W h e n third party inspector carries out the material inspection, then provides the
inspection visit report (IVR), the report contains the following items:

Confirmation of satisfactory document review

Record of the endorsement of certification reviewed/witnessed
Record of all non-conformities
Record of any tests witnessed and the result

Third Party Inspection for Reciprocating Compressor – Fabrication Inspection

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.

T h e 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:

Visual inspection for damage

Dimensional check to drawing requirement
Inspection of parts, particularly cast in passages and piping for cleanliness
Visual examination of welded on connections
Review of welder qualifications
Review of weld procedure record
Confirmation of satisfactory NDE

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.

Third Party Inspection for Reciprocating Compressor Hydrostatic Test

The compressor and other pressure containing parts are hydrostatically tested. The
main items are:

Cylinder Hydro Test

Cooling Jackets
Piping
Pressure Vessels
Filters
Coolers

The third party inspector verifies that the correct test pressure has been applied to the
relevant parts depending on specification requirements.

Third Party Inspection for Reciprocating Compressor Assembly Test

During compressor assembly and when required by the Purchase order or contract
inspection is carried out paying particular attention to the following items:

Piston end clearance

Crankshaft deflection
Run-out check
Proper match marking
Protection of machined surfaces

Detailed information can be found on reciprocating compressor testing article.

Third Party Inspection for Reciprocating Compressor Mechanical Running Test

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:

Lubricating oil - temperature, pressure flow rate

Cooling water - temperature, pressure flow rate
Critical speed
Bearing temperatures
Vibration
Gasket condition/leakage
Proper operation of pressure relief valves speed governors and overspeed
shutdown devices
For more details, review the Reciprocating Compressor Testing article.

Third Party Inspection for Reciprocating Compressor - Strip Down Inspection

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:

Visual condition of cylinder liner

Surface condition of cross head guide piston rods and bearings
Valve plates
Valve springs
Pistons

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.

Third Party Inspection for Reciprocating Compressor Final Visual and

Dimensional Checking

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:

Main dimensions to drawing requirements

Base plate dimensions
Size rating and position of flanged connections
Size and type of threaded connection
Inspection for workmanship, defects and damage
Check on installed condition of parts, assemblies

Third Party Inspection for Reciprocating Compressor - Name Plate Checking

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.

Third Party Inspection for Reciprocating Compressor Painting and

Coating

Surface preparation for painting is checked for the following points, according to
specification by third party inspector:
 Deposited Soluble Salt Measurement
Cleaning level (SSPC-SP 5, SSPC-SP 10, etc.)
Surface Profile Measurement
Freedom from weld spatter, blow-holes and other defects and surfacedust control
before painting application.
Dry film thickness (SSPC PA 2) is checked according to specification

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.

Third Party Inspection for Reciprocating Compressor - Reporting:

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.

Third Party Inspection for Reciprocating Compressor - Release Note:

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.

Third Party Inspection for Reciprocating Compressor Packing, Marking and

Shipping:

The following points are checked by the third party inspector:

All exterior machined surfaces are coated with rust preventative

All internal surfaces that are susceptible to corrosion are coated with rust
 preventative
All flanged openings are fitted with metal protectors in accordance with the
specification
All threaded connections are provided with steel plugs
Exposed shafts and shaft couplings are covered with waterproof material and
sealed
Check manuals and instructions are included to the specification requirements
Packing style and suitability for overseas shipment
Shipping marks control and packing inspection
Pre-assembled systems are marked as required by the specification

Third Party Inspection for Reciprocating Compressor - Final Book (Dossier)

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

Return to Reciprocating Compressor Testing or Third Party Inspection

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