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Inspection And Test Plan

for
Centrifugal Compressor
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 30/09/2008 JOB NO. : 6261
DOC.NO. ITP/ROT/004 HGU PROJECT Page 1 of 4

CLIENT : HPCL, VAISAKH


TEIL JOB NO. : 6261 APPLICABLE CODE : As per PR, PS
ITEM NO. /
PO. NO. :
COMMODITY : Centrifugal Compressors

INSPECTION BY
S. NO. DESCRIPTION OF ACTIVITY EPCC / PMC / RECORD
TPIA
VENDOR OWNER

01 Detailed Inspection & Test Plan after issue of P A A* X


PO/PR/PS including for all items & accessories of
the Compressor skid – Bare Compressor, Main
Driver, Gear box, LO System, Auxiliary Motors, LO
Pumps, Vessels, Coolers, Control panel,
Instrumentation, Piping etc.
02 Inspection & Test Procedures like NDT, Hydro test, P A R** X
Performance test, Mechanical run test, Painting etc.
03 Pre inspection meeting, after issue of PO/PR/PS, P H X
agenda to be prepared by VENDOR
04 Summary of all supplementary requirements as P A X
specified in the PO/PR/PS for all Items &
accessories
05 Sub order verification for Bought out items P A X
06 Inspection of Bought out items at Sub vendor’s W H X
works for Drivers, LO Console, Piping, Vessels,
Coolers, Gear box etc.
07 Welding Procedure Specification & Procedure P A X
Qualification Records – Pressure retaining
components of the Compressor, Fabricated items &
accessories, Piping etc.
08 Material Test Certificate in accordance with A A X
EN10204 3.1 / ISO10474 3.1B & meeting the
requirements of Material specification,
PR/PS/Design code –
Compressor components as Casing (Inner, Outer),
End wall seal housing, Bearing housing, Impellers
(Hub, Cover & Blade or Cast), Shaft, Shaft sleeve,
Balance pistons, Diaphragm bolts and nuts, oil
pumps , oil filters , oil coolers, oil tank, oil console
assembly, dry gas console and any other pressure
retaining part / part exposed to process fluid
09 Coupling (Dynamic balancing report, Compliance A A X
certificate of Manufacturer)
10 Manufacturer’s Test Certificate / Calibration A A X
certificate for Instruments
11 NDT Examination of Compressor components as per P A X
PR/PS/Design code
12 Hydrostatic Pressure Test
a. All Pressure Casing components P H X
b. Auxiliary piping P H X
Inspection And Test Plan
for
Centrifugal Compressor
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 30/09/2008 JOB NO. : 6261
DOC.NO. ITP/ROT/004 HGU PROJECT Page 1 of 4

c. Cooling jacket of bearing, Stuffing box etc. P H X


INSPECTION BY
S. NO. DESCRIPTION OF ACTIVITY EPCC / PMC / RECORD
TPIA
VENDOR OWNER

d Pressure vessels. P H X
e Heat Exchangers P H X
f Filters P H X
g Other applicable items P H X
13 Helium leak test of Casing under water as per P H X
approved PR/PS/Design code
14 Impeller Over speed Spin Test (incl for Spare Rotor)
a. Dimensional check before Spin test (bore, eye seal, P H X
outside diameter)
b. MT/PT before Spin test P H X
c. Over speed spin test P H X
d. Dimensional check after Spin test (bore, eye seal, P H X
outside diameter)
e. MT/PT after Spin test P H X
15 Dynamic balancing (incl for Spares Rotor)
a. Individual Impellers P H X
b. Rotor (as per PR/PS/Design code) P H X
16 Mechanical & Electrical run out of Rotor (incl for P H X
Spares)
17 Rotor Insensitivity check (incl for Spares) P H X
18 Lube Oil Console at sub vendor place
a. Pressure test W H X
b. Cleanliness check W H X
c. Mechanical running for 4 hours & Operation check W H X
d. Review of Material test certificates A A X
e. Review of Manufacturer’s Test certificates & A A X
Reports for Motor, Pump, Instruments etc.
c Contract Instruments W A X
d Contract Drivers W A X
e Check changeover valves W A X
f Check Auto- Start, Running and stop of stand-by W A X
pumps
g Check controls and all instrument functions W A X

19 Assembled Compressor with Job & Spare Rotor


a. Mechanical run test as per PR/PS/Design code P H H** X
Following conditions apply:
• Contract Coupling
• Contract Probes
• Contract Seals
• Main Rotor
• Contract Gear- Box
• Vary Lube oil pressures and temperatures
• Spare Rotor
Inspection And Test Plan
for
Centrifugal Compressor
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 30/09/2008 JOB NO. : 6261
DOC.NO. ITP/ROT/004 HGU PROJECT Page 1 of 4

• Polar Form of Vibration data


• Tape recording of Vibration Data
• Torsional Vibration Measurements

b. Vibration measurement as per PR/PS/Design code P H X


c. Temperature rise measurement as per PR/PS/Design P H X
code for eg. Bearing and lube oil.
d. Sound level measurement P H X
e. Control system functional check P H X
f. Performance test as per PR/PS/Design code P H H** X
According to ASME PTC -10 Type 2
g. Dry Gas Seal Functional / Performance Test P H H** X
Following conditions apply:
• Contract instruments
• Check change over valves
• Check controls and all instrument functions.
h. Shop verification of unbalanced response analysis as
per PR/PS/Design code (main &Spare rotor )
i. Strip test P H X
20 Assembled Compressor Gas (Inert) Leakage test as P H X
per approved PR/PS/Design code
21 Complete unit Test (Compressor & all accessories as P H H** X
per scope of supply), as per approved PR/PS/Design
code, may be merged with 19 a. with job motor
22 Surface preparation & painting P A X
23 Final inspection of Complete Unit
a. Visual check for completeness & appearance P H X
b. Dimensional check P H X
c. DFT check of final painting P H X
24 Review of final documents, minimum as marked in P H H** X
the column for RECORDS
25 Final stamping & issue of Inspection release H H X
certificate.

LEGEND 1) VENDOR, 2) TPAI – THIRD PARTY INSPECTION AGENCY APPOINTED BY VENDOR, (LLOYDS, BVIS & DNV)
3) PMC - TOYO ENGINEERING INDIA LIMITED, 4) OWNER – HPCL, VAISAKH 5) H – HOLD (OFFER FOR WITNESS
& OBTAIN CLEARANCE), 6) W - WITNESS, 7) RN - RANDOM WITNESS, 8) A – REVIEW & APPROVE,
9) R – REVIEW ONLY, 10) P – PERFORM, 11) X – REQUIREMENT OF RECORD.

NOTE 1) THIS IS ONLY A INDICATIVE ITP AND VENDOR SHALL PREPARE A DETAILED ITP IN LINE WITH ABOVE AND
SPECIFIC TECHNICAL REQUIREMENTS OF APPLICABLE PR/PS/DESIGN CODE.
2) VENDOR SHALL ENSURE THAT ALL TEST AND MEASURING INSTRUMENTS ARE DULY CALIBRATED AND
CALIBRATION SHALL BE VALID AT THE TIME OF INSPECTION. CALIBRATION PROCEDURE & RECORDS SHALL BE
REVIEWED BY TPIA
3) SUB VENDOR FOR BOUGHT OUT ITEMS SHALL BE FROM PMC / OWNER APPROVED VENDOR LIST.
4) ‘*’ INDICATES FOR CATEGORY A, B ONLY & ‘**’ FOR CATEGORY A ONLY
5) PMI TEST SHALL BE PERFOMED ON ALL AS/SS PRESSURE RETAINING PUMP COMPONETS, AUXILIARY PIPING,
API PLAN ETC. AT THE TIME OF PRESSURE TESTING. PMI TEST SHALL BE WITNESS BY TPIA
6) FOUNDATION TEMPLATE, GAGE PLATE FOR BASE RING & FOUNDATION BOLTS SHALL BE SUBJECT TO A FINAL
INSPECTION BY TPIA INCLUDING VISUAL, DIMENSIONAL CHECK AND REVIEW OF TEST CERTIFICATES.
7) COMPRESSOR DRIVERS SHALL BE INSPECTED AT MANUFACTURERS SHOP AS PER RELEVENT INSPECTION & TEST
PLAN
8) NO SHIPMENT OF GOODS MAY BE EFFECTED UNLESS AN ‘INSPECTION RELEASE CERTIFICATE’ HAS BEEN
SUBMITTED TO SELLER.
Inspection And Test Plan
for
Centrifugal Compressor
HPCL, Visakh TOYO ENGINEERING INDIA LTD.
ISSUED : 30/09/2008 JOB NO. : 6261
DOC.NO. ITP/ROT/004 HGU PROJECT Page 1 of 4