F.sq-p-009 Rev. 0 Procedure for Inspection of Rotating Equipment

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PROCEDURE AUTHORIZATION This procedure have been generated and implemented to identify the control that shall be applied by members of staff in the department when carrying out their duties

This confirms that this procedure has been approved for official issue and that members of staff shall complete the tasks assigned in accordance with the mechanisms defined herein

The procedure forms part of a formal system within the company which ensure that this document is handled in a controlled manner in accordance with documented procedures. This procedure will be subject to audit as part of the company policy towards quality

Department Authorization

Date:

Signed: Corporate Authorization (Company Director)

Date:

Signed: Quality Authorization Quality Manager

Date:

Signed:

PROCEDURE REVISION Rev.

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Outline of Changed

Authorization

First Issue

1 2 3 4

STATEMENT OF CONFIDENTIALITY This procedure is for controlled circulation unless stamped "Uncontrolled Copy”. The documents or extracts from documents must nor be passed or copied to other companies, agents or persons without the permission of the relevant Company Directors.

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TABLE OF CONTENT

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PURPOSE

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SCOPE

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DEFINITIONS

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REFERENCES

4

4.1 GENERAL

4

4.2 TECHNICAL STANDARDS

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5.0

RESPONSIBILITIES

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6.0

PROCEDURES

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6.1 INTRODUCTION

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6.2 PRE-INSPECTION MEETING

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6.3 DOCUMENT REVIEW

5

6.4 INSPECTION

6

6.5 HYDROSTATIC AND PERFORMANCE TEST

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6.6 REPORT AND RECORDS

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ATTACHMENT

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PURPOSE a.

The purpose of this document is to ensure that the rotating equipment is in safe condition, both prior to and during in service.

b.

To provide guideline for surveyor to perform inspection, testing, reviewing and verifying of rotating equipment comply with quality requirements.

SCOPE a.

This procedure shall be applied for quality verification during design, fabrication, installation, testing, and reporting of rotating equipment.

b.

This procedure covers the minimum requirement of International Code or Client's requirement.

c.

This is the Company approved procedure and shall be adhered to at all times except where Client or Contract Document specifies other requirement.

DEFINITIONS a.

Company

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PT. Sertco Quality

b.

Client

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Those Companies, Organizations Individuals to which the Company contracted to provide services

c.

Contract Document

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The form of agreement for the provision of the Services to the Client by the Company

d.

Services

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All things provided under the Contract Document including all activities to be carried out by the Company for the Client

e.

Line Management

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Operation Director, Engineering

f.

Manufacturer

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The Company responsible for fabrication or Pressure Vessel(s), either in its facilities or on site

g.

General Definitions

-

For the purpose of this procedure the definitions given in references referred to shall apply

Department

or is

Heads,

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The personnel who perform the inspection activities under employed by company.

REFERENCES 4.1 GENERAL This list of standards is provided for guidance only and is not intended to be comprehensive. It is included to assist the Inspector in selecting relevant sources of information where client's specific requirements do not exist. 4.2 GOVERNMENT REGULATION AND TECHNICAL STANDARDS a. Undang Undang Republik Indonesia Nomor 22 Tahun 2001: Minyak Dan Gas Bumi b. Mijn Politie Reglement Sb.1930 No. 341: Peraturan Kepolisian Pertambangan c. Peraturan Pemerintah Nomor 19 Tahun 1973: Pengaturan Dan Pengawasan Keselamatan Kerja Di Bidang Pertambangan d. Peraturan Pemerintah Nomor 17 Tahun 1974: Pengawasan Pelaksanaan Eksplorasi Dan Eksploitasi Minyak dan Gas Bumi Di Daerah Lepas Pantai e. Peraturan Pemerintah Nomor 11 Tahun 1979: Keselamatan Kerja Pada Pemurnian Dan Pengolahan Minyak dan Gas Bumi f. Peraturan Menteri Pertambangan dan Energi Nomor 06P/0746/M.PE/1991: Pemeriksaan Keselamatan Kerja Atas Instalasi, Peralatan Dan Teknik Yang Dipergunakan Dalam Pertambangan Minyak Dan Gas Bumi Dan Pengusahaan Sumber Daya Panas Bumi g. Keputusan Direktur Jenderal Minyak dan Gas Bumi No. 84.K/38/DJM/1998: Pedoman Dan Tata Cara Pemeriksaan Keselamatan Kerja Atas Instalasi, Peralatan, dan Teknik Yang Dipergunakan Dalam Usaha Pertambangan Minyak dan Gas Bumi Dan Pengusahaan Sumber Daya Panas Bumi h. API Std 610 : Centrifugal Pump for General Refinery Services i. API Std 613 : Special Purpose Gear Units for Refinery Services j. API Std 616 : Combustion Gas Turbines for General Refinery Services k. API Std 617 : Centrifugal Compressors for General Refinery Services l. API Std 670 : Vibration and Bearing Temperature Monitoring Systems. m. API Std 671 : Couplings n. ASME-PTC 10 : Power Test Code – Compressors and Exhausters o. ASME B16.5 : Pipe Flanges and Flanges Fittings

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p. NFPA 37 q. NFPA 72 E r. I.E.C. 34 s. ANSI. C.50 t. NEMA - MG1

5.0

: Installation and Use of Stationary Combustion Engine and Gas Turbine : Automatic Fire Detector : International Standard for Rotating Electrical Machines : American National Standard for Rotating Electrical Machinery : Rotating Electrical Machines

RESPONSIBILITIES a.

The Company Management shall be responsible for ensuring that the necessary resources are made available for the requirements of this procedure to be carried out in a safe manner

b.

Line Management shall be responsible for ensuring that the requirements of this procedure are fully implemented at all times.

c. 6.0

All employees involved in the implementation of this procedure shall be responsible for adherence to the requirements stated within. PROCEDURES 6.1 INTRODUCTION The inspection services setup in this procedure is a general guidance that shall be performed by the inspection personnel. The detail inspection and the acceptance criteria shall refer to applicable code and standard used that stated in contract document or client specification. The inspection personnel shall be qualified by training and experience, such personnel shall be capable of performing the inspection services mentioned below. 6.2 PRE-INSPECTION MEETING Prior to manufacturing and installation of the rotating equipment take in place, a pre-inspection meeting shall be hold, to setup an inspection and test plan, getting information regarding to schedule of fabrication, and other things that necessary required in performing inspection. The pre-inspection meeting should be held between Company, Client and Manufacturer. If no such meeting held then requirement shall be established. The inspection and test plan should contain item to be inspected and verified, which more detailed in section 6.4 Inspection below, acceptance criteria, verifying document, verifying material, etc.

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The agreed inspection and test plan shall be as a reference of in performing inspection for all parties who involved in construction of Pressure Vessel.

6.3 DOCUMENT REVIEW The Inspector assigned to this work must be provided with the following; a.

Client's purchase order and specification (if applicable);

b.

Complete set of drawings approved by client;

c.

Latest or specified edition of the relevant specification and standard material specifications as required for the construction;

d.

Confirmation that the client has approved drawings, test procedures etc;

e.

Review of test procedure and arrangements for witnessing of performance tests, also Operating Manual of the rotating equipment. Note: Instances will arise when all of the above cannot be made available at the time the order is assigned to an Inspector. The Inspector must then obtain the information from the Vendor and particular care must be taken that drawings/specifications are the latest editions and have been approved by the Client.

6.4 INSPECTION 6.4.1 Final and Surface Inspection Only a.

Internal Cleanliness The Inspector should assure himself that the Vendor takes care that all rotating equipment casings, bearing housings etc. are completely clean prior to assembly. Surfaces of castings must be completely free from molding sand, machinery swarf or any other dirt.

b.

Balancing Balancing of the rotating components is always important and becomes increasingly so as diameter, weight and running speed increase. The rotating equipment specification should be

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consulted to check whether static or dynamic balancing is required. The inspector should by observation, confirm that the Vendor's standard practice conforms to the specification requirements. c.

Clearance Does the Vendor have a satisfactory system for checking that correct running clearances are achieved on assembly.

d.

Performance Tests Does the Vendor conscientiously carry our tests according to Specification.

6.4.2 Visual and Dimensional Inspection a. Painted Surfaces Rotating Equipment casings and bearing housings that arc painted before they are inspected are to be rejected. It is possible, in priming a surface for painting, to deliberately cover up casting defects. Hydrostatic and performance testing must always be completed prior to painting. b. Visual Examination and Dimensional Check The surface inspection should consist of a visual examination, check of overall dimensions, including location of mounting holes, flange drilling, flange thickness, facings, shaft height, shaft diameter etc. The casing should be examined, and if the casing is not opened for internal examination, the inside of the suction and discharge nozzles should be visually inspected to ensure that they are smooth and free from any excrescence which would restrict flow. If the casing has vents and drains, the order must be checked to see if they are authorized. c.

Flange Thickness Some Vendors assign a rotating equipment case a series of pressure ratings with the flange thickness and casing thickness being based on the highest rating. When the casing is used for a lower rating the flange faces are drilled accordingly but the flange thickness is often left at their original thickness, thus they are excessively thick. In the absence of an order limitation, this extra thickness would not be considered a cause for rejection.

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d. Casing Thickness When required by the order, the rotating equipment casing thickness should be measured at several points to establish that the nominal thickness is not under the minimum shown on the rotating equipment manufacturer's drawings. These thickness would normally be obtained before the rotating equipment is assembled as only a limited amount of measuring can be done through open nozzles If the casing is open for this propose, an internal surface examination should be made as described in Para . It is the responsibility of the Manufacturer to specify the casing thickness and furnish sketches showing actual readings, or a certification that thickness are as specified. e. Oil Levels Check that oil levels are clearly marked on bearing housings except on rotating equipments which will have oil mist lubrication. f. Nameplate Data on the nameplate and nameplate material must conform with all the requirements of the specification. If possible, the nameplate should be examined before mounting. Units must be those specified in the order.

6.5 HYDROSTATIC AND PERFORMANCE TEST 6.5.1

Witnessed Hydrostatic Test 6.5.1.1

Casing The casing surface should be examined as soon as possible after full test pressure is applied and periodically through the test period. The surface should be dry and free from dirt, oil or grease. All permanent connections, threaded into the casing proper, should be checked to see if they require seal welding. Seal welds may leak on the first application of pressure and require repair. If vent and drain connections are in, the purchase order should be checked to see if they are permitted the client should be contacted.

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The rotating equipment case should be hydrostatically tested at the pressure given in the order, specification or data sheet. If a case contains bowls.. such as in a multistage vertical rotating equipment, which develop a differential head across them, the above mentioned hydrostatic test refers to the test on the outer case. Bowls are tested out of the case. The maximum allowable casing pressure should be used in computing the test pressure. Check that calibration of pressure gauges. Ensure that no air pockets exist before applying pressure. The stuffing box must be tested with the casing. The casing is sometimes hydro-tested after the rotating equipment is assembled. Unless specifically required in the order, mechanical seals should not be installed during hydrotest.

6.5.1.2

Pedestals etc. Cooling passages and jackets for bearings, stuffing boxes, pedestals, etc. must be tested as required by specification. These tests are only witnessed when specified on the Purchase Order/Data Sheets.

6.5.1.3

Duration of Test Hydrostatic test pressure should be held for a minimum of 30 minutes unless otherwise specified or approved by the client.

6.5.1.4

Auxiliary Equipment The Inspector must ensure that all auxiliary equipment coolers pipe work etc. included in the rotating equipment supply is hydro-statically tested as required by the specification. These tests may or may not be required to be witnessed dependant on the order requirements.

6.5.2 Performance test The Inspector must clearly establish that the Vendor's test procedure, and method of recording results will provide all the

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information required by the client order. Both the mechanical and hydraulic performance characteristic of the rotating equipment must be demonstrated during the test. Check calibration of test recording equipment. 6.5.2.1

Drivers Ideally, shop performance tests should be carried out using the client driver which will ultimately be used on site However, this driver may not be available or there may be other valid reasons why it cannot be used; e.g. the rotating equipment may be intended for use with low S.C liquids and shop test with water as the test medium may overload the client driver, or the final drive may be by a steam turbine which the rotating equipment vendor has no means of running In such cases, the test will be carried out using a shop motor and Inspector must obtain an efficiency curve of the motor to enable test results to be correctly assessed.

6.5.2.2

Mechanical Performance To check mechanical performance, the rotating equipment must run at rated speed and capacity. The duration of this test should be as required by client specification or alternatively of sufficient time to permit steady operating conditions, temperatures etc. to be reached and the required mechanical checks made. The mechanical checks made during the performance test must include: a. Vibration Vibration readings should be taken with a vibrometer capable of, or adjusted to, reading specified limits near mid scale. These readings must be within the tolerances specified. If electronic equipment is used, the filter must be tuned out for the Inspector's readings. The vendor should not be prohibited from taking filter readings for his own purposes. Note: Excessive vibration may result from the shop test facilities i.e., inadequate mountings, badly supported

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pipe work, valves etc. or from the shop test driver or coupling. A Vendor's claim that the excessive vibration would drop to an acceptable level if the rotating equipment had been property mounted, should not be accepted unless it drops to an acceptable level when remounted. Other problems causing high vibration must be corrected before the rotating equipment is released. On rotating equipments fitted with anti-friction bearings, readings should be made on the bearings housings. An anti-friction bearing is one that contains rolling elements - balls or cylindrical rollers. When the bearing is in the motor on a vertical rotating equipment, the vibration should be measured on the rotating equipment frame adjacent to where to motor is bolted down. Shaft readings can be taken but it is standard practice in the field to read on the bearing housing. This picks up looseness in the bearing fit. Vibration readings must be taken on adjacent to the bearing housing.

the shaft

b. Bearing Check If the bearings overheat, the cause should be investigated and corrected by the Manufacturer. Clients may specify varying acceptable maximum temperatures for the shop test depending on the ambient conditions of the site location. As a general rule, if bearing housings become too hot to touch the Inspector should check to see that specified temperatures are not being exceeded. c. Mechanical Shaft Seal The Inspector should check that the seal circulation system used for the performance test with water is the same as that required on site. If a flow restricting orifice is required, check that it has not been omitted. d. Stuffing Box Leakage If the rotating equipment has a packed stuffing box, some leakage through the packing is necessary and

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normal. It lubricates the packing and also prevents it from over-heating. e. Shaft Sleeve Leakage Leakage between the shaft sleeve and shaft is not permitted. f. Distress Any signs of distress, such as noise caused by cavitations or rubbing should be investigated and the cause determined and corrected. 6.5.2.3

Hydraulic Performance a. Data Recording During the running, test data must be recorded through the operating range of the rotating equipment. Reading must be taken of capacity, brake horsepower input and speed. For various reasons it may not be possible to carry out the performance test at the correct rated speed. The Inspector must only accept such deviation when approval has been received from the client.

b. Performance Test Data and Curves The Inspector must review the performance test data and rotating equipment test curve to satisfy himself that the rotating equipment meets the requirements of the order. This applies for both witnessed and nonwitnessed performance test. c. Alarm and Trip Operation Large rotating equipments are usually provided with protective alarm and/or trip devices and the operation of these should be simulated at the Vendor's works. They may include:  Low inlet pressure  High discharge pressure  Excessive vibration  High journal bearing temperature  High thrust bearing temperature F.SQ-P-009 Rev. 0 Procedure For Inspection of Rotating Equipment.doc

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

Seal leakage etc.

6.6 REPORT AND RECORDS During performing inspection, the inspection personnel shall make inspection records use company standard form. 7.0

ATTACHMENTS F.SQ-F-009.1 rev 0 Form for Pump Certificate of Inspection F.SQ-F-009.2 rev 0 Form for Compressor Certificate of Inspection

F.SQ-P-009 Rev. 0 Procedure For Inspection of Rotating Equipment.doc