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PROCEDURE FOR INSPECTION OF ROTATING


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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.

Date

26 Sep 2011

Section

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.

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

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PROCEDURE FOR INSPECTION OF ROTATING


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TABLE OF CONTENT

Page
1.0

PURPOSE

2.0

SCOPE

3.0

DEFINITIONS

4.0

REFERENCES

4.1 GENERAL

4.2 TECHNICAL STANDARDS

5.0

RESPONSIBILITIES

6.0

PROCEDURES

6.1 INTRODUCTION

6.2 PRE-INSPECTION MEETING

6.3 DOCUMENT REVIEW

6.4 INSPECTION

6.5 HYDROSTATIC AND PERFORMANCE TEST

6.6 REPORT AND RECORDS

12

ATTACHMENT

12

7.0

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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

PT. Sertco Quality

b.

Client

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

c.

Contract Document

The form of agreement for the provision of


the Services to the Client by the Company

d.

Services

All things provided under the Contract


Document including all activities to be carried
out by the Company for the Client

e.

Line Management

Operation Director,
Engineering

f.

Manufacturer

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
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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

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