Third Party Inspection For Centrifugal Pump Procedure: Comprehensive Surveillance & Quality Verification

The Third Party Inspection for Centrifugal Pump article provides a sample procedure for pump inspection and testing in manufacturing shop and includes horizontal, vertical and in-line pumps. The article might be reviewed with centrifugal pump inspection and test plan.

This content guides you through all the necessary stages in the production of the centrifugal pumps, including the material, fabrication, casing inspection, casing hydrostatic testing, performance test, mechanical running test, net positive suction heat test, vibration test to the final inspection, preservation and packing, and dispatch to site.

You need to take this point into account: this article is written for a typical centrifugal pump and might not be detailed for special cases.

All centrifugal pump inspection and testing is done 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.

The applicable codes and specifications for a centrifugal pump that is under the construction process is:

• Design code
• Purchase order specification
• Purchaser’s standards
• Approved drawings

And the applicable codes and standard are:

• API 610

The applicable codes and standards may be based on other international standards such as BS 7784, 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:

• Centrifugal Pump Purchase Order or Contract
• Centrifugal Pump Manufacture Quality Control Plan
• Centrifugal Pump Inspection and Test Plan
• Centrifugal Pump Data Sheet
• Centrifugal Pump Approved Drawings
• Centrifugal Pump Material Test Reports
• Centrifugal Pump Welding Specification Procedures (WPS) and Procedure Qualification Records(PQR)
• Centrifugal Pump Welding Map
• Centrifugal Pump Welders Qualifications Reports
• Centrifugal Pump NDE Procedures (Radiography, Ultrasonic, Magnetic Particle, Dye Penetration, etc.)
• Centrifugal Pump NDE Personnel Qualifications Reports
• Centrifugal Pump Heat Treatment Procedure
• Centrifugal Pump Calibration Certificates for Test Equipment
• Centrifugal Pump Hydrostatic Testing Procedure and Water Quality Document
• Centrifugal Pump Impeller Inspection Procedure
• Centrifugal Pump Performance Test Procedure
• Centrifugal Pump Mechanical Running Test Procedure
• Centrifugal Pump Net Positive Suction Head Test Procedure
• Centrifugal Pump Vibration Test (FFT Plot) Procedure
• Centrifugal Pump Preparation and Painting Procedure
• Centrifugal Pump Preservation, Packing and Shipping Procedure
• Centrifugal Pump Packing List

Third Party Inspection for Centrifugal Pump – Material Inspection

The first actual inspection work in the centrifugal pump is the 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 the materials marking. It is also necessary to check these with the centrifugal pump drawing datasheet, material list and other specifications as appropriate.

Visual inspection for surface finish and probable defects is done and dimensional compliance with specification need to be controlled, as well.

When the 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 Centrifugal Pump – Casing Inspection

When the centrifugal pump raw material inspection is carried out, and the results were satisfactory or non-conformities were closed by remedial action, then the centrifugal pump manufacturer will start fabrication.

The third party inspector checks the following points on the centrifugal pump, based on the inspection and test plan (ITP), which has already been agreed upon between the purchaser and the centrifugal pump 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 centrifugal pump casing inspection process:

• Visual inspection for damage
• Dimensional check to drawing requirements
• Witness or review hydrostatic test
• Witness or review NDE examination
• Application of test marks
• Visual examination of welded on connections
• Review weld qualification and weld procedure records

Third Party Inspection for Centrifugal Pump – Impeller Inspection

The third party inspector checks the following items in the centrifugal pump impeller inspection process:

• Witness or review Run Out test
• Witness or review Dynamic Balance test
• Review NDE examination results

Third Party Inspection for Centrifugal Pump – Performance Test

After complete assembly, the pump is submitted to a performance test. The test is conducted within the contract and code requirements. The third party inspector witnesses the following items:

• Collection of test data
• Preparation of test curves
• Rated speed
• Check bearings for overheating
• Noise test
• Vibration test

Third Party Inspection for Centrifugal Pump – NPSH Test

Where required by the contract or purchase order, the third party inspector witnesses the NPSH test and approves the results.

The inspector checks the following points:

• Test method is as required by the contract that is used
• Confirmation of results

Third Party Inspection for Centrifugal Pump – Mechanical Running Test

When required by the contract or purchase order, where the pump runs for a pre-determined time depending on its type, the pump and its driver will be as complete as possible. The third party inspector will check the following items:

• Flow requirement
• Excessive vibration
• Excessive noise
• Bearing temperatures

Third Party Inspection for Centrifugal Pump – Dismantling Inspection

A pump with three or more stages is inspected by dismantling after the test. Other types may be inspected when required by the contract or purchase order.

The third party inspector checks, as necessary, to ensure that no damage has occurred during tests, and that the necessary care is taken during re-assembly, including rust prevention procedures where necessary.

Third Party Inspection for Centrifugal Pump – Clearance Checking

The establishment of running clearances is determined by giving consideration to variables such as pumping temperature, suction condition, fluid characteristics, thermal expansion or galling characteristics of the materials, etc.

The final clearances are based in accordance to the manufacturer’s standard. Where required, the third party inspector confirms that the standards have been met.

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 centrifugal pump manufacturer quality control report in his/her coming visit or on the final inspection day.

Third Party Inspection for Centrifugal Pump Final Visual and Dimensional Control

After completion of all of the manufacturing and tests, the third party inspector carries out a final inspection of the pump. 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 Centrifugal Pump – Name Plate Control

The third party inspector checks the content in accordance with the approved drawings and specifications and makes sure it is stamped in accordance with the code requirements.

Third Party Inspection for Centrifugal Pump – Painting and Coating Inspection

Surface preparation for painting is checked for the following points, according to specification by third party inspector:

• Chloride tesing and solvent cleaning (if required)
• Cleaning method (near-white metal blast cleaning, commercial balst cleaning, etc.)
• Surface Preparation
• Freedom from weld spatter, blow-holes and other defects, dust
• Dry film thickness is checked according to specification

It is necessary that the surface condition is free from pin-holes, runs damage and other discontinuity.

Third Party Inspection for Centrifugal Pump – Spare Parts, Loose Items and Accessories

Spare parts, loose items and accessories are 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 Centrifugal Pump – 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 pump 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 centrifugal pump.

Third Party Inspection for Centrifugal Pump – 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 pumps have been accepted.

Third Party Inspection for Centrifugal Pump – 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 are correct and packing inspection
• Pre-assembled systems are marked as required by the specification

Third Party Inspection for Centrifugal Pump – Final Book (Dossier)

The following final documents are reviewed and signed off by the third party inspector:

Manufacturers data report, Material certification, Dimensional record, NDE reports, Hydrostatic test reports, Performance test requirements, NPSH reports, Run-test reports, Strip down reports, Final inspection report, Marking inspection report, Packing list and Spare parts list