Shop Inspection and Testing of Reciprocating Compressors

1. SCOPE …………………………………………………………………….2. REFERENCES 3. DEFINITIONS 4. GENERAL ………………………………………………………………..5. INSPECTION 5.1 General 5.2 Material Certificates ………………………………………………5.3 Material Inspection
5.4 Casting Inspection 6. TESTING ………………………………………………………………….6.1 Mechanical Test 6.2 Hydrostatic and Gas Leakage Tests 7. APPEARANCE AND DIMENSIONAL INSPECTION 8. OTHER TESTS
APPENDIX
1 List of Shop Inspection, Material Inspection and Test Items2 Inspection Report for Reciprocating Compressor 3 Inspection Report for Reciprocating Compressor 4A Inspection Report for Reciprocating Compressor ……………4B Inspection Report for Reciprocating Compressor 4C Inspection Report for Reciprocating Compressor 4D Inspection Report for Reciprocating Compressor ……………5 Inspection Report for Reciprocating Compressor

1. Scope
1.1 This standard is for

the inspection and testing of process compressors and their components that are
procured in accordance with SES G13-S01.
1.2 This standard supplements the inspection criteria in SES G13-S01 Section 4 – Inspection, Testing, and
Preparation for Shipping.
2. References
Reference is made in this standard to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
SES G13-S01 Reciprocating Compressors for Process Service
American Petroleum Institute (API)
618 Reciprocating Compressors for General Refinery Service
American Society of Mechanical Engineers (ASME)
Section V Nondestructive Testing
Section VIII Div 1 UW-51 and UW-52
Section IX Welding and Brazing Qualifications
American Society for Testing and Materials (ASTM)
A 247 Standard Test Method for Evaluating the Microstructure of Graphite in Iron Castings
A 388 Standard Practice for Ultrasonic Examination of Heavy Steel Forgings
A 395 Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated
Temperatures
A 503 Specification for Ultrasonic Examination of Forged Crankshafts
E 94 Standard Guide for Radiographic Examination
E 125 Standard Reference Photographs for Magnetic Particle Indications on Ferrous Castings
E 142 Standard Method for Controlling Quality of Radiographic Testing
E 709 Standard Guide for Magnetic Particle Examination
International Standards Organization (ISO)
9001 Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation and
Servicing
9003 Quality Systems – Model for Quality Assurance in Final Inspection and Test
9004 Quality Management and Quality System Elements – Guidelines
Manufacturers Standardization Society (MSS)
SP-55 Quality Standard for Steel Castings for Valves, Flanges and Fittings and other Piping
3. Definitions
Components-Visual Method
For the purpose of understanding this standard, the following definitions apply.
Major Weld Repair.
A repair on a casting in which the depth of the cavity, when prepared for repair
welding, exceeds 20 percent of the wall thickness of the part, or 25 mm, whichever is smaller. It is further
defined as a repair in which the total volume of the cavity, when prepared for repair welding, exceeds
65 cm
2
.
Minor Weld Repair.
A repair that does not meet the definition of a major weld repair.
Observed.
SABIC shall receive the same notification of the expected timing of the inspection or test as
would be given for a witness test; however, the inspection or test shall be performed as scheduled, even if
SABIC is not present. Results shall be made available for SABIC review.

Witnessed.
A hold shall be applied to the production schedule for the part(s) included in the test until
SABIC is in attendance to witness the test procedure. For mechanical run or performance tests this would
normally include a successful preliminary test by the manufacturer.
4. General
4.1 All inspection and testing shall be done in accordance with the purchase order documents. Vendor
shall be responsible for coordinating any required activities with local and national code and regulatory
agencies.
4.2 SABIC shall have entry to all vendor and sub-vendor plants.
4.3 Vendor shall notify sub-vendors of SABIC’s inspection and testing requirements.
4.4 Vendor shall provide at least 15 working days advance notice to SABIC before conducting witnessed
or observed inspections and tests.
4.5 Vendor shall make available to SABIC all calibration records for all instrumentation used in performing
the inspections and tests carried out in the execution of the purchase order.
4.6 SABIC and vendor shall agree on the acceptance criteria for all inspections and tests prior to the
commencement of manufacturing, inspection and testing. This will normally be done in the coordination
meeting.
4.7 Welder qualifications and radiography certifications will be reviewed during the
coordination/pre-inspection meetings.
4.8 Notification requirements, procedures and contacts shall be established during the coordination
meeting.
4.9 Manufacturing hold-points for inspection/testing shall be identified by vendor and submitted for SABIC
approval after receipt of the purchase order.
4.10 Vendor shall provide the facilities, equipment, and apparatus required for inspection/tests.
4.11 Vendor shall calibrate their instruments to within the manufacturer’s tolerances prior to inspection or
tests. Vendor shall provide records of instrument calibration to SABIC when requested.
4.12 ASME Weld Procedure Specification (WPS), Procedure Qualification Records (PQR), and Welder
Qualification Records shall be submitted to SABIC for review and approval.
4.13 Approved copies of WPS, PQR, and Welder Qualification Records shall be available in the vendor’s
and sub-vendor’s shops for SABIC review.
4.14 Unless exempted by qualification under 4.14.3, the vendor shall submit a quality assurance and
quality control (QA/QC) program specific for the compressor(s), for SABIC’s review and approval. This
shall be after release of the purchase order, but before starting manufacture.
4.14.1 Vendor shall implement a QA/QC program and clearly establish the authority and responsibility of
those responsible for the quality system. Persons performing quality functions shall have sufficient and well
defined authority to enforce quality requirements, initiate, identify, recommend and provide solutions to
quality problems and verify the effectiveness of the corrective action.
4.14.2 Vendor’s quality system shall conform to ISO 9001, 9003 and 9004. The quality system shall
provide for the planned and systematic control of all quality-related activities performed.
4.14.3 If the vendor’s QA/QC program and facility, where the work is to be performed, is ISO 9003 certified,
then a copy of the vendor’s ISO 9003 certificate shall be required. In addition, if the vendor’s facility is
ISO 9003 certified, SABIC’s QA audit requirements will be waived, unless the vendor’s QA/QC program
indicates areas of concern.
4.15

Any conflict(s) between this specification, SES and industry standards, engineering drawings, and
contract documents shall be resolved at the discretion of SABIC.

5. Inspection
5.1 General
5.1.1 The inspection of equipment covered by this standard shall be carried out in addition to those
specified in SES G13-S01.
5.1.2 SABIC and the vendor shall agree on the inspection matrix and predicted schedule at the
coordination meeting.
5.1.3 The inspection checklist (Appendix 1) will be signed off after the completion of testing, and prior to
shipment of the compressor.
5.1.4 Vendor shall keep the manufacturing data, and inspection and test reports available for examination
by SABIC. Unless otherwise specified the data/reports shall be kept for at least 10 years, or shall be
offered to SABIC after 5 years.
5.1.5 The repair welding procedures and the repair welder’s qualification for weldable grade of casting
shall be in accordance with ASME Section IX.
5.1.6 Leaks and defects in pressure containing castings shall not be repaired by peening, burning-in, or
impregnation with plastic or cement compounds. Repair by welding or by plugging shall be undertaken
only when permitted by the material specification, and in accordance with the procedure detailed in the
material specification.
5.1.7 The scope of shop inspection shall be confirmed with SABIC prior to manufacture. It shall include:
a. A check against approved certified outline drawings for main dimensions, baseplate dimensions,
location of foundation bolt holes, pitch tolerance between adjacent bolt holes, size/positioning/rating
of flanges
b. An inspection of flange face finish
c. A verification of the required material certification, for example, mill test reports, or certification of
material compliance by the vendor for standard stocked items and their traceability to the respective
components
d. A verification that the vendor has performed the specified inspections and test with satisfactory
results
e. The vendor’s purchase specifications for the items shown on the bills of materials
f. Measurement of the final clearances
g. A visual check for good workmanship and finish of materials
h. Verification of conformance of painting to specification
i. Verification of casing marking (serial no.) and nameplate data
j. Inspection of preparation for shipment, shipping documents, and tags
5.1.8 Cleanliness of the equipment, piping and furnished components shall be required before and after
assembly at the vendor or sub-vendor plant.
5.2 Material Certificates
5.2.1 Vendor shall furnish material certificates in accordance with the following. Certificates shall be valid
only when stamped and signed by the testing inspector. Certificates shall be submitted for the following:
a. Frame
b. Crankshaft
c. Connecting rod
d. Big-end bolt
e. Crosshead

f. Crosshead guide
g. Crosshead pin
h. Piston rod
i. Cylinder and cover
j. Stud bolts for cylinder cover
k. Cylinder liner
l. Valve (seats, plates, springs)
m. Distance piece
n. Surge drum
o. Oil cooler(shell, tube, tube sheet)
p. Oil filter(shell)
5.2.2 Material Certificates and Certificates of Material Compliance shall be issued by the manufacturing
works, the processing works, or in combination, to attest to the correctness of materials. The certificates
shall be in English, or shall include an English translation. SI units shall be used. The certificates shall be
suitable for subsequent microfilming and photocopying.
5.3 Material Inspection
5.3.1 Destructive mechanical tests and impact tests, if required, shall be carried out on test blocks after
heat treatments have been performed. The following parts shall be subjected to the appropriate subsurface
inspection, and shall have mill test certificates supplied:
a. Compressor frame
b. Compressor crankshaft
c. Connecting rod
d. Rod bolts
e. Crosshead
f. Crosshead pin
g. Cylinder and cover
h. Cylinder liner
i All valve components
j. Distance pieces
5.3.2 Radiographic (RT), Ultrasonic (UT), Magnetic Particle (MT), and Liquid Penetrant (PT) inspection of
welds or materials shall be in accordance with SES G13-S01. The personnel performing and interpreting
the NDE results shall be suitably qualified.
5.3.3 Radiographic Examination (RT)
a. RT shall be in accordance with SES G13-S01.
b. RT of welds shall be in accordance with ASTM E 94 and ASTM E 142. The acceptance standard
used for welded fabrications shall be ASME Section VIII, UW-52. The acceptance standard used for
castings shall be ASME Section VIII, Appendix 7.
5.3.4 UT inspection shall be in accordance with SES G13-S01.
5.3.5 Magnetic Particle Examination (MT)
a. Both wet and dry methods of magnetic particle inspection shall be in accordance with
ASTM E 709.

b. MT shall be applied to all accessible surfaces, including those exposed by machining.
Indications shall be investigated by light grinding to a minimum depth of 1 mm.
c. MT of welded fabrications and castings shall be in accordance with SES G13-S01.
5.3.6 Liquid penetrant (PT) shall be performed only when the specified MT is not possible. PT shall be in
accordance with SES G13-S01.
5.3.7 Visual inspection shall be in accordance with ASME Section V, Article 9. All surfaces shall be
inspected. Acceptance criteria for pressure-containing steel castings shall be in accordance with
MSS SP-55. Acceptance for other parts shall be in accordance with the material specification and
manufacturer’s documented procedures.
5.4 Casting Inspection
Pressure containing castings shall conform to the requirements of this sub-section.
5.4.1 All castings shall be visually inspected to ensure that they are sound and free from shrinkage
cracks, hot tears, gas holes, blisters, or other similar injurious defects.
5.4.2 Nodular iron castings shall be inspected as follows:
a. A minimum of one set of Charpy V-notch impact specimens shall be made from material
adjacent to the tensile specimen on each keel or Y-block. These specimens shall have a minimum
impact value of 1.38 kgm at 20 °C.
b. The keel or Y-block cast at the end of the pour shall have a minimum thickness equal to the
thickest section of the main casting
c. Test bosses, integrally cast and preferably at least 25 mm in height and diameter, shall be
provided at critical areas of casting for subsequent removal, for the purpose of hardness testing and
microscopic examination. Critical areas typically are heavy sections, section changes, high stress
points, flanges and so forth. Classification of graphite nodules shall be in accordance with
ASTM A 247.
d. Brinnell hardness readings shall be made on the actual castings at feasible locations. Sufficient
surface material shall be removed prior to hardness readings to eliminate skin effects. Readings shall
also be made at the extremities of the casting at locations representing sections poured first and last.
These shall be made in addition to Brinnell readings on the keel or Y-blocks.
5.4.3 Ferrous castings shall not be repaired by welding, peening, plugging, burning-in, or impregnating
except for the following measures:
a. Weldable grades of steel castings may be repaired by welding using a qualified welding
procedure based on ASME Section VIII and IX
b. Cast gray iron or nodular iron may be repaired by plugging within the limits specified in
ASTM A 395. However, unless otherwise agreed upon by SABIC and the manufacturer, plugs shall
not be used in the gas-pressure-containing wall sections, including the bore under the liner. The
drilled holes for a plug shall be carefully examined by liquid penetrant to ensure the removal of all
defective material. All necessary repairs not covered by ASTM shall be subject to approval by SABIC.
5.4.4 When magnetic particle inspection as described in ASTM E 709 is required, acceptability of defects
shall be based on a comparison with the photographs in ASTM E 125. For each type of defect, the degree
of severity shall not exceed the following limits:

Shop Inspection and Testing of Reciprocating Compressors

Regardless of these generalized limits, it shall be the vendor’s responsibility to review the design limits of
all castings in the event that more stringent requirements are specified. Defects that exceed the limits
above shall be cleaned out to meet the quality standards cited above, as determined by additional
magnetic particle inspection before repair welding.
3.4.5 Liquid penetrant inspection shall be performed on all repair welds.
3.4.6 Flux-core welding shall not be used for equipment in hydrogen service.
6. Testing
6.1 Mechanical Test
6.1.1 Running and optional tests, including all manufacturer’s standard tests, that are not defined in this
standard or in the supporting documents, shall be defined by vendor in proposal. Detailed procedures for
all tests shall be submitted for SABIC review and approval at least 6 weeks before the scheduled test
dates. These procedures shall contain qualifying values for all measured parameters.
6.1.2 Acceptance of shop tests shall not constitute a waiver of requirements of a field test run under
specified operating conditions, nor does inspection relieve the vendor of responsibility in any way.
6.1.3 Before the mechanical running test, crank web deflection shall be recorded and checked (see
Appendix 2).
6.1.4 A bar-over test of the frame and cylinders shall be made in the vendor’s shop to verify piston-end
clearances.
6.1.5 The piston rod runout shall be recorded. The inspected data shall be within the following tolerances:
(See Appendix 5), where runout is the difference between maximum and minimum readings measured with
a dial gage.

Shop Inspection and Testing of Reciprocating Compressors

6.1.6 The mechanical running test shall be carried out with at least one suction valve assembly and one
discharge valve assembly for checking the valve action.
6.1.7 All mechanical lubricators shall be filled with lubricant prior to compressor start-up, and all turning
mechanisms shall be checked for suitable pre-operation.
6.1.8 The mechanical running test shall be held for at least 2 h after the lube oil or bearing temperatures
have stabilized.

6.1.9 During the test, the following items shall be recorded at intervals of 15 minutes:
a. Speed (rpm) of compressor
b. Pressure lube oil if forced feed lube oil system is used
c. Temperature of atmosphere, lube oil, rod packing, and cooling water
d. Vibration
e. Noise level, if required
f. Power consumption, if required
6.1.10 The compressor speed during the mechanical running test shall not be less than the compressor’s
rated speed.
6.1.11 The bearing oil drain temperature shall not exceed 60 °C, unless otherwise specified. Oil
temperature rise through the bearing shall not exceed 10 °C.
6.1.12 During the mechanical running test, vibration shall be measured on the crankcase. Following shall
be the maximum allowable vibration amplitudes (peak to peak):

Shop Inspection and Testing of Reciprocating Compressors

6.1.13 During the mechanical running test, unusual sounds, for example knocking or tapping shall not be
acceptable.
6.1.14 If required for reference data, the sound level test shall be carried out during the mechanical
running test.
6.1.15 When pneumatic unloaders are specified, at least one of the unloaders shall be inspected for the
specified movement by pneumatic load, before or after the mechanical running tests.
6.1.16 Immediately after completion of the mechanical running test, the main bearings, crank bearings,
and cross head bearings shall be checked for temperature and sufficient lubrication. Crank web deflection
shall also be recorded and checked. See Appendix 2.
6.1.17 If dismantling is needed because of any corrections, for example improvement of bearing
temperature or vibration, the initial test shall not be acceptable. The test shall be repeated after such
corrections are completed.
6.1.18 When specified on the data sheets, auxiliary equipment and consoles shall be given independent
4 h run tests.
6.1.19 When specified, compressor shall be dismantled after the mechanical running test and the
following parts shall be visually inspected on each stage:
a. Cylinder or cylinder liners, or both
b. Piston rod
c. Piston rings or rider rings, or both
d. Suction and discharge valve assembly used in mechanical running test or performance test, or
both
e. Rod seal packing

f. Lube oil filter element
g. At least one main bearing
h. Piston and rider rings grooves
i. Crank pin bearing and connecting rod bearing
6.1.20 Prior to the commencement of any operational tests, a complete dimensional inspection, Quality
Control document review, and functional test of all subsystems/auxiliaries shall be conducted, including bar
over test, piston end clearance check, and rod runout measurements.
6.1.21 If it is necessary to investigate the cause for undue heating and sound, the bearings shall be
visually inspected.
6.1.22 If required by SABIC, the crankcase shall be visually inspected.
6.2 Hydrostatic and Gas Leakage Tests
Pressure containing parts, (including auxiliaries) shall be hydrostatically and gas leakage tested in
accordance with SES G13-S01.
7. Appearance and Dimensional Inspection
7.1 Unless otherwise specified, the following inspection reports shall be recorded by the vendor and
witnessed by SABIC:
a. Elongation of big-end bolts (see Appendix 3)
b. Clearance table (see Appendix 4)
c. Valve lift and unloader stroke
7.2 The following items shall be checked:
a. Main dimensions
b. Size, position, and rating of flanges at points of battery limit
c. Dimensions of frame or baseplate and template, if any. The allowable tolerances of the distance
between the foundation boltholes shall be as follows, unless otherwise specified:
(i) Pitch tolerance between each adjacent hole ± 1.5 mm
(ii) Total pitch tolerance between end holes in a straight line ± 3.0 mm
d. Size, position and type of threaded connections at points of battery limit
e. Type and size of coupling and their guards, if any
f. Type, size and number of anchor bolts, if any
7.3 The nameplate shall be checked for correctness of data and the direction of rotation, which shall be
indicated by an arrow.
Note: Checklist for appearance and dimensional inspection will be prepared by SABIC.
8. Other Tests
8.1 The cast flywheel shall be balanced after machining.
8.2 Instrumentation (including local panel) shall be inspected and tested in accordance with the applicable
instrumentation specifications as specified.
8.3 When pressure vessels, for example pulsation suppression equipment, heat exchangers, separators,
and receivers, are provided, they shall be inspected and tested in accordance with the applicable
specification.
8.4 Auxiliary equipment, for example lube oil pump, cooler and filter, shall be checked against the
applicable drawings and specifications.

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