How to specify high pressure feed pump?

HOW TO SPECIFY HIGH PRESSURE FEED PUMP?

1. General

This specification covers a horizontal axially split centrifugal pumps with heads above 150 meters of water. and the power capacity above 500 kW. They are indended for heavy-duty operation and reasonable service life for highly corrosive environment usual for SWRO desalination plants.

2. Standards

These standards cover the pump manufacturing and testing.
  1. Flange dimensions as per ANSI
  2. Coupling guard according to ANSI B15.1 or equivalent European standard,
  3. Pump test as per Hydraulic Institute level A  ANSI/HI 2.6-1994.
  4. Motor test as per IEC standard.
  5. Material Certificates – EN10204 3.1 for the main components according to DIN 50049. For each component a foundry heat melting batch certificate validating PREN-38 or more shall be provided.
  6. Stamping of name plates will be in accordance with Crenger template.

The HI level A standard establishes the following performance tolerances: at the rated capacity – 0,+ 5% for head, at the rated head and rpm – 0,+10% for the flow rate, the contract pump efficiency being considered as the minimum efficiency.

3. Performance

Pumps should be reliably operable (from hydraulic, mechanical and control points of view) in the operation range specified by the client. Hydraulic stability implies free-of-cavitation operation sufficiently off the minimum continuous flow point and the run-away zone. All pieces of equipment (motors and VFD included) should be matched without unnecessary redundancy or over-sizing.

The pump design should meet the following criteria.

  1. The requested pressure-flow range.
  2. Maximum overall (wire-to-water) efficiency of the whole unit.
  3. Safety margin between the available and required NPSH for the pump.
  4. Operation within the allowable limits (set by the minimum continuous flow rate and maximum flow rate).

The Vendor shall submit the performance curves depicting total dynamic head, pump hydraulic efficiency, NPSHr, NPSH40000 for 40000 hours of operation as a function of the flow rate. The curve formats are shown in Fig.1 below.



Predicted efficiency

The predicted values of the pump efficiency should take into account the following points.

  1. Overall (wire-to-water) efficiency should be equal to the pump efficiency reduced by losses such as, but not limited to, driver losses including thrust bearing losses and motor and VFD losses.
  2. The efficiencies stated in the pump datasheet and the performance curves shall be regarded as guaranteed ones. They shall absorb the instrumentation inaccuracies given in Table 3 below.
  3. The minimum acceptable pump efficiency at the rated conditions stated above shall be not less than as shown in Fig.2 (www.pumps.org) below
  4. The pump  datasheet is a part of the present specification. The pump performance curves  shall be in full agreement with the datasheet.

Curves for pump minimum efficiency estimation

4. Sizing

Pumps shall be sized according to the weight-averaged maximum efficiency for at least 3 operation points submitted by the Client for the pumps driven by the variable speed drive. Point 4 (extreme operation) shall be used for the continuous maximum RPM selection.

5. Construction

  1. The pump design shall be horizontal, axially split, in-line.
  2. Double volute design is requested
  3. Impeller and casing wear rings shall be in a duplex overlaid.
  4. Impeller shall be of enclosed double suction type.
  5. For capacities above 1000 kW sleeve bearing are required.
  6. Bearings shall be of the SKF type.
  7. Lubrication shall be by a ring or flood oil bath methods.
  8. Bearing isolators shall include metallic labyrinth seals. The Vendor shall specify the maximum operating speed, pressure, and temperature for the offered isolators.
  9. Mechanical seals should be of single, cartridge, hydraulically balanced, non-fretting, stationary seal design. The seals should have hastelloy C springs. There should be no “dynamic” elastomer mounted on a pump shaft. Lapped faces should be easily vented.
  10. Seals to be flushed with sea water after 20μm cartridges.
  11. Coupling shall be of flexible disc spacer type. Coupling shall have an appropriate spool piece spacer, to enable quick installation of the torque meter if field performance test with a torque meter will be required. Coupling to be machined on pump. Motor half coupling hub to be pilot bored and free-issued to the motor manufacturing for fitting and balancing on the motor rotor
  12. All flanges shall be of ANSI standard.

6. Materials

All wetted parts of the pump and all shaft sleeves shall be of duplex stainless steel or better material. The PREN will be calculated according to the PRE and effective sum for the stainless steels alloys proposed. The calculation will be based on minimum and maximum weight percentages of the elements per the material specification and / or standard proposed.
- PREN = %Cr +3.3x %Mo+16x %N.
- PREN-value recommended to be above 38 (see graph below).
- effective sum = %Cr +3.3x %Mo+2x%Cu+2x%W+16x %N.
- effective sum-value preferred to be above 38 .

The evaluation and ranking of the proposed materials of construction will be based on the PREN and effective sum calculations and on mechanical, physical, workability, casting and welding properties.

The Vendor shall avoid usage of gaskets and seals containing graphite. Avoid the use of graphite in greases and packing. Carbon, graphite-lubricated gaskets, packing, greases etc. will initiate severe corrosion of stainless steel.

External and internal bolting shall be of SS316L and UNS31803 (duplex SS) respectively.

7. Instrumentation

Table 1 Pump instrumentation

No Instrument supplier
1 X-Vibration sensor, pump NDE provision
2 Y-Vibration sensor, pump NDE provision
3 X-Vibration sensor, pump driving end provision
4 Y-Vibration sensor, pump driving end provision
5 Z-Vibration sensor, pump axial direction, non-driving end provision
6 X-Vibration sensor, motor drive end with motor
7 Shroud sensor provision
8 Y-Vibration sensor, motor drive end with motor
9 Temperature sensor, pump driving end 1
10 Temperature sensor, pump NDE 1
11 Vibration IO transmitter-converter Supplied by Client
12 Oil level gauge 1

8. Alarm & Trip Points

Table 2 Alarm limits for pump temperature and vibration sensors

No Measurement Alarm (H) Trip (HH)
1 Temperature, pump bearing 80 90
2 Vibration, pump bearing 5 mm/s 9 mm/s

9. Oil Lubrication System

A self-contained oil lubrication system shall be included in the scope of each high pressure pump supply if forced lubrication is selected by the Vendor. The API-complied system shall include the following.

  1. 2 micron filters.
  2. Return magnetic filter.
  3. Oil/water heat-exchanger.
  4. Main motor driven lube oil pump.
  5. Backup pump sized as the main pump .
  6. Carbon steel oil reservoir and associated instrumentation (eyeglass indicator, level transmitter, electrical oil heater).
  7. Oil temperature RTD and local temperature indicator
  8. Oil low pressure switch.
  9. Oil temperature control valve.
  10. Pump size to be suitable for 150% of oil required and equipped with a by-pass  valve for excess oil.
For details see "General requirements for oil lubricatrion system".

10. Electric Motor

The motor shall be a heavy duty squirrel cage induction type IP55, Class F insulation. A thrust bearing of ample capacity to the maximum hydraulic thrust load under all conditions of operation calculated L10 life shall be no less than 8800 hours. The motor shall be standard (or premium) efficiency, 1.0 service factor. The motor shall be supplied with 6 RTD temperature elements and a space heater.
For details see "General requirements for high capacity motors".

11. Prototyping

The Vendor should present the construction details of the nearest Ns pump – a prototype that has been in continuous trouble-free operation for more then one year.

Table 3: Proposed Design and Prototype Geometry Details

  Category Proposed design Prototype
1 Casing diameter    
2 Impeller diameter    
3 Shaft diameter at coupling    
4 Shaft diameter at Impeller    
5 Span at Bearings    
6 Flow m3/hr    
7 Head m    
8 Speed rpm    
9 Ns    

12. Tests

  1. Pumps are to be tested according to DIN1944 and Hydraulic Institute Standard Test Code, acceptance level “A”.
  2. The performance test at the Vendor's workshop shall be according to BS 5316 Part 1. The performance test shall demonstrate the equipment reached the guaranteed values. The performance test does not exempt the Vendor from performance warranties as described in paragraph 8.
  3. The Vendor shall perform a pre-installation Performance Acceptance Test. The test shall take place in the Vendor’s facility on equipment operated under the load conditions specified above. The Vendor shall give notice three weeks prior to the date on which the laboratory, shop or field-witnessed test is to be made, so that a representative of each party may be present.
  4. The non-witnessed pump vibration test is at full-speed using the slave motor.
Vibration Monitoring
  1. The complete unit, when operating within the specified head range, shall be free of excessive vibration, cavitation and noise. The following should be taken into account. The vibration acceptance test shall comply with the API/ISO  and HI codes.
  2. Vendor should state and clarify the codes and procedures for vibration test (ISO 2373-B-III or API 610 Table 2-5).
  3. Unfiltered vibration x and y reading on pump thrust bearing at any flow within the pump's preferred operating region should be below 3.0 mm/s RMS and on motor's top bearing below 5.0 mm/s RMS (API 610 9th Edition).
  4. Vendor should provide the vibration field readings on the prototype pump (with similar Ns and Nss) for 3 cases: BEP, minimum flow rate, and maximum flow rate conditions.

Table 4. Sensor quantity and location – pumps with installed spare pump

Service Operation < 1000 hours/year  Operation > 5000 hours/year
Size, kW =< 75 kW 90 - 630 kW >= 710 kW =< 75 kW 90 - 630 kW >= 710 kW
End-suction pump none none none None none none
Axially-split pump n/a none none n/a V1, V2 V1, V2
Motor none none none None V1, V2 V1, V2

Table 5. Sensor quantity and location – pumps without installed spare pump or remote operation

Service Operation < 1000 hours/year  Operation > 5000 hours/year
Size, kW =< 75 kW 90 - 630 kW >= 710 kW =< 75 kW 90 - 630 kW >= 710 kW
End-suction pump none none none None V1 V1
Axially-split pump n/a V1,V2 V1,V2 n/a V1,V2 H1, V1, H2, V2,
Motor none none none None V1, V2 V1, V2
Site Test

Pumps are to be field tested according to the Hydraulic Institute level A standard.
Accuracy grades of measurement devices shall be considered equal or better then the following.

Table 6. Accuracy grades of measurement devices

  Device type Accuracy, % of measured value
1 Level transmitter A(L) ±0.1
2 Pressure transmitter, A(P) ±0.5
3 Flow transmitter, A(Q) ±1.0
4 Power transmitter, A(Power) ±0.5
5 Rotation speed, A(rpm) ±0.3

Before the field test the Vendor shall check and approve the instrumentation selection and its calibration and mounting.
The performance test shall be conducted for all duty points described in the pump datasheet. The contracted efficiencies guaranteed by the Vendor (or the performance curves) shall absorb the instrumentation inaccuracies given in table 2.
The performance test does not exempt the Vendor from performance warranties described in paragraph 13.
The shop tests requested are listed in Table 5.

Table 7. Pump shop tests

No Test type Non-witnessed (successive pumps) Witnessed (first pump)
1 NDT(1) X --
2 Bump resonance -- X
3 Vibration X X
4 Hydrostatic X --
5 Performance X X
6 Bearing temperature X X
7 NPSHr -- X
8 Noise -- X
9 String test For capacities higher than 500 kW, witnessed
10 Oil lubrication system (if applicable) During string test
  1. NDT reports are required for cast parts: stage casing, impeller, etc.
  2. NPSHR 3% curve is to be supplied from a model test of the same Ns & Nss speeds hydraulic design.
  3. The sound pressure level test may be done on site as an alternative to the factory test.
  4. String test duration shall be not less than one hour for each performance point. Only one string test per the pump type shall be performed. The pump string test shall be conducted with the contract motor and contract VFD for all duty points specified in the pump datasheet.

The Vendor shall perform a pre-installation performance acceptance test. The test shall take place at the Vendor’s facility on equipment operated under the rated conditions specified above. The Vendor shall give notice three weeks prior to the date on which the laboratory, shop or field-witnessed test is to be made, so that a representative of each party may be present.
The witnessed first pump performance test shall be within the full range of the design rotation speeds.
The motor test standard should be specified. (The IEC Summation of Losses Method without any minus tolerance is preferable one.)
The shop performance test results shall not be de-rated to the site conditions under any pretext (i.e. hydraulic imperfection of the intake station sump geometry or interconnecting piping, instrumentation type and location not meeting the applied standards).
It is the whole responsibility of the Vendor to request from the Purchaser any relevant information about the site conditions and his (the Purchaser) commitment to “good engineering practice” design criteria (for example: HI recommendations for the suction and discharge design), and to alarm the Purchaser to any potential problems.

13. Noise Emission

The Vendor shall complete the attached submittal form (Table 5) and submit one for specified loading and design conditions with the quotation, indicating whether they relate to no-load or full-load running conditions. When sound level data is requested and sound power level data is also available, this information shall be included.

When noise emission requirements cannot be satisfied by the Vendor’s standard design, alternatives for special design or for acoustical treatment of the standard design shall be quoted as a separate line item.

Charges for testing and any increase in the quoted price, because of noise specifications, shall be noted in the overall equipment cost and shall be shown as separate items in the Contractor's quotation.

Abatement designs shall not limit equipment operations or accessibility, nor shall they conflict in any way with the Purchaser's safety and engineering standards.

The range of operating conditions expected for the pump is specified in Table 1.

Specified noise emission limits shall not be exceeded for operation at any point within this range.

13.1 Maximum Permissible Sound Level (MPSL)

Equipment sound levels in decibels (re: 20 µPa) at a distance of 1 meter from the equipment, shall not exceed 85 dBA as measured in post-installation testing, when operated under the loading conditions specified above. Post-installation sound testing will be conducted according to ANSI/ASME PTC-36 – Measurement of industrial sound.

The noise level shall be determined by using an “A-weighing curve” [IEC 123] and the sound levels shall be expressed in dB[A]. The test shall be performed in accordance with ISO recommendation R.1680, July, 1970.

13.2 Maximum Permissible Octave Band Sound Power Levels (PWL)

(This section applies only to equipment sited outdoors.)

Equipment sound power levels, in decibels (re 1 picowatt), shall not exceed the values tabulated below in any octave band when operated under the loading conditions specified above.

Table 8. Equipment Sound Levels Guaranteed by the Vendor
Frequency Hz 63 125 250 500 1000 2000 4000 8000
Acceptable Sound Pressure Level 127 120 113 110 108 107 107 106
Total motor pump set in dB(A) (to be filled in by Vendor) * * * * * * * *
*To be filled in by the Vendor
13.3 Warranty of Equipment Noise Emission

The Vendor’s equipment shall not exceed the Maximum Permissible Sound-Level (MPSL) and, if applicable, the octave band sound Power Levels (PWL) stated in the specification.

The Vendor shall be responsible for performing all remedial work necessary for compliance with this specification at no additional cost to the Purchaser.

A pre-installation acceptance test shall be performed by the Vendor. The test shall take place at the Vendor’s facility, at a qualified laboratory, or at an installation in the field, according to ANSI B93.71M (Test code for the determination of airborne noise level of hydraulic fluid power pumps) and IEEE-85 (Test procedure for airborne sound measurements on rotating electric machinery) on same or similar equipment operated under the load conditions specified above. The Vendor shall give notice three weeks prior to the date on which the laboratory, shop or field-witnessed test is to be made, so that a representative of each party may be present.

The Vendor for approval by the Purchaser may propose an alternative sound-level test code or procedure. The Purchaser will perform a post-installation verification test. The test will be conducted in accordance with Purchaser post-installation field verification test procedures.

The Purchaser reserves the right to waive pre-installation acceptance tests or post-installation acceptance tests when certified equipment sound-level test data, acceptable to Purchaser, are furnished.

The Purchaser reserves the right to reject any item which, when tested using specified test procedures, does not meet the required limits. If a pre-installation sound-level test has been waived and the equipment exceeds required sound-level limits on field-testing, remedial Vendor action will be required.

13.4 Noise Vibration Isolation

If the noise level surpasses the Maximum Permissible Sound-Level (MPSL), equipment shall be furnished with noise vibration isolation treatments in accordance with ASHRAE 1995 Applications Guide, Chapter 43, Sound and Vibration Control, Table 42. Equipment not covered in Table 42 shall be provided with, at minimum, ribbed neoprene pads loaded for a static deflection equal to 20% of their rest height. Steel-spring isolators shall be provided with ribbed neoprene pads mounted in series with the springs.

14.0 Documents Submittal

Table 9. Documents submittal: PO - purchase order, MRB - manufacturer record book
No Document type Used for When
1 Certified GA drawing Interconnecting piping layout and civil construction drawings preparation 4 weeks after PO
2 Cross section & parts and material list Design and construction details and material check 4 weeks after PO
3 Mechanical seal Material check 16 weeks after PO
4 Performance curves Requested performance check 4 weeks after PO
5 Torque curves Motor specification 4 weeks after PO
6 Coupling drawing Motor shaft construction check and torque meter selection 16 weeks after PO
7 Piping & Instrumentation Diagram (P&ID) Check of instrumentation included in the scope of supply and site installation check 4 weeks after PO
8 Hook-up drawing (instrumentation and seal flushing) Site installation check 4 weeks after PO
9 Instrument list Check for compliance with the project specification 4 weeks after PO
10 Certificate of compliance Check for product components origin with MRB
11 Material certificates (3.1B) for casing, impeller, shaft Check for compliance with the materials requested by the specification with MRB
12 Allowable forces and moments report Interconnecting piping layout and civil construction drawings preparation 4 weeks after PO
13 Spare parts list Check to see whether it meets quantities needed for commissioning and the guaranteed operation period 4 weeks after PO
14 Alignment certificate Should be obtained before the performance, string and vibration tests with MRB
15 Manufacturing schedule Manufacturing schedule shall be taken into account when negotiating the payment schedule with the vendor. 4 weeks after PO
16 Inspection test plan (ITP) Check if it contains all planned inspections and their times 4 weeks after PO
17 Interlock list (vibration, temperature, flow rate @ rpm) This data is part of guaranteed performance 4 weeks after PO
18 Operation & maintenance manual Shall be submitted together with pump with MRB
19 Building records of run-outs and clearances (wear rings, shaft,  rotor, throttle sleeve, sealing chamber) Shall be obtained before bearing vibration test with MRB
20 Welding repairs of castings Check visually during acceptance control with MRB
21 Dynamic balancing of impeller (ISO1940 Gr2.5) Shall be submitted before bearing vibration test with MRB
  Test reports    
22 Test procedure specification Formal basis for the test procedure approval 4 weeks after PO
23 Test instrumentation calibration certificates Formal basis for the test procedure approval with MRB
24 String test Full pump set test at the guaranteed conditions including all operation points with MRB
25 Bump test Shall be submitted for any new pump (differing from prototype by more than 30% in flow rate) 4 weeks after PO
26 Noise test Shall be done during the string test with MRB
  Non-destructive examination (NDT)    
27

Visual NDT

Shall be submitted if welding repairs are executed with MRB
28

Radiographic NDT

  with MRB
29

Ultrasonic NDT

  with MRB
30

Magnetic NDT

  with MRB
31

Penetration NDT

Shall be submitted if welding repairs are executed with MRB
32 Casing hydrostatic test   with MRB
33 NPSHR (3%) test   with MRB
34 Performance test Shall be executed for at least 5 points with MRB
35 Bearing temperature test Shall be executed for at least 1 hour of uninterrupted run with MRB
36 Vibration test (overall unfiltered and FFT spectrum) Shall be executed for at least 1 hour of uninterrupted run with MRB
37 Bearing housings resonance test Shall be submitted for any new pump (differing from prototype by more than 30% in flow rate) with MRB

15.0 Performance Warranty

  1. Site performance test is described in paragraph 10.1. It shall be conducted to verify the wire-to-water efficiencies composed of the pump and motor efficiencies.
  2. The wire-to-water efficiency values shall be defined for pumps according to the procedure described in Appendix A.
  3. If efficiencies measured are below the contractual ones, the Vendor shall upgrade the pumps at no costs to the Client.
  4. The performance warranty period is five (5) years of operation from commissioning. The warranty shall be supported by the Preventive Maintenance (PM) plan approved by the Client. The Vendor is encouraged to suggest another warranty period, in accordance to related PM plan.
  5. During the warranty period the pump efficiency decrease rate shall be not more than [0.25]% (abs) per year, normalized to design conditions according to PM plan.
  6. Actually measured wire-to-water efficiency at the pump commissioning is the starting point for the decrease rate monitoring, after completion of acceptance test . The contractual values for pumps and motors shall not be used for reference.
  7. Data normalization shall be done according to the pump affinity laws.
  8. The efficiency decrease rate shall be monitored for each pump and be measured and reported to the Vendor quarterly. 
  9. At higher efficiency decrease rates than the one stated in p.5 the Vendor shall pay for the excess energy until the pump remedy. Should the power consumption exceed the warranted prior to the termination of the 5 [five] year period (or other period as per contract), the pump manufacturer will refurbish the pump and pay the proportional amount of the refurbishment cost, labor and spare parts according to the following formula. See also General Terms and Conditions Contract. Payment = Refurbishment Cost x [ 60 – remaining months]/60
    The excess of the power consumption cost beyond the warranted value will be paid by the supplier/manufacturer until the successful completion of the refurbishment.
    The excess energy consumption cost will be calculated as per 0.075 US$ per  kW*hr. This amount shall be adjusted to the local tariffs  as published by Public Utility Administration.
  10. The PM plan shall guarantee the pump performance after overhaul be fully restored to the contracted one.
  11. It is full responsibility of the Vendor to periodically check and approve the pumps preventive maintenance plan, the pumps data acquisition system, the pumps operation history, and the instrumentation calibration plan. By the Vendor request the Client shall submit all relevant information at any time. The Vendor shall alert the Client of any possible problems prior to the efficiency degradation measurement.

16. Mechanical Warranty

  1. All equipment shall be guaranteed against defective workmanship and materials for a period of three (3) years after the date of shipment from the plant. If the Purchaser claims the equipment or parts are defective within the one year warranty period, he or she shall notify the manufacturer immediately so that inspection of the equipment in question by an authorized agent or issuance of shipping instructions for return of the equipment can be undertaken. In the event the equipment or part is determined to be defective, it shall be corrected by repair or replacement at [*] site.
  2. Paragraph 1 does not cover consumable and wear parts [wear rings, sleeves, brushing, etc.], which are under the performance warranty as described previously.
  3. All bearings shall have the guaranteed service life of over 40,000 hours (B10 life), minimum guaranteed life expectancy – two [2] years.
  4. Mechanical seals shall have a guarantee of two [2] years operation.
  5. The electric motors will have a guarantee of two [2] years operation (if applicable).
  6. The repair, replacement of the defective items and its supervision shall be at the Vendor expense wholly. This item doesn’t cover the losses of the purchaser revenue due to the unit downtime.
  7. To minimize the revenue losses, the vendor shall submit the spare parts list to be stored at the site.

17. Non-Destructive Inspection of Pump Parts

Reference Documents are listed below.

  • BS EN 10204 Documents on Material Testing
  • MSS SP-55 Visual Inspection of Steel Castings
  • ASTM E94 Recommended Practice for Radiographic Testing
  • ASTM E125 Reference Photographs for Magnetic Particle Indications on Ferrous Castings
  • ASTM E165 Practice for Liquid Penetrant Inspection Method
  • ASTM E186 Reference Radiographs for Heavy Walled (2”/50mm to 4.1/2”/115mm) Steel Castings.
  • ASTM E446 Reference Radiographs for Steel Castings up to 2”/50mm thickness
  • ASTM A609 Standard Specification for Ultrasonic Examination.
  • ASTM E709 Practice for Magnetic Particle Examination.
  • ASME IX Welding and Brazing Qualifications.
  • API 610 Centrifugal Pumps for General Refinery Service 10th Edition.
  • ASME V Non Destructive Examination
  • ASME VIII ASME Boiler and Pressure Vessel Code Division 1
Material Test Reports (Ref BS EN 10204 3.1)

Chemical analysis and mechanical test reports are required confirming full compliance with the specified requirements. The test confirming compliance shall be carried out on specimens related to the actual castings. This testing shall be carried out by a testing centre which is independent of production in the manufacturers works and which has the necessary facilities at its disposal; in the event that the independence of the testing centre cannot demonstrated then the client must be notified.

All certificates shall contain the following information.

  1. Name of Vendor
  2. Purchase order number and date
  3. Vendors order number
  4. Identification number of certificate and its date of issue
  5. Material specification(s)
  6. Material charge number, batch number or heat lot number
  7. Mechanical properties recorded from results of chemical analysis
  8. NDT methods and results, where applicable
  9. Heat treatment procedures, furnace charge number and heat treatment records, where applicable
  10. Such supplementary or additional information as may be required
The chemical analysis shall be witnessed by the company representative.
Visual Inspection

Visual inspection shall be performed in accordance with ASME V Article 9 after final heat treatment. The castings surfaces shall be examined visually and shall be free from sand, scale, cracks and hot tears. Surface conditions shall comply with the requirements of MSS SP-55.

Non-Destructive Testing

100% magnetic particle examination of all accessible surfaces, including those exposed by final machining, shall be carried out on all castings. The acceptability of defects shall be based on a comparison with the photographs given in ASTM E 125.

Dye penetrant examination shall be carried out when magnetic particle examination is not feasible. 100% Dye penetrant examination of all accessible surfaces, including those exposed by final machining shall be carried on all castings.

Radiographic inspection shall be carried out to the requirements of ASME VIII Division 1 Appendix 7. It shall be applied to all areas agreed as critical between the client and the supplier taking account of both foundry techniques and service stresses.
Prior to inspection the supplier shall submit for approval a sketch technique for checking each area so defined.
Ultrasonic inspection shall be carried out where radiographic inspection is not feasible.

Repairs

Major repairs shall be undertaken only after written permission has been obtained. Only properly controlled weld repairs are permitted, An approved Welding Procedure Specification is required. no other type of method may be used and mechanical methods, e.g. peening or plugging are not permitted. Qualified personnel working to written and qualified procedure in accordance with ASME IX shall only carry out weld repairs and procedures must include pre-weld and post-weld heat treatment if applicable. Providing the above conditions are fulfilled, permission to carry out major repairs will be granted, unless the total mass of the resulting welds exceeds 10% of the mass of the casting. All weld repairs shall be followed by heat treatment as and when appropriate.

Definition of Major Repair
  1. Repairs to leaks occurring on hydrostatic test.
  2. Any repair where the depth of excavation exceeds 50% of the wall thickness or 25mm whichever is smaller, or a length or more than 150mm in one or more directions.
  3. Any individual repair where the area of excavation exceeds 65 sq.cm.
  4. Any repair where the total surface area of the repair exceeds 20% of the total casting area.
Inspection After Repair

All weld repairs shall be subject to non-destructive examination. For repairs classed as major the casting shall be inspected again, either in accordance with the next more severe inspection class, than that required originally, or to increase inspection requirements as agreed between the supplier and the Client.

18. Quality Plan & ITP

An Inspection Test Program (ITP) shall be submitted to the Purchaser, which identifies critical manufacturing stages and the controls used at each stage. Specific reference to NDT and casting upgrading controls must be included but in the interests of soundness all precasting activities, which have a bearing on casting quality, must also be covered. ITP shall be approved by the Purchaser with the instructions to proceed.

19. Quality Control Inspection

  1. The Purchaser QC inspector or representative has the right to inspect the items at the manufacturer's premises.
  2. QC inspector may audit manufacturing processes and verify the quality system implemented.
  3. The Vendor will notify The Purchaser at least fourteen (14) calendar days in advance of the date of planned inspection or test.
  4. In no circumstances ITP inspections may be cancelled.
  5. Test equipment used by the manufacturer will be calibrated by a certified laboratory.
Documents Supplied with MRB (Manufacturer Record Book)
  1. Certified drawings which include main dimensions and essential interface dimensions. The certified drawing shall be submitted as specified in the purchase order.
  2. Certificate of Compliance (C.O.C) according to EN-10204 (2.1) designation.
  3. Raw materials: Mechanical properties and chemical analysis according to EN-10204 (3.1) designation.
  4. Functional Test Reports and records; as specified in this specification.
  5. Installation instruction.
  6. Manuals for operation and maintenance.
  7. Calibration charts
Quality Control Inspection at Purchaser Premises
  1. The equipment items should be supplied properly packed and with enclosed MRB.
  2. The Vendor shall be notified within two days of any damaged packing cracks, structural damage, missing parts, discrepancies between Packing List and the Purchaser’s purchase order, inaccuracies in the nameplate data.
  3. Using this specification and the Vendor’s technical documents and certified drawings, the QC inspector shall check the dimensions, connection size and types, [flanges, standard or thread] for compliance.