‘APLSIRE: ‘Source inspection and Quality Surveillance of Rotating Equipment Scope 1) Study Guide for Source Inspection and Quality Surveillance of Rotating Equipment may be used as the basis for providing a systematic approach to source inspection to. Ans ensure that mechanical rotating equipment purchased meets the requirements specified in project documents and contracts. ‘Ans: determine whether manufacturers own quality systems have functioned appropriate! purchased equipment will mect contractual agreements. ‘Ans! > verify that the vendor quality process is working as it should, > verify that certain vital stops inthe inspection and test plan (ITP) have begn satisfactorily accomplished prior to manufacturing completion andor shipping, 2 Ref ces 4) Material Verification Program for New and Existing Alloy Piping Systems is given by. Ans. APL RP 578, 5) Steam Turbines is given Ans: ASME PTC 6, 6) Performance Test Code on Compressors and Exhausters is given by, ‘Ans: ASME PTC 10, 7) Gas Turbines is given by. ‘Ans: ASME PTC 22, 8) Standard Spcieation for Forged ov Rolled Alloy and Stainless-Steel Pipe Flanges Forged Fitings and ‘Valves and Parts for High-Temperature Service is given by, Ans: ASTM A182. 9) Quality Standard for Stee! Castings for Valves, Flanges, Fittings and Other Piping Components is given Ans: MSS-SPS5.— 10) Procedure for Deter given by. ‘Ans: SSPC-PA 2. ng Conformance to Dry Coa ings Thickness 11) SSPCis ‘Ans: Surface Preparation Guide. 1[Page3 Definitions, Abbreviations, and Acronyms 12) Portion of a pump’s hydraulic coverage over which the pur within the upper by the manufacturer is called: Ans: Allowable operating region. allowed to operate, based on vibration perature rise or other limitation, specified 13) 300 Series of stainless steel has austenite as its primary phase (face centered cubic erystal). Stainless steels in the 300 Series contain chromium and nickel, and some molybdenum and manganese is called: ‘Ans: Austenitie stainless steel 14) A fabricated (or east) str auxiliary components. it may be directly grouted {0 concrete foundations (after proper level bolted to pre-grauted chock plates is called: Ans: Beseplate, ‘ure, typically metal, used to mount, support, and align machinery and its i) oF '5) Bearing and lube oil temperature stabilization is generally accepted to be ‘Ans: not more than an increase of 2 °F (1 °C) over a 10-minute period at maximum continuous speed 16) What is the type of mechanical seal that uses a flexible metal bellows to provide secondary sealing and spring loading ? ‘Ans: Bellows seal 17) Flow rate at which a pump achieves its highest efficiency at rated impeller diameter is called: ‘Ans: Best efficiency point (BEP) Note: In API 610, speed is not included. 18) What is the chemical symbol for carbor equipment ? Ans: C 1¥ appear on an MTR or in aspecification/standard for 19) Documented and signed testimony of qualification, Certification generally refers to the confirmation of certain, specified characteristies of a produet or confirmation of a person meeting requirements for a specific qualification is called: Ans: Certification 20) A summation of carbon plus alloying elements contained in steel or alloy steel. The term may be found in specifications/standards and equipment purchase orders is called: Ans: Carbon equivalent (CE) 21) Typically used for an additional level of surety that materials in equipment actually contain the elements ‘Stated is called: ‘Ans: Certified Mill Test Report (CMTR) 22) A metal integrally bonded onto another metal (eg. plate), under high pressure and temperature whose properties are better suited to resist damage from the process fluids than the underlying base metal is called: Ans: Cladding 23) Plastic deformation (forming, rolling, forging, etc.) of metals below the reerystallization temperature of the metal is called: Ans: Cold working 7 ‘Ans: Compressor rated point 2|Page25) Shaft rotational speed at which the rotor-bearing-support system is ‘Ans: Critical speed ‘state of resonance is called 26) applications that are unspared/single-t significant loss of production, loss of called: Ans: Critical service stallations whereby loss of operation would result in ary process containment, or threat to personnel safety is 27) The factor that is applied to the tooth pitting index and the bending stress number, depending upon the characteristics of the driver and the driven equipment, fo account for differences in potential overload, shock load, and/or continuous oscillatory torque characteristics is called: ‘Ans: Gear service factor 28) What type of the equipment that is custom designed and engineered by the client and/or EPC to perform a project-specific function? ‘Ans: Engineered equipment ‘Note: Engineered equipment will typically require more source inspection than hon-engineered equipment. 29) Exists for mating gears when a tooth on the pinion does not repeat contact with ithas contacted all the other gear teeth is called: Ans: Hunting Tooth Combination tooth on the gear until 30) The position of a surface of a component or structure that is horizontal (within tolerances) with the base plate and at 90 degrees to the vertical plumb line is called: Ans: levelness Note 4) Nozzle and attachment levelness tolerances are not addressed in ASME BPVC, Section Vill Division. A; however, in the pressure vessel handbook, a % tolerance is permissible. 2) Tocheck levelness of a nozzle 6n a vessel, a level gauge Is used. If the bubble isin the middle of the designated lines, the nozzle is level. 3) Allevel gauge wauld be Used for verification and measurement that the angle ofa hillside (tangential) nozze is properly installed relative to the vessel centerline, 31) What is the document that certifies that a metal/material produet isin eonforn requirements (eg, chemical and mechanical properties)? ‘Ans: Material test report Mill test report (MTR) 32) The highest combined rod load at which none of the forees in the running gear (piston, piston rod, crosshead assembly, connecting rod, crankshaft, bearings, et.) and the compressor frame exceed the values in any component for which the manufacturer’s design permits continuous operation is called: Ans: Maximum allowable continuous rod load, 33) Highest speed at which the manufacturer's design permits continuous operation is called: ‘Ans: Maximum allowable speed. 34) The maximum continuous pressure for which the manufacturer has designed the rotating equipment (or any part to which the term is referred) when operating on the specified liquid or gas at the specified ‘maximum operating temperature (does not include mechanical seal) is called: ‘Ans: Maximum allowable working pressure (MAWP). 3|Page35) Maximum specified suction pressure plus the maximum differential pressure the pump with the furnished impeller is able to develop when operating at rated speed with liquid of the specified normal relative density (specific gravity) is called: ‘Ans: Maximum discharge pressure, 36) The highest exhaust steam pressure that the purchaser requires the easing fo contain, supplied at maximum inlet conditions is called: Ans: Maximum exhaust casing pressure, steam 37) An inaccuracy of rotating mechanical systems, specifically indicating that the tool or shaft does not rotate exactly inline with the main axis. Should be measured with a dial indicator, typically on V-blocks is. called: ‘Ans: Mechanical runout, 38) Mechanical runout is an inaccuracy of rotating mechanical systems, specifically indicating that the tool or shaft does not rotate exactly in line with the main axis, Should be measured ‘Ans: a dial indicator, ypically on V-blecks. 39) What is the chen Ans: Me. ical symbol for magnesium, which may appear on an MTR? 40) ‘The lowest pressure (measured at the inlet flange of the cylinder) below which the combined rod load, gas load, discharge temperature, or crankshaft torque load (whichever is governing) exceeds the maximum allowable value during operation at the set pressure of the discharge relief valve and other specified inlet gas conditions for the stage is called: Ans: Minimum allowable suction pressure 41) Lowest flow at which the pump can operate without exceeding the vibration limits imposed by the pertinent pump standard is called: Ans: Minimum continuous stable flow (MCSF). 42) The lowest exhaust steam pressure at which the turbi Ans: Minimum exhaust pressure is required to operate continuously is called: 43) The lowest inlet steam pressure and temperature conditions at which the turbine is required to operate continuously is called: ‘Ans: Minimum inlet pressure. le. eee ‘Ans: Misalignment. 45) What is the chemical symbol for m ‘Ans: Ma, nganese, which may appear on an MTR? 46) What is the chen ‘Ans: Mo. ical symbol for molybdenum, which may appear on an MTR? 47) NPSH determined by the purchaser for the pumping syst pumping temperature is called: ‘Ans: Net pump suction head available (NPSHa), With the liquid at the rated flow and nor 48) NPSH that results in a 3 % loss of head (first-stage head in a multistage pump) determined by the vendor by testing with water is called: ‘Ans: Net pump suetion head requited NPSHG3 (per API 610). 4|Page49) A standard for designating pipe sizes (inches) and associated wall thickness (schedule) is called: ‘Ans: Nominal pipe size (NPS). Note: e.g. the nominal pipe size for a 4-in. pipe is normally shown as NPS 4, 50) What is the report filled out by the SI detailing an issue that has been discovered to not be in accordance with project contractual agreements, such as the PO, engineering design, specified codes, standards, or procedures? ‘Note: Nonconformance report (NCR). 51) A quality process that involves the examination, testing, and evaluation of materials, components, or assemblies without affecting their functionality, e.g, VT, PT, MT, UT, and RT is called: Note: Nondestructive Examination / Nondestructive Testing. 52) A departure/deviation from project contractual agreements, such as the PO, engineering design, specified codes, standards, or procedures is called: Note: Nonconformance. 53) Wiha Is the type of equipment that is designed and fabricated by vendors that includes off the-shelf items. such as valves, fittings, some skid units, instruments, pumps, and electrical gear. Such equipment is usually purchased by catalog model number? ‘Ans: Nonengineered equipment. ‘Note: Nonengineered equipment will typically require less source inspection than engineered equipment 84) What is the point at which usual operation is expected and optimum efficiency is desired and it usually the point at which the vendor certifies the heat rate is within the tolerances stated in this standard? Ans: Normal operating point 55) The power at which usual operation is expected and optimum efficiency is desired is called ‘Ans: Normal transmitted power (gears only). Note: The nonmal transmitted power may be equal to oF less than the gear-rated power, 56) Turbine stationary (nonrotating) airfoils Inlet, outlet, or pressure casing connections for pumps is called: ‘Ans: Nozzles 57) Inspection or test where the purchaser is notified of the timing of the inspection or test and the inspection or test is performed as scheduled, regardless of whether the purchaser or is called: Ans: Observed inspection (Observed test). ir representative is prese! 58) Pump whose impeller is supported by a cantilever shaft from its bearing assembly is called: ‘Ans: Overhung pump. 59) The difference between positive called: Ans: Peak-to-peak value. 1d negative extreme values of an electronic signal or dynamic m 60) A measurement of the position of the piston rod relative to the measurement probe mounting location(s) (typically oriented vertically at the pressure packing on horizontal cylinders) is called: Ans: Piston rod drop. 61) The change in position of the piston rod in either the vertical or horizontal direction as measured at a single point (typically at or near the pressure packing case) while the piston rod is moved through the ‘outbound portion of its stroke is called: ‘Ans: Piston rod runout. 5|Page62) Portion of a pump's hydraulic coverage over which the pump's vibration is: of the pertinent pump standard is called: Ans: Preferred operating region, 63) PQRi Ans: Procedure qualification record (PQR) Per ASME BPVC, Section IX, QW 200. 2, 64) The length from the nozzle or attachment face to the vessel shell centerline is called: ‘Ans: Projection. 65) A non-contacting sensor that consists of « tip, a probe body, an integral coaxial or tri connector, and that is used fo translate distance (gap) £0 voltage when used in conjunetion wi ‘oseillator-demodulator is called: Ans: Proximity probe. 66) A proactive quality process that and preventative activities i confidence that a product w ‘Ans: Quality assurance (Qa), Note: > QAincludes systematic measurement, comparison with a standard, monitoring of processes, and an associated feedback loop that is intencled to avoid deviations from specification > The QA process will specify the QC steps necessary during manufacture’ fabrication of a product ms fo prevent defects and refers to a program of planned, systematic, nted in a quality system that is intended to provide a degree of -onsistently meet specifications is ealled: 67) The specific steps in a QA process that aim to find potential defects in a product before itis released for delivery, eg. VI, PT, RT, UT, dimensional verification, etc. is called: ‘Ans: Quality control (QC) 68) DEORE skil, GERORSTEATED knowledge, HOeUmENE training, and GSeuimEHTEM experience required for personnel to perform the duties of a specific job, e.g. a certified source inspector is called: Ans: Qualification 69) The process of monitoring or observing the inspection and/or components for adherence to the specific procedure, product specification, code, or standard specified in contractual requirements is called: Ans: Quality surveillance. Note: quality surveillance and source inspection mean the same thing, gS es ‘Ans: Rated operating point. Note: Normally, the rated operating point is the specified operating point with the highest flow 71) Highest speed (revolutions per minute) of the gas turbine output shaft required of any of the operating conditions for the driven equipment and sit which site-rated power is developed, is called: Ans: Rated speed / 100 % speed. 72) Assembly of all the rotating parts of a pump is called: ‘Ans: Rotor 73) The term used to describe discoloration that occurs on the surface of stee] that has been previously blasted, eg. near-white or white metal in preparation for coating is called: Ans: Rust bloom Note: When rust bloom is found, the surface should generally be recleaned before coating using the same blast-cleaning process, 6|Page174) Fluid that is introduced into the seal chamber on the process fluid side in close proximity to the seal faces; typically used for cooling and lubricating the seal faces and/or to keep them clean is called: ‘Ans: Seal Dush ‘Ans: Seal gas, ‘Ans: Seal Buffer gas 77) A person who is an author icular area or topic. Supplier observation reports Documents filled ‘out by the SI s of what was noticed during product, surveillance, but not necessarily issues that may be considered defects or require NCRS: ‘Ans: Subject matter expert (SME) 78) The process of providing quality ‘a vendor or manufacturer/fabricator for use in the oil, petrochem upstream, midstream, and downstream segments is called: Ans: Source inspection Note: Source inspection largely consists of verifying that the vendor's own quality assurance process is functioning as it should to produce quality products that meet contractual agreements .and equipment being supplied by ‘and gas industry, including 79) Individual responsible for performing the actual source inspection activities at the vendor's facilities in accordance with the applicable inspection and test plan (ITP): ‘Ans: Source inspector 82) Application for which the equipment is designed for uninterrupted, continuous operation in critical service and for which there is usually no spare equipment is called: ‘Ans: Special purpose application 83) Normally idle piece of equipment that is capable of immediate automatic or manual startup and. continuous operation is called: Ans: Standby serviee. 84) A trade association of leading manufacturers of shell and tube heat exchangers: ‘Ans: Tubular Exchanger Manufacturers Association (TEMA) 85) What is the chemi Ans: Ti -al symbol for titanium, which may appear on an MTR? 86) The limits) of specified dimensions, physical properties, or other measured values ofa component is, called ‘Ans: Tolerance 7 [Pageinh aro eo omen as ‘Ans: Total indicator reading (VIR) oy. nanan, ‘Ans: Turndown 89) An organized program developed to impart the skills and knowledge necessary for qualification as a fours ciel called: 90) A rotor condition where the mass centerline (principal axis of inertia) does not coincide with the geometric centerline, expressed in units of gram-inches, gram-centimeters, or ounee-inchwes is ealled: Ans: Unbalance ‘Ans: Vertical inline pump —_———— eee ‘Ans: Vertically suspended pump 93) WPQis. ‘Ans: Welding performance qualification record per ASME BPVC, Section IX,QW 301 4 94) WPSis ‘Ans: Welding procedure specification per ASME BPVC, Section IX, QW 200.1 95) Inspection or test for which the purchaser is notified of the timing of the inspection or test and a hold is placed on the inspection or test until the purchaser or its representative is in attendance is called: Ans: Witnessed test 96) ASNT is ‘Ans: American Sodiety for Nondestructive Testing 91) ISAs ‘Ans: insiment Sostety of America 98) ISO is ‘Ans: Intemational Organization for Standrdization. : Manufachurers Standardization Society 100) NFPA is ‘Ans: National Fire Protection Association, 101) NEC is ‘Ans: National Electrical Code. B[ Page102) SSPC is ‘Ans: The Society for Protective Coatings, 4 Training and Certification i -ation for vendor/source inspection is, Ans: unigue to each organization § Source Inspection Management Program 104) Source Inspection Management Program are____. ‘Ans: generic in that they provide requirements and guidance on all types of projects that will require source inspection. 105) Source Inspection management programs may reference many other company-specifie source inspection procedures, practices, and policies, with more details needed for specific types of source inspection activities. Such as Ans: guidance on scheduling and conducting significant source inspection events, such as the pre-inspection (fabrication kick-off) meeting, the vendor quality coordination meeting, final acceptance testing, Ans: allow coordination with other project members involved in the ivity 107) Who should review the details of the project plan, location of the S/V and duration of the work and select the appropriate source inspector(s) for the assignment? Ans: The source inspection coordinator. is: 8 combination of the POF and COF assessments, S Project-specific Source Inspection Planning Activities 109) a project-specific inspection plan should be developed by. ‘Ans: the end user/EPC inspection coordinator 110) Who should identify dates for source inspection scheduled work process events? Ans: End users or EPCs, the end user, EPC, or other lien ‘Ans: the source inspector should Ans: conduct themselves professionally while visiting a vendor facility as a representative of their employer andicr purchaser. 113) If any conflict should arise during the inspection activity, the source inspector should _. ‘Ans: notify their supervisorpurchaser for resolution as soon as possible. Note: It is important thatthe source inspector not be confrontational or argumentative regardless of the ‘importance ofthe issue at hand; but rather simply indicate in objective terms how the vendor intends to proceed to resolve the issue. 9|Page114) Review of Project Documents include ‘Ans: REREHAINSIUREGR (purctace orders andor subcontracts), source TP, project specifications, tnginerng or labrcation drawings dala sheets, appcble cove, efetence, standards Las, | | cena acacia ‘Ans: confirm that the vendor has the most current approved documents, drawings, etc. specified in the engineering desien Note: Later editions of industry codes and standards do not apply ifthe engineering design has specified an earlier edition of a specitie standard. ‘Ans: the purchaser. 117) Contractual agreements, including __. ‘Ans: the purchase order, all specified engineering design documents, specified company standards, and specified industry standards, form the basis for the requirements for source inspection of the purchased products, ‘Ans: typically augment or supplement industry standards for issues not sufficiently well covered in industry standards, ‘Note: Company and client standards may cover engineered and nonengineered equipment. 119) “shall” statements, included in the Company and Client Standards ‘Ans: shall be met. Note All mandatory requirements. > They should be handled in accordanée with standard purchaser management NCR systems requirements. ‘Ans: expectations of the vendor, but not necessarily requirements. Note: > recommended requirements > These may become an issue to be reported in supplier observation ‘accordance with standard purchaser management systems, ports (SOR’s) and handled in ‘Ans: the user Of EPC in the contractual agreements ‘Or Ans: as specified standards development organizations (SDO's) 122) For sealless pumps, reference can be made to ‘Ans: API 685, 123) For heavy-duty pump applications in industries other than petroleum, petroch processing, reference ean be made (0 Ans: ISO 9905, al, and gas 124) Gas Turbines will be governed by, Ans: API 616, 10|Page125) Which of the following standard cover QVhich of the following standard covers Ans: APL6I6. 126) Machinery Protection Systems Ans: API 670, be governed by. 127) Spectal Purpose Couplings will be governed by Ans: API671 128) PERERA, Integrally Geared CentFiiGalINIECORSFERGR will he governed by. Ans: API 672 129) Centrifugal Ei for Petroleum, Chemical, and Gas Industry Services will be governed by ‘Ans: APL 673 130) Positive Displacement Pumps-RESiSHOSHIAE will be governed by Ans: APL674 131) Positive Displacement Pum ps Rta will he governed by. Ans: APL 67. 132) Liquid Ring Vacuum Pumps and Compressors will be governed by, Ans: APL 68] 133) Pum ps—Shaft Sealing Systems for Ans: API 682 ilugal and Rotary Pumps will be governed by. 134) Which of the following standard specifies requirements and gives recommendations for sealing systems for centrifugal and rotary pumps used in the petroleum, natural gas, and chemical industries? ‘Ans: APL 682, 135) API 682 is does apply/cover to, Ans: 1) mainly for hazardous, flammable, andlor toxie services where a greater degree of reliability is required for the improvement of equipment availability and the reduction of both emissions to the atmosphere and life-cycle sealing costs. 2) seals for pump shaft diameters from 20 mm (0,75 in) to 110 mm (4,3 in). 136) Dry Gus Sealing Systems for Axial, Centrifugal, and Rotary Screw Compressors and Expanders, governed by. ‘Ans: API 692 137) Rotodymamle Pumps for HUES Performance Acceptance Tests (CnTIgaITESE) by: : Ans: HE 14.6, Centeifugal Tests Note: Hydraulic Institute (FD) ll be governed ing standard is used for centrifugal, sealless centrifugal, and regenerative turbine pumps of all industrial types, except vertical multistage diffuser and includes detailed pracedures on the setup and conduct of hydrostatic and performance tests of such pumps? Ans: HI 14.6, Centrifugal Tests. [Page139) Which of the following section of the BPVC is covering materials for the construction of piping and pressure vessels? ‘Ans: ASME BPVC Section II Materials Part A—Ferrous Material Specifications Part B—Nonferrous Material Specifications > Part C—Speaitications for Welding Rods, Electrodes and Filler Metals. > Part D—Materials Properties. ‘Ans: ASME BPVC Section V ‘Note: For the purposes of Sl examination, some of the content covered in ASME BPVC Section V that applicants should focus on include: > Atticle 2 on Radiographic Examination. Acceptance Criteria ASME Section Vil, appendix 4 > Article 4 on Ultrasonic Examination Methods of Welds, Acceptance Criterla ASME Section Vill ‘appendix 12, [ticle 5 on Ultrasonic Examination Methods for Materials. Article 6 on Liquid Penetrant Examination. Acceptance Criteria ASME Section Vil, appendix 6 ‘ticle 7 on Magnetic Particle Examination, Acceptance Criteria ASME Section Vill, appendix 8 Article 9 on Visual Examination, Article 10 on Leak Testing, ‘ticle 23, Section 797 on UT Thickness Testing. > alldefinitions in Appendix 3, ASME Section Vill, Division 1, Boiler Pressure Vessel Code > Appendix 7, Examination of Steel Casting vyvvvy 141) Which of the following standard cover qualification Standard for Welding and Brazi Wolders, Brazers, and Wolding and Brazing Operators? ‘Ans: ASME BPVC Section IX. Procedures, 142) Which of the following is Recommended practice establishes a general framework for a qualification and certification program for NDE technicians? ‘Ans: ASNT SNT-TC-1A, ‘Ans: SSPC-PA 2 Coating Applications Standard No. 2. ‘Ans: $SPC-SP1—Solvent Cleaning > SSPC-SP3—Power Tool Cleaning > SSPC-SP6 or NACE 3—Commercial Blast Cleaning > _SSPC-SP7 or NACE 4—Brush-Off Blast Cleaning. > SSPC-SP11—Power Tool Cleaning to Bare Met 145) Welding procedure qualifications are the responsibility of Ans: the vendor. 12| Page146) Prior to verifying welding inspection documents provided by the vendor, the source inspector should, . ‘Ans: confirm that the version of the WPS that was used was the one approved by the responsible person, e.g. cengineer/WPS/POR SVE for both the purchaser and vendor. ‘Ans: the vendor. ‘Ans: confirm that the version of the NDT procedure has been reviewed and approved by the responsible person, e.g. engineer/NOT SME. ‘Ans: The AWS Welding Inspection Handbook, ASME BPVC Section V, AWS D1. 3, and ASNT SNT-TC-1A 150) Visual inspection, welding inspection, dimensional inspections, observing NDT, and all other oxaminations and tests shall be performed in accordance with, . ‘Ans: the source ITP, project specification, and applicable code and standards, and meet the applicable acceptance criteria. ‘Ans: requested to report on fabrication status or slippage of milestone progress. = ee es ‘Ans: schedule pressures, ) Individuals assigned to perform the source i ‘Ans: the approved ITP. ) One important stop in the source inspection work process i to ‘Ans: verify evidence that the vendor personnel conducting the fabrication and quality control steps during. fabrication are qualified and certified, as specified in the ITP or other contractual documents. ‘Ans: request that the vendor propose such changes in writing for review and approval by the purchaser of the equipment, ‘Ans: pre-purchase meeting (Prior to Contract Placement). ‘Ans: cover some specific design, fabrication, and/or QA/QC requirements expected of the S/V to make sure that their bid does not in-edvertently overlook them and result in unanticipated surprises during fabrication and source inspection activities. 13] Page‘Ans: Pre-inspection Meeting/Kickoff meeting (Prior to Start of Manufacturing). ‘Ans: ensure that everyone at the S/V who will be involved in manufacturing, fabrication, and monitoring the quality of the equipment fully understands spocific requirements and details of the job, especially those requirements that may be non-routine or different relative to normal S/V quality surveillance. ‘Ans: others besides the source inspector. ‘Ans: ensure the meeting covers all necessary requirements as outlined in the purchaser'and vendor meeting outline. Or Ans: ensure the meeting coversall necessary issues requirements as specified in the contractual ‘agreement and source inspector’s company policy/practices, ‘Ans: the progressive inspection report detailing tems of the inspection. Note: A key deliverable of source inspection is the progressive inspection reports detailing the documents reviewed, Inspection activity performed, observed and/or witnessed during the source Inspection visit. 163) The source inspector should request permission from prior to taking any photographs. Ans: the vendor, Nite: sun pte sede en REL SO > Wido-angle and close-up photos should be sufcient to dooument a 3 protrshoud be dred sod nbelag ity and results. 164) inspection Reports should be submitted to. for review of content and technical clarity hefore they are distributed to the purchaser, unless otherwise instructed. ‘Ans: the inspection coordinator. ‘Ans: identified as nonconformance and reported to the pure ‘Ans: the inspection coordinator. ‘Ans: the inspection coordinator/purchaser for review and i 168) deviations from specifications should be approved by ‘Ans: the responsible engineet/purchaser. Ans: 1) Use as is (with purchaser accepting the nonconformance} 2) Rework/repair per purchaser agreed approved repair procedure. 14 | Page3) Serap the equipment/component involved. ‘Ans: determining if the nonconforming item currently conforms to the original or revised requirements based on the agreed disposition ‘Ans: the source inspector's. This should include. ‘Ans: an evaluation of the performance of the S/V. 8 Examination Methods, Tools, and Equipment 173) Requirements for examinations from the purchaser or references in the contract agreement that may bo sont than: ‘Ans: industry codes/standards or the vendor’s normal procedures should be included in the ITP. 174) Review and Confirmation of Materials of Construction including. 7 Ans: 11) Ensuring that the vendor is using the correct material during the manufacturing of equipment is 2 critical element of quality surveillance. 2). The source inspector should be 175) The information necessary for the source inspector to know and understand about MTRs is covered in____. ‘Ans: ASME BPVC Section I, SA-370, and EN10204, ‘Ans: indicate the potential that the material or component is counterfeit material ‘Note: All MTRs shall be legible. 177) Confirming that the construction materials proposed are the actual materials used during construction is @ typical source inspection activity. The source inspector should: Ans 1) Confirm the correct material type and grad 2) Confirm the origin ofthe material 3) Checkmaterial size and/or thickness, 4) Verify traceability of the materialto a certifying document. 5) Verify that the material complies with specific chemical and/or mechanical properties as specified in the contractual documents. 6) Check for evidence of spacified heat treatment. 7). Verity heat treat and hardness. 8) Check or evidence of specified heat treatment. 9) verifying that material grade, type, and serial number match the material certifying document. 178) For equipment in sour service, Verify compliance to. ‘Ans: NACE MRO175/ISO 15156. 15| Page179) Maximum hardness requirements for P-Numbered alloy stecls are given in. ‘Ans: NACE MRO103, Table 2. 180) Maximum hardness requirements for P-Numbored alloy stools aro given in NACE MRO103, Table 2. Othor alloy steels shall have a maximum hardness of. ‘Ans: 22 HRC (237 HBW] (NACE MRO103, 2.1.6) 181) Ferrous materials not covered by NACE MR 0103-2007 or NACE MR 0175-2008 shall have_. ‘Ans: 2 maximum yield strength of 620 N/mm2 (80,000 psi} and 2 maximum Rockwell hardiness of HRC 22. 182) Some vendor quality programs, as well as purchasers’ programs, have various methods for ensuring that the correct material is used in manufacturing with the use of ‘Ans: positive material identification (PMI). Note: The source inspector should be familiar with those methods and ensure compliance. 183) a good reference document for material verification and positive material identification is ‘Ans: API RP 578, 184) The source inspector should be aware ofthe potential for ESUHTSHGR miaterals/documents. Key issues to watch for include, Ans: 1) generic documentation that i not product specific. 2) material or equipment containing minimal or no documentation. 3) markings or logos that are questionable or obliterated. 4) ems that have inconsistent appearance. 5) documents that have been altered. 6}_ ems that lack material traceability or product certification 7) ASME or ASTM stampings that may have been counterfeited 185) Tools used for precision measurement are typically calibrated in accordance with a vendor’s written calibration procedure per____. ‘Ans: NIST, ISO Guide 99, or other industry standards. Ans: Calibration ‘Ans: verify the accuracy and provide traceabllty of the instrument. 188) The accuracy of a measuring device can become suspect for various reasons. Some of the common causes of the loss of accuracy are. Ans: 1) normal wear during usage. 2) misuse of the instrument either in application or mishandling (i.e. dropping, incorrect storage, etc.). 3) environmental issues, such as temperature changes, and hazardous or corrosive conditions. 189) The vendor should have a calibration procedure that, at a minimum, addresses, Ans: 1) intervals; environment; tolerances; certification of standards. 2) traceability; eecords; adjustments; removal from service, 16| Page‘Ans: nonconforming. 191) Maintaining accurate calibration records will provide the vendor with an indicator that a measuring device hhas reached the end of its lifetime in relation to ‘Ans: ability to hold calibration, or the extent of recalibration required each time itis subjected to calibration. 192) 1 that a device fails calibration at the established calibration interval wil. ‘Ans: normally require the issuance of a nonconformance In the vendor's quality system. Ans: 1) able to re-measure or rework product that is still in-house. 2) need tocontact customers that have received product to issue a recall or adv service to bring the product into specification requirements. of the need for ‘Ans: any measurements made since the last known calibration are suspect. 195) lf there is inadequate lighting available during the visual inspection, the source inspector should, ‘Ans: address these concerns with the vendor and inspection coordinator to resolve. 196) tests that are performed on metals for the purposes of determining mechanical properties and that involve testing of sample coupons Ans: Destructive testing. 197) Tensile testing is performed to determine, ‘Ans: yield strength and ultimate tensile strength of an Item. 198) Which of the following testing is commonly performed on weld coupons to check the ductility and integrity of welds? ‘Ans: Bend testing. ‘Ans: Charpy impact testing. ‘Ans: the abllty to deform plastically before falling (avold catastrophic brittle fracture). ase the engineering specifications may require impact testing at other temperatures as well 202) Most of the information necessary for the source inspector to know and understand destructive testing of metals is covered ‘Ans: ASME BPVC Section IX. 17| Page203) Prossuro/loak testing is normally specified by. ‘Ans: the applicable codes/standards and contractual agreements. 204) Hydrostatic testing is conducted with liquid for ‘Ans: the integrity of the equipment, 205) A gas test is typically performed as ‘Ans: a leak test 206) pressure testing involves testing with clevated pressures, often above that at which the component wi normally operate, so is of utmost importance when witnessing a pressure test. ‘Ans: safety. 207) Pressure tests shall be conducted in accordance with, ‘Ans: the construction code or standard to which the item was bullt, e.g. ASME BPVC Section Vill for vessels or ASME 831.3 for process piping. 208) Which of the following standard addross minimum requirements to hydrostatic test pump pressure- containing parts before further testing (such as performance or running tests)? ‘Ans: AP! standards (such as API 610). 209) codes used for Prossure/leak testing generally indicat ‘Ans: how to witness such atest safely after the pressure has equalzedand stabilized. 210) Whether texting by hydrostatic test, hydo-pneumatc or preumati the pressure testing equipment should have. ‘Ans: the means to prevent over-pressuring the equipment under test. 211) the most common method of pressure testing and is, ai wolves the appl Hydrotesting. 212) Its very important that fighsptitVenieb See during fling and botore the application of pressure we, ‘Ansi ensure thet there Isno air left in the system. ‘Ans: prior to hydrostatic test. ee ‘Ans: less than 50 ppm, ‘Ans: prevent deposition of chlorides. ‘Ans: never be conducted without the full knowledge and consent of the responsible engineer who has been satisfied that the potential for brittle fracture during test is negligible. 217) Who is responsible to satisfy that the potential for brittle fracture during pneumatic testing is negligible? ‘Ans: engineer. 18| Page218) The danger comes from pieces of the equipment that fail under pneumatic pressure being propelled with great force for long distances, thereby doing. ‘Ans: a lot of damage and/or inflicting severe Injury. 219) Leak testing is generally the term used to describe low-pressure testing with air or gas just to, ‘Ans: see if the Joints in a piece of equipment, e.g. flanges and threaded connections, are leak tight after assembly, 220) Leaktests are usually done at low pressures that are. ‘Ans: substentially below equipment design pressures tori risk oF injury. 21) hhave to be specified by contractual document, which will detail the leak test procedure and generally reference an industry standard. ‘Ans: Specialized leak tasts with hellurn or other gases. 222) Which of the following testing is typically required for all rotating equipment? ‘Ans: Performance and functional testing. Note: The source inspector should be very familiar with the functional/performance test procedures and a detailed report that is expected at the end of the test. The source inspector should also verify that all attributes of the test are accurately reported in the final test report provided by the vendor. 223) Prior to performance or functional testing, the vendor should provide a detailed functional test procedure that has bean submitted for reviaw and comment from ‘Ans: the purchaser. 224) The A vance notice of performance or functional testing shall he made in accordance with ‘API 610 or the purchase order, whichever was agreed upon, 225) Which ofthe following curve is plotted to indicate the ‘volumetric flow of guid at an indicated while consuming » specfc quantity of horsepower? ‘Ans: A performance curve. 226) The performance curve typically consists Which of the following curves in relation with each other on a ‘common graph? Ans: 1) the head:flow curve. Itis called the H-Q curve. 2), the efficiency curve. 3}. the energy curve, It records brake horsepower; 4} net positive suction head (NPSH3) curve if required to be tested}, ‘Ans: ensure that the actual performance of @ pump is consistent with the curve shown on the predicted iss wares sl clos al ori cores 19| Pageee eee Ans: from Ot 120% of Best ffioncy point (BEB), depending on te tet siardard Note: For A610 pump, these normally ae 1) shutoff (no vibration data required) 2) minimum continuous stable flow (beginning of allowable operating region) 3) between 95% and 99 % of rated flow 4) between rated flow and 105 % of rated flow 5) approximately the best efficiency fiow {if rated flow is not within 5 % of best efficiency flow fateh end ofallowabecpeatng eon, For ANSI pump, low As vequiroments 229) If specified, the pump should be, Ans: 2) tun on the test stand at the rated flow until oll temperature vibration stabilization has been. achieved. 2} mechanically run at the rated flow for 4 hours or as agreed upon 230) Disassembly inspection is may be performed to ‘Ans: inspect the rotating equipment internals for contact a testing. 231) Disassembly duo to the need to. ‘Ans: reduce Impeller diameter by more than 5 Ye tomeet performance requires a retest. 232) Eq A mont Disassombly Inspection requirod If ‘a pump has antifriction (ball or roller) bearings, oll may be drained from bearing housings and ispected on the subject of color change and foreign material inclusion, 233) Equipment Disassembly Inspection requir bearings may be, ‘Ans: removed and inspected after the test if specified, Hf» pump has hydrodynamic bearings (sleeve and or thrust), 234) Equipment Disassembly Inspection required If i is necessary to disturb the mechanical seal assembly following the performance test, or ifthe test seal faces are replaced with the job seal faces, the final seal assombly may be pneumatic tested if specified. ‘Ans: the how well the substrate or surface is prepared for coating applications. SS ee eee Ans: 1) surface profile measurement. 2} visual surface comparison, 3) verification of blasting medium, 20| Page‘Ans: SSPC-PA 2, which the source inspector should be familiar with, 238) The source inspector should also be aware of specific coating requirements, such as stripe coating of welds, ‘edges, corners, etc., that are performed to. : ‘Ans: ensure coating performance on rough or uneven surfaces. 239) Any areas found in need of costing repairs should be ‘Ans: propery Wentied and documented with an NCR by toe sre! oppo ved by as should any testing and re-inspection performed after repairs have been made. {9 Final Accoptancé 240) Shipping preparations may also be specified in the contractual and engineering documents. It is important that the source inspector ‘Ans: confirm that all bracing, strapping, mounting, covering, packaging, marking, and protection from the weather, etc, ‘Ans: the completion of the manufacturing prior to shipment of the materials or equipment. 10 Manufacturing and Fabrication Processes ‘Ans: The vendor (The manufacturer/fabricator. ‘Ans: The source inspector. 244) Rework and repair should b ‘Ans: approved by the purchaser and verified by the source inspector. 245) Typical defects associated with the casting process that the SI should he aware of includ. ‘Ans: Shrinkage voids > Gas porosity > Trapped inclusions 246) Castings are susceptible to the creation of voids during the casting process that could result in ‘Ans: through wall leaks. 247) Standard Specification for Steel Castings, General Requirements, for Pressure contait 1g Parts is given by__. Ans: ASTM ATS. [PageAns: ASTM A703 ing, phigging, and impregnating defects ileastinga to HOP leak, as GpipOHe to making more permanent welding repairs. \Note: The SI should make sure that any casting repairs needed a adequate repair procedures can he prepared, 250) Grade symbols are required such as WCB, WC9, CF8M in order to indicate the type of. ‘Ans: casting material (valve castings) Ans: MSS-SP-55, ‘Ans: ASTM A788 Ans 2) The purchaser may specify additional requirements. 2 esi ee arin shed bE, tareorn mechanical ener ‘welding is not allowed unless permitted by the product specification, and if approved by a re 254) The principal machining processes are. 7 Ans: turning, drilling, grinding, and miling "Note: Other machining operations include shaping, planing boring, broaching, and sawing. 255) Which of the following. against the cutting tool? ‘Ans: Turning operations 1 operations that rotat ‘the workpiece as the primary method of moving metal ‘Ans: Milling operations. Is the principal machine tool used in miling. 258) Which of the following are operations in which holes are produced or rofined by bringing a rotating cutter ‘with cutting edgos at the lower extromity into contact with the workpiece? ing operations, ons are done pri ariy in dil presses, but sometimes are done on lathes or mills. 2|Page259) Grinding provides additional accuracy that typically will allow the finished part or surface to have a tolerance of. . ‘Ans: 0.0002 in. or batter 1) Bumishing is used if exceptional surface finish Is needed for pr probes, for example. 2). Grinding may be used for rotor balancing corrections, but the level of precision is not as stringent. 260) Typically, there is no in-process inspection by the source inspector for the machining operation; however, the source inspector may be required to, ‘Ans: check dimensional aspects and tolerances of machined components. 261) Although assembly also incorporates instrumentation, control systems, and electrical gear prior to shipment, the source inspector is, : ‘Ans: concerned with assembly of the rotating and stationary parts. ‘Note: The inspections that are important to assembly may’ 1) mounting clearances, mounting, and straightness; 2) assembled rotor TR: 3) surface finish at journal areas; 4) ‘of nozzles and parting flange(s): 5) of the pressure casing bores; 6) _perpendicularity ofthe seal mounting faces; 8) axial movement of the rotor in the pressure casing (typically with respect to the thrust bearing). 9) checking final torqueing and torque sequence for: ‘all pressure casing bolts and studs, + bearing housing and other auxiliary bolting and studs, ‘Ans: The physical properties. ‘Ans: chemical composition, melting temperature, thermal conductivity, electrical conductivity, coefficient of thermal expansion, and density. 264) Chemical composition and heat treatments often change hardness, weldability, tensile strength, otc. Sometimes, alloying elements can add benefit in one area and detract in another. Iti important for ‘the source inspector to bi ‘Ans: aware of elementsin the MTR. 265) Materials of construction are selected to provide adequate strength and toughness for the maximum. and minimum temperatures and pressures on the datasheet. For the inspector, verification that ‘mechanical properties meet the requirements specified by the component definition, is ‘Ans: essential. ee eee ‘Ans: Hardenabi ‘Ans: plastic deformation by Indentation 23| Page‘Ans: the carbon content of the material urdenabilty Is strongly affected by the presence of alloying elements, such as chromium, ‘molybdenum and vanadium, and to a lesser extont by carbon content and alloying elements such as nickel, copper and silicon, 269) APISL pi (with a weld seam) disallows both vanadium and boron above API SL pipe for because of cracking issues, ‘Ans: any diameter and wall thickness 1. (25 mm). ‘a pipe is attached to a nozzle on the pressure casing, weld required. 270) heating of the weld and surrounding base metal to a predetermined temperature prlortto the start of ‘welding is called: Ans: Preheating, 271) The primary purpose for preheating carbon and low-alloy stools is, ‘Ans: to reduce the tendency for hydrogen induced delayed cracking. 272) The higher temperature at the weld site allows better hydrogen diffusion from the weld, which helps ‘Ans: prevent the formation of martensite (a more crack-prone microstructure) in the weld and base metal HAZ 273) Aecording to 831.3 the ps ‘Ans: extend atleast one inch hoyond the od at zone for welding of new process piping should, ‘of the weld for piping. 274) Pro-weld proheat shall be done evenly at the prescribed rate to ‘Ans: ensure proper temperature distribution. 275) Postweld heat treatment (PWHT) produces, ‘Ans: both mechanical and metallurgical effects in carbon and low-alloy steels. 276) PWHT is the most common form of fabrication heat treatment applied to. ‘Ans: fixed equipment. 277) When PWHT is required by code or the vendor, the source inspector needs to. ‘Ans: coordinate with the user and vendor to ensure ternperature, ramp-up, hold, and ramp-down rates are adhered to. 278) During PWHT, Thermocouples shall be located in order to, ‘Ans: verify even distribution of temperature on components and to ensure that no component is over cor underheated during PWHT. for one hour per inch of thickness with 15 minute Ans: ‘with no variation permitted of fisalthan/250'F nian i5-foct segment of the equipment. | Page281) Most of the information necessary for the source inspector to know and understand about PWHT is covered in, ‘Ans: ASME EPVC Section Vil, islon 1 282) Heating an object to and then holding it at a specified temperature and then cooling at a suitable rrate for such purposes as reducing hardness, improving machinability, facilitating cold working, producing a desired microstructure, or obtaining desired mechanical properties is called: ‘Ans: Annealing heat treatment. 283) heat treating process in which a ferrous material or alloy is heated to a specified temperature above the transformation range of the metal and subsequently cooled in still air at room, temperature is : Ans: Normalizing heat teatment. Note: Typically, normalizing heat treatments will refine the grain size and improye the impact properties of steels 284) heat treatment Heating an alloy to a specified temperature, holding at the temperature long enough for to reenter into solid solution, then cooling rapidly enough to hold Ans: Solution anneal Reheating a hardened metal to a t toughness is, Ans: Tempering nperature below the t nsformation range to improve 25| Page11 Centrifugal Pumps (APTGAO, Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries 286) CEFARALEAS for Petroleum, Petrochemical and Natural Gas Industries is covered in ‘Ans APTGIO™ 287) Which of the following standard specifies requirements for centrifugal pumps, including pum ps running in reverse as hydraulic power recovery turbines, for use in petroleum, petrochemical, and gas industry process services? Ans: API 610. Note: > API610 is applicable to overhung pumps, between bearing pumps, and vertically suspenied Ans: 4). As issued for PO (purchase): part of PO package submitted by the purchaser and accepted by vendor. submitted by vendor as one of the documents with vendor's bid. 3) As built: submitted by vendor after final pump test and before final inspection. 289) The Centrifugal Pump TTP is. Ans: a purchaser-approved document 290) The Centrifugal Pump ITP should be developed for ‘each major component, subassembly, anc! final package, 291) The Pump cross section with BOM (bill of materials) should list. ‘Ans: the part name, quantity, identification number, part number, and material of Consinietion with ASTM codes for all major parts, a ‘Ans: The vendor. Note: [VR] is vendor documentation and data report eee ‘Ans: a weld repair procedure ‘Ans: repair procedures, including weld maps Ans: The purchaser, 26| Pageeee ‘Ans: casting material specification (producing specification IN) a ‘Ans: Vendor unpriced quotes and buyouts for major parts, 298) Vendor unpriced quotes and buyouts for major parts of Centrifugal pump, should be reviewed, pee eee Ans: the source Inspector 299) Vendor unpriced quotes and buyouts for major parts of Centrifugal pump, must be included in ITP as Ans: a "review" action. 300) Vendor unpriced quotes and buyouts for major parts of Cen and hydro testing completed at ‘Ans: sub-vendor shops, Ans: easily legible ifugal pump, all the required NDT 302) The vendor should furnish material certificates of Centrifugal pump that include chemical analysis and mechanical properties for the heats from which the material is supplied for. Ans pressure-containing castings and forgings, impellers, and shafts. 303) Material certificates of Centrifugal pump not required for ‘Ans: piping nipples, auxiliary piping components, and bolting ‘Ans: different part numbers listed on material certificates than those listed on a pump cross section a ‘Ans: the final part number and assembly number. Note: Material Certificates should be easily legible Ans: the pi 's review and/or approval for use. 307) PMI and NDT procedures for Centrifugal pump should be listed on the and should be reviewed and approved by the purchaser Hig to the start of manufacturing Ans: purchaser’s VDDR. Note: [VDDR] is vendor documentation and data report 308) Acceptance criteria for various NDEs For Centrifugal pump can be found in ‘Ans: ASME Section VIII as follows. 1) Mandatory Appendix 4, "Rowe THGHESHIONS Charts Acceptance Standard for Radiographically Determined Rounded Indications In Welis" 2) Mandatory Appendix 6, “Methods for Magnetic Particle Examination (MT)” 3) Mandatory Appendix 8, “Methods for Liquid PenetrantBxam nation (P 4) Mandatory Appendix 12, “Ultrasonic Examination of Welds (UT)” 27| PageAns: The source inspector. ‘Ans: easily traceable to the components to which they apply 311) Tools, instruments, and other equipment used for tests for Centrifugal pump need to be, Ans: listed and calibration records provided, 312) If the source inspector observes PMI or NDT testing for Centrifugal pump, Ans: pictures should be taken and attached to the souree inspection report. Ans: 1) Stationary: includes pressure casing and bearing housings. 2) Rotating: Inciudes impeller(s) and shaft. Ans: hydrostatic testing, ‘Ans: balancing Ans: individually ‘Ans: shaft, sleeves, and impellers mounted Note: 1) Formore information on balancing requirements, refer to API 610, Section 6.9.4 (Balancing). 2) The pump data sheet specifies the extent of balancing required. ‘Ans: anti-friction or hydrodynamic bearings, or a combination of bath, ‘Ans: thrust bearings unless thrust bearings are provided in the pump driver. ‘Ans: Oil surop with ring or finger, oil mist, forced ol lubrication ‘or prease Note: Sometimes, two of these are combined 321) Pump unitsare supplied with mechanical sel) APL G82) drivers coupling, shalt guard auxiliary piping, and instrumentation. All equipment is usually installed on ‘Ans: a single baseplate 322) Vertically suspended pumps are typically supplied with Ans: a sale plate 323) Pressure casing parts of Centrifugal pump may be subject to, ‘Ans: surface and subsurface examinations. 28| Page324) pressure casing material inspection requirements for Centrifugal pump can be found in, Ans: API6IO. Note: AP{ 610 standards establish minimum acceptance eriteria for casings 325) Which of the following pump? Ans: Inspection class 1 Note: Job-specific requirements often involve MP or LP inspections as per class 2. imum requirements for pressure casing inspection of Centrifugal 326) Casting quality can be affected by considerable variations in material processing. Castings can be subject to areas of Ans: shrinkage, gas porosity, hot teats, sand inclusions, improper weld repairs, ete, 327) Some Casting materials are also prone to grain boundary tears or eracks that ean propagate under in-service stresses caused by. Ans: temperature, pressure, vibration, and pipe Strain 328) Industry accepted practices of casting examination are contained in, Ans: ASME Section VIII, Mandatory Appendix 7 (Examination of Steel Castings) Note: NDT methods such as magnetic-particl, liquid-penetrant, radiographic, and ultrasonic ‘examinations are the most frequently performed at the easting foundry, 329) When casting should be heat treated in accordance with the material specification? Ans: before rough machining and hydrostatic testing, 330) Final machine surfaces (Cast Casing) are subject to the examination, Nondestructive examinations are performed to, Ans: ensue that casting Is fee from porosity, cavities, and other surface or intemal defects, and ready for final machining, 331) Any defects that are found at a foundry (Cast Casing) may either be fixed by Ans: approved weld repairs or the casting scrapped and re-cast if weld repair is not possible, ‘Ans: Centrifugal casting. Ans: force voids and gases out of the molten metal (to pressure melted steel to avoid porosities, blow holes, gas holes and other defect associated with casting) 334) What is a manufacturing process involving shaping of the metal using localized compressive forces? Ans: Forging. Ans: improved strength and toughness characteristics. 1) Increased wear resistance without increased hardness/loss of ductility. 2) Stronger/tougher than an equivalent cast or machined component. 3) Less expensive alloys can be used to produce high strength components. 4) Components are not susceptible to common casting defects. 29| Page337) Forging inspection involves Ans: the same NDT methods as casting Ans: a hot metal working, Ans: porosities, blow holes, and gas holes. ‘Ans: surface cracking and or laminations, Ans: er Ree ee 342) Pump casing almost always has parts attached by, » such as pipe attachments of ‘Ans: fabrication Ans: welded, 345) Which of the following test is typically required for the nozzle weld attachments before ® part €ai [SREREISURERTAY of Pomp cong? Ans: RT or UT test 346) Which ofthe following inspections should be done on the machined surfaces ifl@P ROU ‘of Pump casing? ‘Ans: MI or LP inspections 347) Connection welds ae subject to an test BEE the part cam be sent for heat rent and final machining of Pump: Ans: RT, MP, or LP test Ir the RT method is utilized, see ASME Section VII, Top covers will be dimensionally inspected for flatness and hydro-testing of the can will be performed after all welding inspection has been completed Ans: ASME Section VIII, Mandatory Appendix 7, in job-specifie requirements, ar both 350) Pump pressure casing hydrotests are performed per Ans: APL 610, Section 8.3 ‘Ans: ensure that the pump pressure-containing components and joints are leak fiee from ambient to the maximum operation conditions as defined on the data sheet. 30| Pagenot exceed. Ans: SU mgikg (51) ppm) 353) Pressure gauges used in the fest centrifugal pump casing should have, Ans: current calibration dates shown on the permanently atlached tags or located ona dial ‘Ans: neither leaks nor seepage through the pressure-containing parts and joints occurs within 30 minutes or as defined by the approved hydrotest procedure Note: It is Ok, if neither leaks nor seepage through occurs within 30 min or as defined by the purchaser 385) hydrostatic test for fit (Pip PFESUFSEIAD occurs within : ‘Ans: 30/minites or as defined by the approved hycrotest procedure 386) hydrostatic test for Pipl pinipS normally require ; Ans: a four-hour test Ans: castings process, (sand cast of investment casting) depending on the eritieality of pump design, a oe eel ‘Ans: Investment casting. 359) Impellers and diffusers of Centrifugal pump undergo the same type of basic NDT as, Ans: pressure casing. 360) Per API 610, the minimum inspection of an impeller of Centrifugal pump is Ans: 5 further inspection ean be required bythe purchaser or noted in the TTP 361) Which of the following are not standard examination methods for Impellors of Centrifugal pump? Ans: RT or UT. Note: MT, PT, and visual inspections are first done at the foundry level ‘Then, MT or PT examinations are performed on the final machined surfaces, ‘Ans: the pump data sheets, technical notes, job specifications, or, at a minimum, as required per API 610, Ans: ISO 1940-1, grade G2.5, oF as approved by the purchaser in the ITP. 364) Shafts, Wear Rings, Sloeves, Bushings, and Thrust Balance Drums of Centrifugal pump are machined from, Ans: bar siock Note: Visual examination inclucles surface finish 365) Large sleeves, wear rings, and bushings of Centrifugal pump can also be manufactured from, : Ans: centrifugal casting raw material, 366) Which of the following inspection are often used for Shafts of large multista Ans: UT inspection, pumps? 31] Page367) Which of the following examinations are routinely used for Shafts of large multistage pumps? Ans: visual, dimensional, MP, or PI Note: Visual examination includes surface finish. 2 Ans: rebalancing. ‘Ans: a balance certificate upon completion, 370) the amount of unbalance remaining in Pump rotor after balancing is Ans: Residual unbalance ‘Ans: test the rotor with a known amount of unbalance. 372) Although somo balancing machines may be set up to read out the oxact amount of unbalance, that ‘measurement may be, Ans: erroneous as it depends on the ealibration 373) API610 requires seals of Pump to be selected and designed pet Ans: API 682, Ans: Seal Gland, ‘Ans: a containing easing for mechanical seal parts and is bolted as an assembly to a pump Seal Chamber. Note: Seal Gland is supposed to be hydtotested to 1.5 times of seal MAWP (LS times maximum 376) The pump vendor and seal vendor collaborate for proper seal design and material selection. Reference documents for this design include, Ans: the APT 682 seal chamber cawing data sheet, API 610 pump da sheet, and related specifications 377) Who should propare and submit for reviow and approval the seal cross-sectional drawing with detailed BOM and all dimensions that are required to check the seal design and properfit to the pump? Ans: The seal vendor. Note: All documents should be listed on the purchaser's VDDR. 378) Which of the following soals should be used in the pump for the performance tost? Ans: Only the contractually designed seals, 379) Some seals of pump are not designed to run on water, in this situation, the vendor shall . ‘Ans: supply atest seal for the performance test of the pump. 380) Which of the following seals of pump should be installed during the pump hydrostatic test, but should be used during all the running or performance tests? Ans: Mechanical seals. 32| Page381) Seal leakage during performance testing pump shall be in accordance with, ‘Ans: API 610 or purchase documents, whichever is stricter, 382) Seal leakage during performance testing pump shall be in accordance with API 610 or purchase documents, whichever is stricter. Many users requir : Ans no visible leakage 383) If seals are removed from the pump after the performance testing for any reason, such as fixing a oak or installing contract seals, the seal should be. Ans: retested with an air test of the pump. 384) If specified, seal leakage during tests may require the assembled pump and seal to be. Ans: rerun fo demonstrate satisfactory seal performance, 385) The two basic designs of Mechanical Seals for Centrifugal Pumps are. 2 Ans: 1) Single seal: has one set of stationary/rotating elements, 2) Dual seal: has two sets of stationary/rotating elements 386) Mechanical seals (Soal Flush Piping and Accossorios) for Centrifugal Pumps neod to bo for successful operation, ‘Ans: lubricated and cooled. 387) Mechanical seals (Seal Flush Piping and Accessories) for Centrifugal Pumps need to be lubricated and cooled for successful operation. This is achioved by, Ans: providing flush liquid seross the stationary and rotating sealing rings 388) Different arrangements of seal flush piping are described in Ans: API 682, Note: Seal Flush provides sealant, Lubricant, coolant, dilatant 389) Pump and seal vondors have to submit drawings, schematics, data shoots, and BOM for piping, ‘equipment, and instrumentation for purchaser review and approval. Allthese documents should bo. Ans: available during the final inspection, 390) Pumps and compressors are driven by. ‘Ans: electric motors, gas or steam turbines, or diesel engines, 391) When the speed of the pump is different than the speed of the driver, a gear is used for. ‘Ans: gynchronization Fs are installed on. 392) In most cases, pumps and dri Ans: the same baseplate 393) Compressors may have drivers installed on ‘Ans: a separate baseplate or sole plate. ‘Ans: either API 677 for general-purpose gear units oF to API 613 for spectal-purpose gear units 395) Requirements for couplings and guards of Centrifugal Pumps can be found in, . Ans: the applicable API rotating equipment standard 33| Page396) The two types of guards for Centrifugal Pumps are. Ans: one at the coupling and another between the bearing housing and seal gland. Ans: 900 N (200 Ibf) static point load in any direction without the guard contacting moving parts, Ans: an agreed sparkoresistant material 399) The pump or compressor data sheets include information such a Ans: coupling service factor, aplicable standard (eg if the coupling has to comply with API 671 or not), vendor, model, size, and balancing requirements. 400) Rofor to the applicable API rotating equipment standard for guidance, Coupling and shaft guards for Centrifugal Pumps should be constructed in accordance with, J Ans: the purchase order of contract. 401) Pumps and their drivers and gears are typically installed on, Ans: fabricated or cast baseplate, 492) Basoplates for Centrifugal Pumps may be with or without grout, have, Ans: special anchor options or have special paint requirements 403) inspection of baseplates for Centrifugal Pumps involves. ‘Ans: visual inspection of all welds to make sure that welds are continuous and of good quality, dimensional inspection, bolt hole/anchor bolt location, and machined pedestal flatness check 404) If forced lubrication is required for one or more components of the pump train, the pump supplier ‘typically provides. Ans: lube oil piping to conest the pump iain andthe lube ol system. 405) Who should provide for purchaser's review and approval a detailed drawing with BOM showing all parts, instrumentation, gaskets, and fasteners used for lube oll piping? ‘Ans: The pump vendor 406) Lube oil piping, components, welding, and configuration should be selected or designed according to, Ansi The ADI 614 and related job specifications 407) Lube oil piping is subject to hydrostatic tost at, ‘Ans; |. S times maximum operating pressure, 408) When required, the vendor provides cooling water pi ‘Ans: API610. Piping schematics can be found 409) Piping material for cooling water piping and components are specified on, Ans; the pump data sheet 410) Cooling and water piping is subject to hydrostatic test at, ‘Ans: 1.5 times maximum operating pressure 34] PageAns: an assigned tag number. ‘Ans: proper tagging, as shown in accompanying decuments, Note: The source inspector should also verify the equipment component specification against the ‘component certificate document. ‘Ans a serial number, area classification, and latest calibration date listed 414) Measurement ranges and units of measurements should be verified with ‘Ans: data sheets and instrumentation list i Ans: rated flow, rated total differential head, NPSH3, and NPSHA, 416) The purpose of the pump performance testis Ans: 1) to confirm that pump perfomance is as specified on the purchase order and pump data sheet; 2) to check for pump vibrations, and 3). to check NPSH3 and run to bearing temperature sbilization if specified in the PO andl as documented on the ITP. 417) Pump Flow Rate, the common units are ‘Ans: mh in metric units and GPM (gallons perminats) im U.S. Customary units (USC), Note: The flow rate Q is the usable flow (yolume of liquid per unit of time) discharged by the pump through its cutlet branch 418) Instruments for Pump flow measurement are: Ans: turbine, electromagnetic, Venturi, pitot, ultrasonic, positive displacement meter. Note: Flowmeters and variable area ean be used, ‘Ans: Total differential head (TDA). ‘Note: Conversion is necessary to exclude specific gravity (SG) of the liquid being pumped by the pump. ‘Ans: the same TDH regardless of fluid pumped, but differential pressure created by the pump when operating on water will be twice as high as when operating on liquid with SG = 0.8 Note: Stable suction pressure should be maintained at each point. 422) Who should prepare a test report that includes all data collected, Pump performance curve, and vibration graphs (if specified) and submitted to the purchaser for review and approval? Ans: The vendor, 35| Page423) The pump should not be released for final inspection unless all the documents, including a test report, h Ans: the purchaser, 4424) Final inspection for Centrifugal Pumps should be conducted in, Ans: two stages (the first inspection is when the equipment is fully aocessible for dimensional and visual inspection, and the second is when the equipment is prepared for shipment) £25) Which of the following isthe list of documents that aro typically required for final dimensional and visual inspection and the actions required based on these documents? Ans: 1) data sheets. 2) pump train general arrangement. 3) _auuillary equipment GA, P&ID, and BOM {seal reservoir, LOS, seal, driver, junction boxes} 4) packinglist Ans: prevent hand jamming ane! injury. Ans: no overhung equipment or piping extending beyond the perimeter of the baseplate 36| PageForm-wound ‘Ans: Purchaser, Ans: Area Classification, where motor will be installed: type of the load, and specific purchaser requirements. ‘Ans: stators and windings Ans: All electical/insulation tests ‘Ans: confirm their completion and acceptance if required as a part of the purchase requirements. 433) Stator testing is described in, and includes tests on stator core, stator winding, and visual inspection before final assembly Ans: API 541 434) Which of the following testing is mandatory for each motor? Ans: Motor routine testing ‘Ans: demonstrate that it is ee from mechanical and electrical defects, 436) Motor rotors should be. if required on the data sheet. Ans: balanced and residual unbalanee checked 437) Motor complete testin Ans: optional Note: API S41 for the detailed description of @ complete test and may be requested on the motor data sheet. 438) The main purpose of the Motor complete testis to, Ans determine accurate motor efficieney. power factor, and torque values under different loads, Note: The oil condition should be checked after the test. Ol should be clean and should not change color when compared with unused ofl 439) If specified for Motor, hydrodynamic hearings may be removed after the test and inspected for ‘Ans: excessive or uneven Wear, foreign material inclusions, hot spots, and other signs of unsatisfactory performance, 37| Page13 Gears (Reducors and increasors 1050 Gear Units & Purpos: Units 440) General-Purpose Gear Units for Petroleum, Chemical and Gas Industey by. Ans: APL67T. -vices will be governed 441) Which of the following standard covers the imum requirements for general-purpose, enclosed single- and multistage gear units incorporating parallel shaft helical and right-angle spiral bevel gears for the petroleum, chemical, and gas industries? Ans: API 677. 442) Gears manufactured accor Ans: 10 API677 shall be (ed 1) the following pitch-tine, 2) Helical gears should not exceed 60 m/s (12,000 ft/min), and 3) spiralbevels shal not exceed 40 m/s (8000 t/min} 4) Spiral bovol gearsets shall be considered matched sets. 443) API 677 is not intended to apply to Ans: 1) gears in special-purpose service, which are covered in API 613. 2) gears integral with other equipment. 3) epicyelic gear assemblies; or to gears with non-involute tooth forms. 4444) Special Purpose Gear Units for Petroleum, Chemieal and Gas Industry Serviees (SHIN PURDON ) will be governed by. Ans: APL 613. Ans: gears integral with other equipment; epieyclie gear assemblies, or gears with non-involute tooth, 446) Which of the following main purposes Gears can serve? Ans: Gears can serve two maiin purposes: 1) to reduce RPM from driver RPM. 2} to increase RPM 4447) Goars are used with rotating equipment whon drivers rotate at a speed either higher or lower than ‘the required speed of the driven equipment to Ans provide required process flow and pressure +448) Increasing rotating speed of the driven equipment. Ans: inereases flow and discharge pressure Note: conversely for speed reduction, An example for pumps ean be calculated with ust ‘Ans: vertical design and a Right-Angle gear. ‘Ans: @ Right-Angle Gear. 38| Page‘Ans: the pump driver isa horizontal machine and the pump itself is vertical ‘Ans: fire water pumps, cooling water pumps and basins, and ecoling tower fans ‘Ans: the full operating speed range, including, ‘Ans: one low-speed and high-speed shaft ‘Ans: the largest diameter gear, which is referred to as the gear wheel (bull gear). ‘Ans: the smaller diameter gear, which is called the pinion. Ans: the main equipment and driver. A ‘X-Y proximity probes for each side and embedded RTDS in each sleeve and thrust bearing. Ans: accelerometers, ‘Ans: X-Y accelerometers 461) Main gear parts are, . ‘Ans: the casing (gear box), gear wheels, pinions, shafts, and bearings. Note: Casings can be fabricated or cast. 462) Genoral requirements for Goar Unit Materials of construction and wold requirements are specifiod Ans: APL6TT. Note: API 677 appendices for material specifications for general-purpose gear units 463) Which ofthe folowing materia is typically used for Fabel ei OFEBBE Unk? Ans: Steel, 464) Which ofthe following materials i typically usd for EGREHEINGSTGGAE Uni? Ans: Steel or cast iron. 465) The casing has a bottom half that can serve: Ans: an oil reservoir, 466) The gear box has precisely machined mounting feet to, Ans: allow for mounting without distorting the casing ane ermal gear alignment, Note: Gear boxes are typically split horizontally into an upper and lower half. 467) If specified, the gear casing should be given a fluid fill leak check to Ans: test for oil tightness, 39| Page468) Goar prossure lube system components should he given a hydrostatic test as specified in, Ans: APL 677. 469) Goar SHARE should bo mado of ‘Ans: one-piece, heat rate, f Note: Shafts shall be accuratet beaineontre. ged or hot rolled steel ‘machined throughout their entire length and suitably finished at their 470) Goar shaft roquiremonts spocifiod Ans: APL 677. 471) Inspection requirements for internal components are specified in Ans: API 613 and API 677 472) The gear manufacturer (of internal components) should provide an ITP/quality plan based Ans: API 613 oF APL 677, as well asthe purchase order, job-specific inspection, and test requirements, Note: Acceptance standards should be documented and agreed to by the purchaser and vendor. 473) Typical inspection and quality assurance requirements for gear mating paits, checking the gear contact aroa, and axial movement of the pinion relative to the gear are specified in Ans: API 613 and API677 ‘Ans: balanced. ‘Ans: performed by the vendor and witnessed by the source inspector. Note: the source inspector should be completely familiar with the equipment, the purchase ‘requirements, and the agreed-upon run test procedure. ‘Ans: the maximum continuous speed for not less than I hour after bearing temperature and lube oil temperature stabilization, the maximum continuous speed for after bearing temperature and lube cil temperatures have stabilized for: Note: The contract hearings shall be used in the machine for the mechanical run test ‘Ans: inspected for surface damage and proper contact patter. 478) When spare gear elements are ordered, each spare element should have Ans: a mechanical run test in accordance with the requirements of API 613 or APL G77. Ans: the, not the source inspector. 480) Final manufacturor facility should be porformed in accordance with spection at the, ‘Ans: the approved packing and shipping procedure and relevant documents, 40| Page