Annexure-AI
QAP for Gas Compressor Packages
Sl. Inspection Activity Extent Reference Acceptance Criteria Document Inspection Agency
No. of Check Documents Required Vendor Sub Vendor OIL
(A) BARE COMPRESSOR
(A-1) RAW MATERIAL & IN PROCESS INSPECTION
1A Material Test Certificate for Crank Case, Full/ PO / Datasheet PO/Datasheet/ Material Test R P R
Crankshaft, Con Rod, Cylinder, Piston, Piston Rod, Batch VENDOR Mat. compliance
Liner and Cylinder Heads Standard certificate
1B Compliance Certificate for Distance piece, Piston Full/ PO/ Datasheet PO/Datasheet/ Material Test R P R
Nut, Conrod Bolt, Main Bearing Bolt and Nut and Batch VENDOR Mat. compliance
guides Standard certificate
2 Hydrotest for Cylinder 100% PO / Datasheet/ No Leakage/ Test certificate P W
DR Hydro Test VENDOR Hydro -
Procedure Test Procedure
3 PneumaticTest for Cylinder 100% PO / Datasheet/ No Leakage/ Test certificate P R
VENDOR VENDOR -
Pneumatic Test Pneumatic Leak
Procedure Test Procedure
4 Ultrasonic Test for Crankshaft, Con Rod,& Piston 100% PO/ Datasheet/ PO / Datasheet/ Test certificate P - R
Rod VENDOR MT VENDOR MT PROC
PROC
5 Magnetic Particle Test for Crankshaft , Con Rod & 100% PO/ Datasheet/ PO / Datasheet/ Test certificate P - R
Piston Rod VENDOR MPT VENDOR MPT
PROC PROC
(A-2) FINAL INSPECTION / TESTING
1 Barring Over to check Cylinder end clearances / 100% As per VENDOR VENDOR Run Test Test certificate P - R
Rod Runout Run Test Procedure
Procedure
2 4 hrs. No Load Mechanical Run Test of Bare 100% As per PO/ PO/VENDOR Run Test certificate P - W
Compressor with shop driver and shop lube oil VENDOR Run Test Procedure
system Test Procedure
3 Partial Stripping & Internal Inspection after No 100% As per PO/ VENDOR Run Test Test certificate P - W
Load Mechanical Run Test VENDOR Run Procedure
Test Procedure
(B) VOLUME BOTTLES, SUCTION & DISCHARGE KOD
1 Review of MTC & Material Identification for Full Approved Conf. to approved MTC/ Test R/W P R
Pressure parts including Flanges, Butt Weld Batch Drawing/ PO/ Drawing/Datasheet Certificate
Fittings, Pipes Approved
Datasheet
2 WPS/PQR As per Approved Conf. to approved WPS/PQR test R/W P R
Vendor/ Drawing/ PO/ Drawing/Datasheet report
Code Approved
Datasheet
3 Finished End dimensions with thickness check As per Approved Conf. to approved Dimension Report R/W R/W R
with DP test of KR Vendor/ Drawing/ PO/ Drawing/Datasheet
Code Approved
Datasheet
4 Set-ups (L-Seam, C-Seam, Nozzle to shell) As per Approved Conf. to approved Inspection Report R/W R/P R
Vendor/ Drawing/ PO/ Drawing/Datasheet
Code Approved
Datasheet
4A Backchip DP Test As per Approved Conf. to approved Inspection Report R/W R/P R
Vendor/ Drawing/ PO/ Drawing/Datasheet
Code Approved
Datasheet
4B DP Test of Weld Joints as required by Code As per Approved Conf. to approved Inspection Report R/W R/P R
Requirement Vendor/ Drawing/ PO/ Drawing/Datasheet
Code Approved
Datasheet
4C Fitment of Internals As per Approved Conf. to approved Inspection Report R/W R/P R
Vendor/ Drawing/ PO/ Drawing/Datasheet
Code Approved
Datasheet
5 Radiography Examination As per Approved Conf. to approved Test Report/ RT R R/P R
Vendor/ Drawing/ PO/ Drawing/Datasheet Films for Review
Code Approved
Datasheet
6 Final, Visual & Dimensional Check Full Approved Conf. to approved Inspection Report R R/P R
Drawing/ PO/ Drawing/Datasheet
Approved
Datasheet
7 HyVendorostatic Test 100% Approved Conf. to approved Test Report R/W R/P R
Drawing/ PO/ Drawing/Datasheet
Approved
Datasheet
8 Final Paint visual and DFT Check At As per Paint Conf. to paint Test Report R R/P R
Random Procedure procedure
D.GAS ENGINE
1 Certificate of Compliance for Engine Components Full/ Approved Conf. to approved Manufacturer’s R P R
Batch Drawing/ PO/ Drawing/Datasheet standard test
Approved report
Datasheet
2 Engine Full Load Performance Test as per 100% Approved Conf. to approved Manufacturer’s R P R
Manufacturer’s standard Drawing/ PO/ Drawing/Datasheet standard test
Approved report
Datasheet
E. Instrumentation and Safety Relief Valves
1 Body Hydro test, Seat Leak Test & Functional Test At Approved Conf. to approved Manufacturer’s R P R
for Control Valve Random Datasheet Datasheet/ test certificate
2 nos. Instrument
each schedule
Size,
Type/rat
ing
F. Air Exchanger Manufacturer’s standard test report
1 MTC & Material Identification for Pressure parts Full/ Approved Conf. to approved Manufacturer’s R P R
including flanges, Butt Weld Fittings, Pipe Plates, Batch Drawing/ PO/ Drawing/Datasheet standard test
Tubes etc. Approved report
Datasheet
2 Header Seam & Nozzle Butt Ends Radiography 100% Approved Approved Drawing/ Manufacturer’s R P R
Drawing/ PO/ PO/ Approved standard test
Approved Datasheet report
Datasheet
3 Certificate of compliance for Fan Full/ Approved Conf. to approved Compliance R P R
Batch Drawing/ PO/ Drawing/Datasheet Certificate
Approved
Datasheet
4 Hydrostatic Test 100% Approved Conf. to approved Inspection Report R P R
Drawing/ PO/ Drawing/Datasheet
Approved
Datasheet
G. CONTROL PANEL FAT
1 Functional/ Continuity Test/ Loop Test/ Logic & 100% Approved Conf. to approved Inspection Report R P R/W
Graphic Test Drawing/ PO/ Drawing/Datasheet
Approved
Datasheet
H. PIPING
1 Review of Gas Piping Material Test Certificate 100%/ Approved Conf. to approved Inspection Report P - R
with traceability Sample Drawing/ PO/ Drawing/Datasheet
Approved
Datasheet
2 Visual & Dimension Verification including Random ANSI B 31.3/ Conf. to approved Compliance R P R
thickness verification for Piping Material 25% Piping Drawing Drawing Certificate
3 WPS/PQR As per Approved Conf. to approved WPS/PQR Test P - R
Vendor/ Drawing/ PO/ Drawing/Datasheet Report
Code Approved
Datasheet
4 Radiography Examination & DP/MT Test for Gas 100% Approved Conf. to approved Radiogrpahy P - R
piping as applicable Drawing/ PO/ Drawing/Datasheet Report & DP/MT
Approved Report
Datasheet
5 HyVendoro test & Visual Inspection of Gas Piping 100% Approved piping Conf. to approved Hydtotest P - R
Drawing/ PO/ piping Drawing/ certificate
Approved PO/ Approved
Datasheet Datasheet
G. STRUCTURAL ITEMS
1 Dimensional Check for Skid Base Frame and NDE 100% Approved GAD/ Conf. to approved Inspection Report P - R
of Lifting Lugs for Skid Fabrication GAD/ Fabrication
Drawing Drawing
2 Concrete Filling (Piling inside skid) 100% Approved GAD/ Conf. to approved Compliance P - R
Fabrication GAD/ Fabrication Report
Drawing Drawing
3 Reinforcements 100% Approved GAD/ Conf. to approved Compliance P - R
Fabrication GAD/ Fabrication Report
Drawing Drawing
H. Miscellaneous Items
1 Certificate of Compliance for Silencer, Main Drive Full Approved Conf. to approved Compliance R P R
Coupling Drawing/ PO/ Drawing/ PO/ Certificate
Approved Approved
Datasheet Datasheet
2. Manufacturer’s test report for Instruments, Batch Approved Conf. to approved Manufacturer’s R P R
Glands Drawing/ PO/ Drawing/ PO/ Test Report /
Approved Approved Calibration
Datasheet Datasheet certificate
I. Erection and Commissioning Spares
1 Visual Inspection of the Spares Full Approved PO/ Conf. to approved Compliance P - W
Approved PO/ Approved certificate
Datasheet Datasheet
J. Final Inspection
1 Final Mock-up Package assembly for Verification Full Approved GAD/ Conf. to Approved Test Certificate P - H
of Battery Limit dimensions, Visual Inspection as PO GAD/ PO
per GA
2 String Test (one unit from each Duty) One As per PO / Conf. to PO / Test Certificate P - H
Unit VENDOR Test VENDOR Test
from Procedure Procedure
Each
Duty
3 Final Paint visual and DFT check for Compressor At As per Paint Conf. to paint Test Certificate P - H
and Major accessory items random Procedure/ PO procedure / PO
FINAL DOCUMENTATION
1 Final review of Certificates/ Quality Dossier as per 100% As per PO/ As per PO/ Dispatch Release P - H
ITP and Issue of Final Dispatch Clearance Approved Approved Drawing/ Clearance
Drawing/ Datasheet
Datasheet
H- Hold Point W- Witness Point P- Performed By R- Review