TPI - Example Report.
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The document is an inspection report of an electrical transfer pump. It summarizes: 1) An inspection was conducted of the pump which included document verification, functional testing at low and high pressures, and verification of calibration certificates. 2) The inspection found the pump to be in good working order, but the bourdon pressure gauge serial number was not marked and needed replacing to meet requirements. 3) Non-conformances were identified regarding certification and testing of the lifting skid and accessories that support the pump. Corrective actions were recommended to address these issues.
TPI - Example Report.
- 1. Report No.: CBLT-TPI-00F-186-12623 AJN : Client: COBALT INTERNATIONAL ENERGY / TOTAL P O: N/A Location: ANGOLA LOGISTICS BASE Date / Period Manufacturer/s: SCHLUMBERGER/HALLIBURTON Item Inspected Sl. No. Item Identification No. Description Qty (Unit) 1 PMP – EA - 761 ELECTRICAL TRANSFER PUMP 1 Inspection Carried Out: Result of Inspection: Accepted Rejected Hold Stage of Inspection: Before assembly. Non Conformance Reports (NCR): During assembly. HOLD : SPECIFIED ON PAGE 6 During Testing. Final Inspection. Verification: Packing. Approved procedures. Photographic survey. Approved Drawings. Kind of Inspections: Operator Competency. Witnessing tests. Calibration & Traceability. Final inspection. Quality control plan & Inspection test plan. Document review. Parts Traceability. Expediting & vendor assessment Vendor Documents. Goods receipt inspection Stamping: Yes. No. Compatibility of mating/system equipment: Upper Connection Type: N/A Fish-neck length: N/A Lower Connection Type: N/A Tong Space: N/A Standards/Specification/Customer documents : Please see standard list as annexed for detailed description. 3 Page 1 of 16 RSG/QA-QC/TPI Rev.01
- 2. Report No.: CBLT-TPI-00F-186-12623 AJN : Inspection Details: Document verification has been carried out prior to starting the job, this includes the following: a) Schlumberger Flow test Procedure – Electrical Transfer Pump – PMP. b) Pressure Safety Valve (PSV) Calibration Certificate. c) Bourdon Pressure Gauge calibration certificate. d) PMP Unit Certificate of Conformity. e) Annual maintenance log and 5 yearly re-certification, including UT survey. f) NDT, Test and Certification of lifting equipment and skid unit. Flow test Preparation:- A suction pipe string was assembled using 3” pipe, connected to the pump inlet using a 3” weco union. The pipe was then connected to a pre-filled surge tank with volume indicator showing levels, the flow Is controlled by a 3”, 300# ball valve. A discharge pipe string was assembled using 3” pipe, connected to the discharge line using a 3” weco Union. The flow is controlled by a 3”, 3 way ball valve fitted to the unit diverting to the PSV. Back pressure is controlled by a 3” ball valve located on the discharge surge tank. In order to function test the pump at maximum working pressure a back pressure was established by Closing the inlet valve on the discharge surge tank. This is to test the PSV. Working pressure is to be monitored using the calibrated Bourdon pressure gauge, this gauge is a permanent fitting. The following topics are covered in the procedure as per attached checklist: a) Connections and Preparation b) Check before start c) Function test at low pressure d) Function test at high pressure e) Final unit inspection The unit was operated at ZERO pressure for 3 minutes, and again at 20 bar for 3 minutes. Back pressure to be Simulated in order to activate and test PSV. RESULT All aspects of the attached procedure have been strictly followed, and the unit is of good working order. The serial number of the bourdon pressure gauge was not visible/marked. Schlumberger was advised that this would need to be replaced with a calibrated unit to conform with Cobalt requirements. The gauge was changed out and tested at min/max working pressure. Page 2 of 16 RSG/QA-QC/TPI Rev.01
- 3. Report No.: CBLT-TPI-00F-186-12623 AJN : EQUIPMENT DATA AND SPECIFICATION MODEL TYPE PUMP APPLICATION CAPACITY MAX WP PMP - EA ELECTRICAL SCREW STANDARD 4000 BBL/D 300 PSI INLET OUTLET FLUID SUPPLY VOLTS GROSS WEIGHT SUPPLY KW FEMALE MALE OIL 400 @ 50Hz 1500 kg 33 460 @ 60Hz Page 3 of 16 RSG/QA-QC/TPI Rev.01
- 4. Report No.: CBLT-TPI-00F-186-12623 AJN : Annex 1 - Standards/Specifications/Customer documents : Title Reference No. Revision Operator Quality Plan th A21-10-018 24 Feb. 2012 Metallic products -Types of inspection documents EN 10204:2004 General principles for the selection of cracking- NACE MRO175 / ISO 15156 Part 1 resistant materials European Pressure Equipment Directive 97/23/EC ATEX Directive – Certified for explosive areas – Zone 2 94/9/EC British Standard – Offshore Cargo Carrying Units BS 7072 1989 ASME- American Society of Mechanical Engineers: B31.3 Process Piping Design. Testing of Bourdon Pressure Gauges EN 837 - 1 Pressure Gauge Calibration ISO 17025 ASME – Performance Test Code – Pressure Relief PTC25 1994 Devices ASME – Performance Test Code –Pressure PTC19.2 1998 measurement ASME – Performance Test Code –Displacement Pumps PTC7.1 1969 ASME- American Society of Mechanical Engineers: B31.9 Working pressure and temperature limits ASME- American Society of Mechanical Engineers: Pipe B16.5 flanges and flange fittings MSS – Manufacturers Standardization Society – Standard marking systems for valves, fittings, flanges SP25 and unions API – American Petroleum Society – Pipeline valve API 6D specification. API - American Petroleum Society –Pressure relief API.RP.520 / API.RP.521 Systems Surface Testing – Pressure testing manual 3045666 Schlumberger – 4000 BOPD PMP Maintenance manual Page 4 of 16 RSG/QA-QC/TPI Rev.01
- 5. Report No.: CBLT-TPI-00F-186-12623 AJN : DOCUMENT AUDIT CHECK LIST INTL ELECTRICAL TRANSFER PUMP – PMP-EA-761 Vendor: VALE TONG Signed: Position: MAINTENANCE MANAGER Auditor: RYAN GILLESPIE Signed: Department: RUSSEL SMITH TPI Item No. Title Location Compliance 01 Procurement Records QA File YES 02 Maintenance Records QA File YES 03 Replacement Records QA File (See Correction note 1) YES Bourdon Gauge 04 QA File / attached herein (See Correction note 1) YES Calibration 05 Annual Survey QA File YES 06 5 Yearly Certification QA File YES 07 As Built P & ID QA File YES 08 SKID Test Certification QA File / Attached herein NO 09 SKID MPI Report QA File / Attached herein NO 10 LOLER SI2307 - LGI QA File / Attached herein NO 11 PRV Calibration QA File / Attached herein YES Pressure Equipment 12 QA File / Attached herein YES Directive - DOC Safety of Machinery 13 QA File / Attached herein YES Directive - DOC 14 Quality Conformity -DOC QA File / Attached herein YES PMP 4000 bpd 15 Surface Testing Maintenance Office YES Maintenance Manual Surface Testing – 16 Surface Testing Maintenance Office YES Pressure Testing Manual Pressure Recorder 17 QA File / Attached herein YES Calibration Page 5 of 16 RSG/QA-QC/TPI Rev.01
- 6. Report No.: CBLT-TPI-00F-186-12623 AJN : CORRECTIVE ACTION RECORD / REQUEST INTL ELECTRICAL TRANSFER PUMP – PMP-EA-761 Vendor: VALENTINE TONG Signed: Position: MAINTENANCE MANAGER Auditor: RYAN GILLESPIE Signed: Department: RUSSEL SMITH TPI NON CONFORMANCE / ACTION REQUESTED DATE REQUESTED / DATE RECTIFIED / CLOSED OUT Bourdon pressure gauge – no Replace with a traceable identification number 1 Calibrated gauge. 22 June 2012 22 June 2012 or calibration certificate. No auditable Record in the QA file test/inspection history Non-Conformance: 1) Skid unit has not proof load test certification and is out of compliance Recommendation – The skid unit is to be proof load tested by a third party as per BS7072 – offshore Cargo Carrying Units 2) No NDT reports available, it is required that lifting points on BS7072 units undergo an MPI examination within a 24 month period. Recommendation – The lifting points of BS7072 units are to undergo an MPI examination every 12 months by a third party. 3) SI2307 certification is out of compliance. The skid unit is to be certified every 6 months by a third party. Recommendation – The skid unit is to undergo a visual examination as per SI2307:LOLER1998 4) SI2307 certification is out of compliance. The lifting accessories i.e the lifting set, inclusive of 4 leg sling and 4 x shackles are to be certified every 6 months by a third party Recommendation – The lifting accessories inclusive of quad sling and shackles are to undergo a visual examination as per SI2307:LOLER1998 NOTE - All of the above should be carried out at the same time by a specialist lifting equipment inspection company Page 6 of 16 RSG/QA-QC/TPI Rev.01
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