Glossary of inspection terms

A

#API 610

American Petroleum Institute standard for centrifugal pumps in petroleum, petrochemical and gas service. Sets design rules and shop tests such as the performance test, NPSH test, mechanical run and the casing hydrostatic test at 1.5 times MAWP.

Referenced in: MRT, Performance test, TIR

#API 617

API standard for axial and centrifugal compressors and expander-compressors, including integrally geared machines. Defines the performance test, MRT, URT and the acceptance tolerances on head, flow and power.

Referenced in: MRT, Performance test, URT

#API 682

API standard for shaft sealing systems of pumps. Defines seal arrangements (single, dual, tandem) and the numbered seal plans for flush, buffer and barrier fluids connected to the seal housing.

Referenced in: Seal plan

#APTAcceptance performance test

Shop performance test that proves a pump or compressor meets its guaranteed head, flow, power and efficiency. Usually a hold point in the ITP.

#ASME PTC 10Performance Test Code 10

ASME code for performance testing of compressors and exhausters. A type 2 test allows the test to be run on a substitute gas and converted to specified conditions, provided similitude is maintained.

Referenced in: Performance test, Similitude, Type 2 test

#ASME VIIIASME BPVC Section VIII

ASME Boiler and Pressure Vessel Code section for pressure vessels. Sets design, fabrication, NDT and the hydrostatic test pressure, typically 1.3 times MAWP corrected for temperature in Division 1.

C

#CoCCertificate of Conformity / Conformance

Supplier's signed statement that delivered items comply with the order and specification. Weaker than an MTR because it does not report measured chemistry or mechanical values; reviewed during final inspection.

D

#Datasheet

Technical sheet defining the duty and construction of an item: operating cases, materials, ratings, connections and test requirements. Part of the MR and the reference for the performance test, FTP and final inspection.

Referenced in: MR, PO, Test pressure vs actual pressure

#DFTDry film thickness

Measured thickness of a cured paint or coating layer, checked with a calibrated gauge against the coating specification during in-process inspection and final inspection.

Referenced in: Final inspection, Witness point

#DossierData book, final documentation, MRB

The complete set of quality records for an item. See MRB.

E

#EN 10204 3.1 / 3.2

European standard defining types of material inspection documents. A 3.1 certificate is issued and validated by the manufacturer's own inspection department; a 3.2 certificate is additionally validated by an independent inspector or the purchaser's representative, who witnesses the tests. Applies to the MTR.

Referenced in: MTR

#EndorsementMTR endorsement

The inspector stamps, signs and dates a document such as an MTR or test report to certify it was reviewed and accepted. Endorsement carries responsibility for document acceptance, so it is agreed in the assignment; a document with a deviation is not endorsed but raised as an NCR. See also witness without endorsement.

Referenced in: MTR, Witness without endorsement

#EPCEngineering, Procurement and Construction; EPC contractor

Engineering, Procurement and Construction. A contract form in which one contractor designs the facility, buys the equipment and builds it for the owner, usually for a lump sum. The EPC contractor places the PO with the vendor and issues the NOI, while the owner (the end client, also called COMPANY) is not the vendor's direct buyer. The owner and the EPC contractor often each send their own TPI to the same test, with separate columns on the ITP.

Referenced in: MR, TPA

F

#FATFactory Acceptance Test

The set of shop tests run at the vendor's works before shipment, as listed in the ITP: for example performance test, MRT, hydrostatic test and functional tests. Witnessed by the buyer's inspector or SQR.

Referenced in: FTP

#Film densityRadiographic density

How dark a developed radiograph is, measured with a calibrated densitometer. ASME Section V requires roughly 1.8 to 4.0 for X-ray and 2.0 to 4.0 for gamma in the area of interest; films outside the range are invalid. Checked in an RT review.

Referenced in: IQI, RT, RT review

#Final inspectionFI, pre-shipment inspection, final visual

The last inspection at the vendor's shop after all manufacturing and testing and before packing. Usually a hold point. Covers completeness against the PO, nameplates, dimensions against the GA drawing, coating (DFT), preservation, marking and packing, and confirms that all earlier ITP points are signed and NCRs closed. Ends with the IRN.

Referenced in: CoC, Datasheet, DFT, GA drawing, Hold point, In-process inspection, IRN, MRB, PO

#Flash reportQuick report, daily report

Short preliminary report sent to the client or agency on the day of an inspection visit, before the formal IR. Lists the job, PO, items witnessed with a one-line result each, any non-conformances, the next visit and key photos, so the client knows at once whether a hold point was released.

Referenced in: IR

#FTPFactory, Functional or Final Test Procedure

The vendor's written procedure for a shop test: scope, references, test setup and instruments, step-by-step method, acceptance criteria and data sheets. Approved by the client before the FAT and the document the inspector judges the test against. Related: Fire Test Procedure for fire-safe valves (API 607 / API 6FA) and Field Test Procedure for tests at site.

Referenced in: Datasheet, Performance test

G

#GA drawingGeneral arrangement drawing

Drawing showing overall dimensions, nozzle sizes, ratings and orientation, weights and connection points of an item, including the lettered connection legend (see port). Used for dimensional checks at final inspection.

Referenced in: Final inspection, Port

H

#Heat numberHeat no., melt number

Identification of a production batch (heat) of steel or alloy, stamped or stencilled on the material and printed on its MTR. The key to traceability from finished part back to the mill certificate.

Referenced in: In-process inspection, MTR, Shaft, Traceability, Work order

#Hold point (H)

An ITP step the vendor cannot pass until the inspector has witnessed and signed it and a RTP is given. Typical: hydrostatic test, performance test, final inspection. Compare witness point and review point.

Referenced in: APT, Final inspection, Flash report, ITP, Review point, RTP, SQR, Witness point, Work order

#Hydrostatic testHydrotest, hydro

Pressure test with water: the item is filled, vented and pressurised above design pressure (typically 1.3 to 1.5 times MAWP depending on the code), then held while checked for pressure drop, leaks and deformation. See test pressure vs actual pressure and pneumatic test.

Referenced in: API 610, ASME VIII, FAT, Hold point, MAWP, PMI, Pneumatic test, Seal housing, Test pressure vs actual pressure

I

#In-process inspectionIP, IP visit

Inspection visit during manufacturing, between the PIM and the final inspection: material identification and heat number transfer, fit-up and welding (WPS / PQR), NDT and PMI as performed, intermediate dimensions, heat treatment records and assembly checks.

Referenced in: DFT, PIM, WPS

#IQIImage quality indicator, penetrameter

Wire or hole-type gauge placed on the part during RT to prove the radiograph's sensitivity. Its visibility, together with film density, is checked in an RT review.

Referenced in: RT, RT review

#IRInspection report

The formal report of an inspection visit with test data, photos, the signed test records and any NCRs and punch list items. Follows the flash report.

Referenced in: Flash report

#IRNInspection Release Note, release for shipment

Document issued by the inspector after an accepted final inspection, which the client uses to approve shipment and payment.

Referenced in: Final inspection, NCR

#ITPInspection and Test Plan

Table of every inspection and test step for an item, with the procedure, acceptance criteria, records and the level of involvement of vendor, inspector and client at each step: hold point, witness point or review point.

Referenced in: APT, EPC, FAT, Final inspection, Hold point, NOI, PIM, PO, Review point, TPA, Witness point

K

#KOMKick-off meeting

See PIM.

M

#MAWPMaximum allowable working pressure

The highest pressure at which a pressure vessel or casing may operate at its design temperature. The basis for the hydrostatic test pressure.

Referenced in: API 610, ASME VIII, Hydrostatic test

#MRMaterial Requisition

The EPC contractor's or owner's technical purchasing document for an item: datasheets, specifications and standards, scope of supply, inspection requirements and the documents the vendor must deliver. The PO references the MR, so the specification and test requirements the inspector checks against are found there. Not to be confused with the MRB.

Referenced in: Datasheet, PO

#MRBManufacturer's Record Book, final dossier, data book

The compiled final documentation for an item: MTRs, NDT and PMI reports, signed test reports, calibration certificates, NCRs and certificates. Reviewed at final inspection.

Referenced in: Dossier, MR, Traceability

#MRTMechanical running test

Shop run of a compressor or pump at maximum continuous speed, typically four hours, to check vibration, shaft displacement, bearing temperatures and the lube oil system against API 617 or API 610 limits.

Referenced in: API 617, FAT, URT

#MTMagnetic particle testing

NDT method for surface and near-surface cracks in ferromagnetic materials: the part is magnetised and fine iron particles gather at defects.

Referenced in: NDT

#MTRMaterial Test Report, Mill Test Report / Certificate, MTC

Certificate issued by the mill or forge for a heat or lot of material, reporting the heat number, specification and grade, chemical analysis, mechanical properties, heat treatment and supplementary tests. Certification level per EN 10204 3.1 / 3.2. Reviewed for traceability and sometimes subject to endorsement.

Referenced in: CoC, EN 10204 3.1 / 3.2, Endorsement, Heat number, MRB, PMI, Review point, Shaft, Traceability

N

#NCRNon-conformance report

Formal record of a deviation from the order, specification, drawing or procedure, with its disposition (repair, rework, use-as-is or reject) and closure. Open NCRs block the IRN.

Referenced in: Endorsement, Final inspection, Flash report, IR, MRB, Punch list, RTP

#NDTNon-destructive testing, NDE

Inspection methods that find defects without damaging the part: VT, PT, MT, UT and RT. RT and UT are volumetric; PT and MT find surface or near-surface defects.

Referenced in: ASME VIII, In-process inspection, MRB, MT, PT, RT, Shaft, UT, VT, Witness point

#NOINotification of Inspection

Notice from the vendor or client that a test or inspection is ready, with dates, location, the ITP steps covered and the procedures. The trigger for the inspector's visit.

Referenced in: EPC, TPA

P

#Performance testAPT, H-Q test

Shop test proving that a pump or compressor meets its guaranteed head, flow, power and efficiency over the operating range, run per the approved FTP and API 610 or API 617 / ASME PTC 10. Compressors are often tested on a test gas as a type 2 test.

Referenced in: API 610, API 617, APT, Datasheet, FAT, Hold point, Stonewall, Surge

#PIMPre-inspection meeting, kick-off meeting (KOM)

Meeting with the vendor before fabrication starts to agree the ITP, procedures, schedule and notification rules for the in-process inspection and later visits.

Referenced in: In-process inspection, KOM

#PMIPositive Material Identification

Non-destructive check of the actual alloy of a part with a handheld XRF / OES or OES analyser, confirming it matches the specified grade and the MTR. Catches material mix-ups that paperwork and the hydrostatic test cannot reveal.

Referenced in: In-process inspection, MRB, XRF / OES

#Pneumatic test

Pressure test with air or nitrogen, used where water cannot be. Stored energy is far higher than in a hydrostatic test, so stricter safety controls and lower test pressures apply.

Referenced in: Hydrostatic test

#POPurchase order

The commercial contract for an item. References the MR, datasheets and ITP, and is the governing document for quantities and scope at final inspection.

Referenced in: EPC, Final inspection, Flash report, MR, Work order

#Port (A, B, C …)Lettered connection

Customer connection on a seal housing, gearbox or casing, identified by a letter on the GA drawing with a legend giving size, thread and function (flush, barrier, vent, drain, oil, cooling water). Letters differ between models and seal plans.

Referenced in: GA drawing, Seal housing, Seal plan

#PQRProcedure Qualification Record

Record of the test weld and its mechanical tests that qualifies a WPS.

Referenced in: In-process inspection, Review point, WPS

#PTLiquid penetrant testing

NDT method for surface-breaking defects: a dye penetrant is applied, excess removed and a developer draws the penetrant out of cracks and pores.

Referenced in: NDT

#Punch listPunch items

List of minor open items found during inspection that must be closed before release, tracked alongside NCRs.

Referenced in: IR

R

#Review point (R)

An ITP step where the inspector verifies documents rather than hardware: material certificates, WPS / PQR, calibration certificates, test records. Compare hold point and witness point.

Referenced in: Hold point, ITP, Witness point

#RTRadiographic testing

Volumetric NDT method using X-rays or gamma rays (Ir-192, Co-60) to image the inside of a weld or casting on film or a digital detector (CR / DR), showing porosity, slag, lack of fusion and cracks. Image quality is proven by IQI sensitivity and film density.

Referenced in: IQI, NDT, RT review

#RT review

Review of the vendor's radiographs and RT reports instead of attending the exposures: coverage of every required joint, film density and IQI sensitivity, technique per procedure, interpretation by a certified Level II / III, and repair and re-shoot of rejects.

Referenced in: Film density, IQI

#RTPRelease to Proceed

The go-ahead for the vendor to continue past a hold point or to ship. 'RTP on hold' means the release is withheld until an open issue such as an NCR, a client review or missing documents is resolved. In other contexts RTP can mean Reinforced Thermoset Plastic (ASME RTP-1 fibreglass equipment) or a Radiographic Test Procedure.

Referenced in: Hold point

S

#Seal housingSeal chamber, stuffing box

Pressure-containing part between the pump or compressor casing and the bearing housing or gearbox that holds the mechanical seals around the shaft. Carries the flush, vent, drain and barrier ports for the seal plan and forms part of the pressure boundary with its own hydrostatic test.

Referenced in: API 682, Port, Seal plan

#Seal planAPI plan

Numbered arrangement from API 682 defining how seal flush, buffer or barrier fluid is supplied and drained (for example Plan 11, 21, 53), connected to the seal housing ports.

Referenced in: API 682, Port, Seal housing

#ShaftRotor shaft, pinion

Rotating element carrying the impeller through the seals and bearings. Inspection covers the MTR and heat number, dimensions, runout (TIR), hardness, NDT and the rotor balance report.

Referenced in: Seal housing, TIR

#SimilitudeSimilarity

Condition that a type 2 test keeps the compressor aerodynamically similar to its specified duty: matching flow coefficient, volume ratio and machine Mach number within ASME PTC 10 limits. Shown in the vendor's similitude calculation.

Referenced in: ASME PTC 10, Test gas, Type 2 test

#SQRSupplier (or Source) Quality Representative, source inspector

The person who attends the vendor's shop on the buyer's behalf to witness tests, release hold points and check quality. Vendors ask for 'the SQR who will be on site' to prepare site access.

Referenced in: FAT, TPI

#StonewallChoke

High-flow limit of a centrifugal compressor where flow cannot increase further. The highest flow point of a performance test; compare surge.

Referenced in: Surge

#Surge

Unstable low-flow limit of a centrifugal compressor where flow reverses. The lowest flow point of a compressor performance test; the highest is stonewall.

Referenced in: Stonewall

T

#Test gasSubstitute gas

Gas used in a compressor type 2 test instead of the process gas, for example nitrogen (inert, molecular weight 28) or CO2 (heavier, molecular weight 44), chosen to keep similitude.

Referenced in: ASME PTC 10, Performance test, Type 2 test

#Test pressure vs actual pressure

Test pressure is the value a pressure test must reach, set by the code, datasheet or procedure; actual pressure is what the calibrated gauges show during the hold. A hydrostatic test is valid only if the actual pressure stays at or above the required value for the full hold time without exceeding the allowed over-pressure.

Referenced in: Hydrostatic test

#TIRTotal indicated runout

Total movement of a dial indicator as a shaft is rotated, measuring runout and straightness against API 610 or vendor limits.

Referenced in: Shaft

#TPAThird-party agency, inspection agency

Third-party agency. The independent inspection company that the owner or EPC contractor engages to inspect at the vendor's shop. TPA is also the name of its column on the ITP and NOI, next to Supplier and Contractor: a hold point marked H in the TPA column is not released until the agency's inspector has attended it or the agency has waived it in writing. The agency assigns the TPI inspector, often through a local sub-agency.

Referenced in: TPI

#TPIThird-party inspection

Inspection by an independent party, neither vendor nor buyer, on the buyer's behalf, often through an inspection agency (TPA). The TPI inspector acts as the SQR at the vendor's shop.

Referenced in: EPC, TPA

#TraceabilityMaterial traceability

The ability to trace a finished part back through the work order and heat number to its MTR. Documented in a traceability matrix in the MRB.

Referenced in: Heat number, MTR, Work order

#Type 2 testPTC 10 Type 2

ASME PTC 10 compressor performance test run on a test gas or at conditions different from the specified ones, with results converted to specified conditions. Valid only if similitude is maintained.

Referenced in: ASME PTC 10, Performance test, Similitude, Test gas

U

#URTUnbalanced rotor response test

Shop test from API 617 in which a known unbalance is added to the rotor and the vibration response is compared with the rotordynamic prediction. Usually follows the MRT.

Referenced in: API 617

#UTUltrasonic testing

Volumetric NDT method using high-frequency sound to find internal defects and measure thickness.

Referenced in: NDT

V

#VTVisual testing

Direct visual examination of welds and surfaces, the first NDT method applied.

Referenced in: NDT

W

#Witness point (W)

An ITP step the inspector is notified of and attends; the vendor may proceed after the notice period if the inspector waives. Typical: NDT, dimensional checks, DFT, functional tests. Compare hold point and review point.

Referenced in: Hold point, ITP, Review point

#Witness without endorsement

Scope in which the inspector observes and reports a test but does not stamp or sign the vendor's test reports, so document acceptance stays with the vendor and client. See endorsement.

Referenced in: Endorsement

#Work orderTraveler, router, job card, shop order

The vendor's internal job paperwork for a specific item: identification (PO, tag, serial, drawing revision), the routing of operations with sign-offs, heat numbers issued, hold points and deviations. Starts the traceability chain.

Referenced in: Traceability

#WPSWelding Procedure Specification

Written welding procedure stating process, materials, positions and parameters, qualified by a PQR. Checked during in-process inspection.

Referenced in: In-process inspection, PQR, Review point

X

#XRF / OESX-ray fluorescence / optical emission spectroscopy

Handheld analysers used for PMI. XRF reads most alloying elements non-destructively; OES also measures carbon but leaves a small burn mark.

Referenced in: PMI