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                                04. Compressor

1. Scope ...................................................................................... 1
2. Inspection Items and Methods ................................................ 1
3. Inspection Procedures and Standards .................................... 3
                                             Inspection Standard                       PS - N - 05 - 04

                                              COMPRESSOR                 Enacted on              Jan. 24, 1980
                                                                            1st Rev.            Sept. 15, 1981
                                                                           2        Rev.        Mar. 31, 1991
                                                                           3 Rev.                Nov. 1, 1994
                   Relevant Specification No.                                  th
                                                                           4 Rev.               Mar. 25, 1997
                                                                           5th Rev.              Jul. 31, 1998
                                                                           6th Rev.             Nov. 28, 2003
                                                     KSB 6351

1. Scope
  This inspection standard shall apply to the test and inspection of the reciprocating-type and centrifugal-type
  compressor with total pressure ratio (P2/P1) ≤ 15 purchased by POSCO. Note, however, that the
  contracted specification and any additional consideration specified in the approved drawings shall have
  precedence in case they have any discrepancy with this standard.

2. Inspection Items and Methods
 A. Centrifugal compressor                                        (uppercase: Witness; lowercase: Report review)
   No.                 Description                           Inspection Item                         Remarks
   1-0      Centrifugal compressor              ma, VI, DM, PA, PF, NV, LK, PP, PK
   1-1      Safety valve                        See this inspection standard.
   1-2      Receiving tank                      See this inspection standard.                (pressure vessel)
   1-3      Cooler                              See this inspection standard.                (heat exchanger)
   1-4      Air dryer                           VI, DM, RT, PR, FC, PP
   1-5      Motor                               See this inspection standard.

  1) Material inspection: Review reports on the chemical analysis and mechanical properties.
  2) Non-destructive inspection: Conduct the PT or MT if the tube nest is of the welding type.
      ※ The air tank RT shall be conducted subject to the pressure vessel inspection standard (the RT scope for each
           welding efficiency level shall comply with Table uw-12, Section Ⅷ DIV.1 of ASME).
  3) Assembly test: Check the coupling alignment.
  4) Pressure (pressure-resistance) test: Perform the pressure test for the cooler and receiver tank in the form of a
      witness test (if the cooler tube nest block is of the welding type).
      ※ The pressure (pressure-resistance) test shall be conducted before painting. For the water pressure test in
           particular, continue applying test pressure equivalent to 1.5 times the design pressure for over 30 min. to
           make sure that neither leak nor deformation occurs.
  5) Performance test
   ① Tolerance for the discharging volume and pressure test: Beyond the specified volume, except the additional
      limitations in tolerance as described below
                    Centrifugal Compressor                                Reciprocating Compressor
         - Within +10% of the specified discharging      - ≤ 10㎾: Within ±6% of the specified discharging volume
           volume at the specified pressure              - 10㎾~100㎾: Within ±5% of the specified discharging volume
         - Within +6% of the specified pressure at the   - > 100㎾: Within ±4% of the specified discharging volume
           specified discharging volume
   ② Revolution per minute (within +10%, -5%)
   ③ Safety valve test: Valve setting within 110% of the standard rated pressure
   ④ Temperature increase test: Bearing part (KS B 6301) and Motor (NEMA-MGI-12.42)

  ⑤ Unloader test: Check whether the unloader works normally up to the specified pressure.
  ⑥ Noise measurement: Check for any abnormal noise.
  ⑦ Vibration measurement: Subject to this inspection standard as per ISO 10816-1(1995);
    Note, however, that the reciprocating compressor shall be subject to the following standard (KS B 6351):
   (Over or near bearing)

           Reciprocating compressor
                              Full                                         Remark
                         amplitude (㎛)

      Mono-roll type                      - Refers to compressor with one connecting rod (including tandem type)
                             ≤ 100
      Multi-roll type                     - Refers to compressor with many connecting rods (including star type)
                              ≤ 50
     Counterbalance                       - Excluding the compact compressor installed on the internal combustion
                              ≤ 30
           type                             engine drive or air tank

  ⑧ Auto & Stop Test
 6) Safety valve: Check whether the safety valve has been tested by Korea Industrial Safety Corp. (KISCO).

B. Reciprocating compressor
     No.                Description                          Inspection Item                       Remarks

     1-0      Reciprocating compressor          ma, VI, DM, PA, PF, NV, LK, PP, PK
     1-1      Cylinder                          ma, mt, VI, DM, PR
     1-2      Piston                            ma, VI, DM
     1-3      Crank shaft                       ma, UT, VI, DM
     1-4      Connecting rod                    ma, UT, VI, DM, LN
     1-5      Separator                         VI, DM, PR, SP, PP
     1-6      Receiving tank                    See this inspection standard.               (pressure vessel)
     1-7      Cooler                            See this inspection standard.               (heat exchanger)
     1-8      Safety/Relief valve               See this inspection standard.
     1-9      Motor                             See this inspection standard.
    1-10      Air Dryer                         VI, DM, PR, FC, PP

※ Special Notes:
 1) Appearance and dimensional inspection
  ① The cylinder, crank shaft, and connecting rod shall be inspected together with the abovementioned inspection
      items and ITP up to more than 150㎾ of their capacity. Otherwise (less than 150㎾), review the reports on each
      inspection item.
  ② Check the cylinder’s interior and piston thread.
  ③ Check the plating and polishing conditions of the piston rod.
  ④ Check the tightening conditions of the piston rod and head.
  ⑤ Check the (mechanical) machining dimensions of the piston.
  ⑥Check the machining dimensions of the piston ring & ring groove.
  ⑦ Conduct the PT or MT around the tube nest welds if the cooler tube is of the welding type.
 2) Non-destructive Inspection
  ① NT (UT) for the crank shaft and piston rod
     - Less than 150㎾: Review the reports.
     - Not less than 150㎾: Conduct a witness inspection.
  ② Perform the MT after the precision machining of the cylinder.
 3) Performance test
  ① Shaft power, discharging volume, rotation speed, noise, temperature rise, safety valve’s working
  ② Unloader’s working
  ③ Conditions of air circulation
 4) Safety/Relief valve: Check whether these parts have been tested by KISCO.

3. Inspection Procedures and Standards
    Items                        Inspection Methods                                 Acceptance Criteria
               Perform the following tests for major members:
                                                                             - Subject to POSCO purchase
1. Material     - Chemical composition test
                                                                               spec, approved drawings, and
inspection      - Mechanical test
                                                                               relevant KS standards
                - Non-destructive inspection
               A. Check the internal and external casting for defects
                  such as harmful cavity, burr, scale, fracture, etc.
                                                                             - No major defect is allowed with
               B. Check the forging for any defect such as involution,
                                                                               uniform machining; use is
                  fracture, flaw, etc.
                                                                               prohibited in case of crack.
2. Visual      C. Check the machined surface for any serious flaw
inspection        and verify the uniformity of finishing.
                                                                             - For welds, comply with the
               D. Check the conditions of welds and finishing after
                                                                               pressure vessel inspection
               E. Check the conditions of name plate records and part
             A. Check the dimensions of major parts.
3.           B. Check the connected piping assembly particularly for
Dimensional     any spot of oil or gas leak during operation.                - Check according to the
and assembly C. Check the belt for adjustment.                                 approved drawings.
inspection   D. Check the fit-up conditions of each gauge, full
                assembly, valve, and cocks.

               A. Conduct the pressure and leakage test for the
                  cooler, separator, and receiver tank.                      - Conduct the PT or MT for the
               B. The test pressure and duration comply with the table         welding-type cooler tube rather
                  below; for details, see the Pressure Vessel and Heat         than for the expansion type.
                  Exchanger Standard.
               Order     Test type            Test pressure                          Test duration
                                        1) Hydraulic pressure test:
                                           Apply pressure
                                                                      Over 30 minutes after reaching the test
                                           equivalent to 1.5 times
                                           the max. available
4. Pressure                                                           ① Pressurize gradually up to 50% of the test
test                                                                    pressure.
                       Pressure test
                 1                                                    ② Pressurize by 10% incrementally and
                       for steel tank   2) Pneumatic pressure
                                                                        maintain the current pressure for over 5
                                           test: Apply pressure
                                                                        min. Afterward, pressurize up to the test
                                           equivalent to 1.25 times
                                           the max. available           pressure and maintain the new pressure
                                           pressure.                    for 30 min.
                                                                      ③ Let the pressure drop to the design
                                                                        pressure before performing the leakage

                                        Applying the pressure
                                                                      Once reached the test pressure, that
                 2     Leakage test     beyond the designed one,
                                                                      pressure for over 15 min.
                                        use foaming agent, etc.

    Items                          Inspection Methods                             Acceptance Criteria
5.               ※For the gas compressor, air may be used for the test.
Performance       Note, however, that the test and acceptance shall be
test              carried out under modified fluid conditions.
                                                                            - Less than the specified shaft
- Shaft          A. Measure the required power based on the regulatory        power
  power             specification using a dynamometer.
                                                                            - In case of universal type, beyond
- Discharging                                                                 the specified volume
  volume,     A. Measure via the orifice and nozzle.
  pressure              60A             60A
              B.   Qs           2h {           2 gh}
                              s                 s
                   Qs: Suction volume (㎥/min)
                   A: Round area = (π/4)d2(㎡)
                   d: Throttle’s hole Ø (m)
                   α: Coefficient of discharge
                      : Adjusted coefficient under air inflation
                   g: Free falling acceleration (9.81m/s2)
                   ρ: Air density just before the orifice pipe (㎏/㎥)
                        (γ: Weight per unit volume [㎏f/㎥])
                   ρS: Density of intake air (㎏/㎥)
                         (γS: Weight per unit volume [㎏f/㎥]
                   h=P1-P2: Pressure gap between the area just outside
                      and beyond the orifice pipe (Pa)(㎏f/㎥ or ㎜Aq)

                 A. Measure the revolution of motor and machines using
- Rotational        the Tacho Meter.                                        - Within +10%,-5% of spec.
  speed                                                                       revolution
                 A. Measure the noise using the Sound Level Meter in        - No effect allowed on the volume,
- Noise             accordance with KS B 1502 (make sure that no              etc.
                    abnormal noise is generated).                           - Check based on the approved
                 A. Continue operating the compressor (over 2 hours) at       drawings or IEC 34-9(1990).
- Temp.             the specified load. Once it reaches the saturation      - Reference value subject to KS B
                    temp, measure the temperature at the foot bearing         6301 (Bearing) and NENAMGI-
                    and cooling water inlet/outlet.                           12.42 (Motor)
                                                                            - Cooling water shall be below the
                 A. Shut off the gate valve of the air tank to continue       spec. design temperature
- Safety valve      operating the safety valve and check its operation.     - Check based on the approved
                 A. Check the operation of the unloader up to the             drawings.
- Unloader          specified pressure.                                     - Check based on the approved
                    Measure the foot bearing in the horizontal, vertical,     drawings.
- Vibration         and axial directions using the Vibration Meter.         - Subject to ISO 10816-1:1995(E).
                                                                              Only, the reciprocating type
                                                                              subject to KS B 6351
                                                                            - Any abnormal vibration shall be
                                                                              rejected even if it falls below the
                 See this inspection standard.                                standard tolerance.
- Motor                                                                     - Check based on the approved
                                                                            - Acceptance based on KS C 4202
                                                                              and KS C 4203