WI/INSP/07/02

Effective date: October

2004
Revision date: December,
Work Instruction – Inspection of pumps INDIA
TUV NORD
G GROUP
2014
G
Page 1 of 5

1.0 Purpose: To provide a guideline to TUV inspectors for inspection of centrifugal, reciprocating &
Screw pumps.

2.0 Scope: This work instruction is applicable to all inspection assignments for pumps undertaken by
TUV unless specifically agreed otherwise. In addition to this work instruction, all additional
requirements of PO specification, approved ITP shall apply.

3.0 Referencing Standards: IS 5120/API 610 (Edition as per Data Sheet/ITP/Purchase

Requisition/Pump testing procedures) Hydraulic Institute standard 1.6.

4.0 Reference Documents:

Purchase order, Purchase Requisition, Approved QAP/ITP, approved Pump Data Sheet, Approved
G.A. Drawing, approved Cross Sectional Drawing, approved Mechanical Seal Drawing, and approved
Pump Testing Procedure.

5.0 Common Materials for Pump castings/shaft/sleeve/seal etc. – ASTM A216 –WCB, A276-
316,410,420, A351-CF8, CF8M, CF3, CF3M, A479, A743-CA6NM, CA40F, CA15 etc. (Data sheet to
be referred for individual jobs).

6.0 Inspection & Tests:

 Perform visual inspection for any objectionable surface marks, visible damage.

 Conduct dimensional inspection of suction & discharge nozzles, flange size & rating, nozzle
orientation, centerline height, auxiliary piping connections, direction of rotation viewed from
motor end, impeller diameter & type (Refer G.A. Drawings for specific details).

 Verify markings on nameplate/tag-plate against requirements specified in the data sheet/

project specification. Following markings shall be engraved/stamped as a minimum;
Manufacturer’s name or symbol, type of pump, model number, tag number, pump serial
number, capacity, head, Brake Kilo Watt (BKW), rated speed, service etc.

 Review Manufacturer’s Test Certificates (MTC) for the pump casing, impeller, cover, stuffing
box, shaft, sleeve & mechanical seal etc. for chemical & mechanical properties, conformance
to NACE requirements ( if specified) & compliance to NDT requirement as applicable.
 Verify traceability of pump casing, impeller, stuffing box, cover & shaft material for
compliance to MTC & supplementary test requirements specified in PO specification (PR).

 Review Radiographs for pump casing/impeller/cover/stuffing box castings as applicable

 Review/Witness Liquid Penetrant test or Magnetic particle examination (as specified in ITP)
on machined surface of pump casing/impeller castings.
Prepared by: N G Prabhu Revised by: Amit Naik Issued by:Sandeep Deshpande
Date : October, 2004 Date: 17th December, 2014 Date : 19th December, 2014
WI/INSP/07/02
Effective date: October
2004
Revision date: December,
Work Instruction – Inspection of pumps INDIA
TUV NORD
G GROUP
2014
G
Page 2 of 5

 Review/Witness Ultrasonic examination of casing castings, shaft.

 Witness dynamic balancing of impeller/rotor (unbalance limit as per ISO 1940 Grade1/2.5/6.3
as specified in the approved QAP/ITP). Before witnessing the balancing of rotors the
calibration status and supporting records of the balancing machine shall be verified. The
older type balancing machines which utilize soft bearings shall be revalidated with the
master rotor prior to the balancing activity. For the modern balancing machines which
utilize hard bearings and belt drives the revalidation is not required. However the inspectors
should cross verify the operability of the balancing machines by suitable means such as
adding a known temporary weight on the balanced shaft & take reading again.

 Witness hydrostatic test of pump Casing, Stuffing box, Cover at specified pressure. (Verify
heat no’s of castings and check for correlation with foundry material test certificates. Check
size/rating of suction & delivery flanges of casing.)

Note: Repair welding of pump Casing, stuffing box, cover castings is not permitted unless specifically
allowed by the material specification and or agreed by the client.

 Perform visual, dimensional check, MTC review and hydro test for seal flushing/cooling
system components and PMI check as specified in the approved QAP/ITP.

7.0 Performance Test:

 Record type of motor used ( test or unit as per QAP), tag no, serial no, test medium,
suction/delivery heads, capacity, input KW, voltage, current, speed, bearing temperature
after stabilizing, vibration on housing(pump side, motor side), noise level, leak tightness of
gland packing/Mechanical seal, leakage of water/oil etc.

 Test motor and testing/measuring instruments calibration records shall be verified before the
test.

 Verify pump calculations and performance curves to verify whether duty conditions i.e. head,
capacity, BKW, pump efficiency, shut off head, are met at rated speed as per data sheet and
are within limits of reference standard.

 Witness Mechanical run test (for specified duration) if specified in QAP. Check whether
vibrations & bearing temperature are within specified limits.

 When the difference between the NPSH available & NPSH required (NPSH available – NPSH
required) is less than 1 meter or as specified in ITP/PR then the pump shall be subjected to
NPSH test (cavitation test).
Prepared by: N G Prabhu Revised by: Amit Naik Issued by:Sandeep Deshpande
Date : October, 2004 Date: 17th December, 2014 Date : 19th December, 2014
WI/INSP/07/02
Effective date: October
2004
Revision date: December,
Work Instruction – Inspection of pumps INDIA
TUV NORD
G GROUP
2014
G
Page 3 of 5

 Witness strip test & examine casing/ impeller/ wear rings for wear and tear or scoring marks.

 Perform DFT check, with a calibrated instrument, at random locations on pump and base
plate. Verify the paint certificates against the specified requirements.

 Review manufacturer’s record book. Collect a soft copy for office records.

 Apply TUV hard stamp on pump casing flange.

 Issue inspection release note in the approved TUV standard format, or in client specified
format if specifically agreed.

Note: Normally dimensional check is offered before or after final painting as Pump,
Coupling, Unit Motor & Accessories are assembled on base plate and base plate dimensions can also
be checked.

8.0 Metering or Dosing Pumps:

8.1 Reference Standard: API 675

8.2 Reference Documents: P.O, Approved QAP/ITP, Approved G.A. drawing, Approved datasheet,
Project specification etc.

8.3 INSPECTION AND TESTS:

 Review nameplate markings for tag no, serial no, liquid, capacity, pressure, speed.

 Review Manufacturer’s test certificates for the pump parts viz; liquid, head, plunger, Non
Return valve (NRV), relief valve, gear box etc. for chemical and mechanical properties &
compliance to additional requirements such as NACE & NDT (RT/UT/MT/PT) as specified in the
approved documents.

 Visual/dimensional verification of pump with gear box, coupling, base plate, unit motor-Verify
suction/discharge nozzles flange size & rating, nozzle orientation, base plate overall size and
bolt holes, direction of rotation viewed from motor end, plunger diameter ,shaft seal etc.

 Witness hydrostatic test of pump liquid head at respective rated pressure.

 Witness performance test: (unit motor required for test) Record test medium, room
temperature, discharge pressure, capacity, input KW, current, voltage, capacity at
25/50/75/100 and again at 100/75/50/25 percent stroke length, relief valve set pressure,
Prepared by: N G Prabhu Revised by: Amit Naik Issued by:Sandeep Deshpande
Date : October, 2004 Date: 17th December, 2014 Date : 19th December, 2014
WI/INSP/07/02
Effective date: October
2004
Revision date: December,
Work Instruction – Inspection of pumps INDIA
TUV NORD
G GROUP
2014
G
Page 4 of 5

bearing temperature after stabilizing, vibrations, noise level, water & oil leaks etc. Calibration
status of testing and measuring instruments is to be verified before the test.

 Check calculations and curves to verify linearity, repetitive accuracy, steady state accuracy,
volumetric efficiency, motor current/BKW at 100 percent stroke length (as per Data
sheet/QAP).

 Witness strip test, examine damage on liquid head & plunger.

 Witness Visual, dimensional, hydro test for pulsation dampener/piping(if applicable).

 Review internal cleaning & application of rust preventive/painting.

 Review manufacturer’s record book (MRB). Collect a soft copy for office records.

 Apply TUV hard stamp on liquid head.

 Issue inspection release note in the approved TUV standard format, or in client specified
format if specifically agreed.

9.0 Positive Displacement Rotary Pumps:

9.1 Reference Standard: API 676

9.2 Reference Documents: P.O, Approved QAP/ITP, Approved G.A. drawing, Approved datasheet,
Project specification etc.

9.3 INSPECTION AND TESTS:

 Verify details on the nameplate for details as per approved datasheet.

 Review Manufacturer’s test certificates for the pump parts viz; pump casing, screw shaft, liner,
bearings, LMRV, mechanical seal for chemical and mechanical properties & compliance to
additional requirements such as NACE & NDT (RT/UT/MT/PT) as specified in the approved
documents.

 Witness hydrostatic test of pump casing if specified in approved ITP.

 Witness performance test with test bed motor or unit motor. Record test medium, room
temperature, discharge pressure, capacity, input KW, current, voltage, capacity, bearing

Prepared by: N G Prabhu Revised by: Amit Naik Issued by:Sandeep Deshpande
Date : October, 2004 Date: 17th December, 2014 Date : 19th December, 2014
WI/INSP/07/02
Effective date: October
2004
Revision date: December,
Work Instruction – Inspection of pumps INDIA
TUV NORD
G GROUP
2014
G
Page 5 of 5

temperature after stabilizing, vibrations, noise level, water & oil leaks etc. Calibration status of
testing and measuring instruments shall be verified before the test.

 Verify calculations for power v/s Head & capacity v/s head against the specified values in
approved datasheet.

 Witness strip test if specified in the approved ITP.

 Review internal cleaning & application of rust preventive/painting.

 Review of manufacturer’s record book (MRB). Collect a soft copy for office records.

 Apply TUV hard stamp on pump casing & name plate.

 Issue inspection release note in the approved TUV standard format, or in client specified
format if specifically agreed.

Prepared by: N G Prabhu Revised by: Amit Naik Issued by:Sandeep Deshpande
Date : October, 2004 Date: 17th December, 2014 Date : 19th December, 2014