-设备制造质量检验规程（Reciprocating Compressors）-.docx

,设备制造质量检验规程(ReCiProCatingCompressors),1、SGSRefNo.:14Rev.:0Page:lof9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/04INSPECTIONGIDELINESRECIPROCATINGCompressorsforgeneralservicesofoApprovall8032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:14Rev.:02、Page:2of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCUmentssinspectionprocess6Shipping7ReciprocatingCOMPRESSORSDATAD0SSIER8INSPECTI0NCHECKLISTSGSRefNo.:14Rev.:0Page:3of9INSPECTI0NGuidelinesreciprocatingcompressorsforgen3、ERALSERVICESDate:18/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatethesupply,manufactureandtestofaReciprocatingCompressorforgeneraluse.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionoftheReciprocatin4、gCompressorfromtheexaminationofcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalReciprocatingCompressorExperienc5、ed,inspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone-off,oralternativedesignofcompressor.Thedesignhavingbeenapprovedbytheclient.Anysuchvariationsshouldbenotedontheinspectorsreport,3.0PROCEDURES.16、GENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonanycontractororder.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionrequiredwil7、Ibeasspecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecifications,purchasersorcompanystandardszandwithinthepracticesandrulesofthecountr½stateorprovinceandanygovernmentdecreeszlaws,ordinanceorregulationasm8、ayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreOnerousrequirementwillapplyunlessthepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSApplicablecodesandSpecifications.Designcode(tobestatedoninspectionreport)Purchase9、orderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)API618JISB83414.0DOCUMENTSTOBEREC曰VED/AVAILABLEATINSPECTIONPurchaseOrderorContractinspectionandTestplansDatasheetSub-assemblydrawingsSGSRefNo.:14Rev.:0Page:410 、of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/04MaterialtestCertificatesWeIdproceduresandProcedureQualificationRecordsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsCalibrationofmeasuringandtestequipmentNDEproceduresz(appropriateto11 、materialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHydrostatictestingprocedurepreparationandpaintingprocedurePreservationzpackingandshippingproceduresupplylist(packinglist)5.0INSPECTIONPR0CESS5.1MATERIALS.1.1REVIEWOFCERTlFICATIONOriginaI12>orauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings:Thereviewwillincludecheckson:-ManufacturersnameandlocationCertificateNoMaterialSpecificationHeatorcastNo13、MakersNoorPlateNoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinish5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspecificationa14、sappropriate.Visualanddimensionalcompliancewithspecification.5.1.3ADDITI0NALSPECIALREQUIREMENTSMayapplyonspecialcomponents.Checktoensurespecificationcontractrequirementshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialchecksshouldinclude15、:ConformationofsatisfactorydocumentreviewRecordofendorsementofcertificationreviewed/witnessedRecordofallnon-conformitiesRecordofanytestswitnessedandtheresultSGSRefNo.:14Rev.:0Page:5of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/045.2RECIPROCA16、TINGCOMPRESSORMANUFACTUREAfterclearanceoftheabovepointstothesatisfactionoftheinspectothefabricatorwillproceedwiththemanufactureofthesubassembliesandcomponentsforareciprocatingcompressor.5.2.!FABRICATIONINSPECTIONFollowingthecompletionofweldingandmachiningoperat17、ionsthecompressorpartswillbeinspectedasrequiredbythespecificationorcontract.Theinspectionwillconsistof:VisualinspectionfordamageDimensionalchecktodrawingrequirementInspectionofparts,particularlycastinpassagesandpipingforcleanlinessVisualexaminationofweldedonco18、nnectionsReviewofwelderqualificationsReviewofweldprocedurerecordConfirmationofsatisfactoryNDE5.2.2HYDROSTATICTESTSThecompressorandotherpressurecontainingpartswillbehydrostaticallytested.Themainitemsbeing:CylinderCoolingJacketsPipingPressurevesselsFiltersCooIersThei19、nspectormustverifythatthecorrecttestpressurehasbeenappliedtotherelevantpartsdependingonspecificationrequirements.5.2.3PRESSURETESTInadditiontothehydrostatictestitmaybenecessarytocarryoutapressuretestusingheliumasthetestmedium.TheinspectorWiIkWitnesspressure20、testasrequiredReviewtestmethodtoensureitisacceptabletothecodespecificationrequirement.5.2.4ASSEMBLYINSPECTIONDuringcompressorassemblyandwhenrequiredbythePurchaseorderorcontractinspectionwillbecarriedoutpayingparticularattentiontothefollowingitems:Pistonendclear21、anceCrankshaftdeflectionRun-outCheckPropermatchmarkingprotectionofmachinedSurfacesSGSRefNo.:14Rev.:0Page:6of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/045.2.5MECHANICALRUNNINGTESTCertaintypesofcompressormaybesubjectedtoamechanicalrunningtest.T22、hisParticularlyappliestoskidmountedunits.Whererequiredbythepurchaseordertheinspectorwillcheckforthefollowingattributesduringthetestperiod.Lubricatingoil-temperature,pressureflowrateCoolingwater-temperature,pressureflowrateCriticalspeedBearingtemperaturesVibrationGas23、 ketcondition/leakageProperoperationofpressurereliefvalvesspeedgovernorsandoverspeedshutdowndevices5.2.6DISMANTLINGINSPECTIONSomepurchasersmayrequireastripdowninspectionaftertesting.Wherethereisaninspectionthefollowingpointswillbecheckedasaminimum:Visualconditionof24、 cylinderlinerSurfaceconditionofcrossheadguidepistonrodsandbearingsValveplatesValvespringsPistons5.2.7FINALVISUALANDDIMENSIONALINSPECTIONAftercompletionofallmanufactureandtesttheinspectorwillundertakefinalinspectionofthecompressorpayingparticularattentionto:Main25NdimensionstodrawingrequirementsSkiddimensionsMatchmarksforre-assemblyPositionofoutsideconnectionpointsInspectionofworkmanshipDirectionofrotationmarkedcorrectly5.3NAMEPLATEContentstobecheckedinaccordancewiththeapproveddrawingsandspecificationsandstamped/markedina26、 ccordancetoclientsrequirements.5.4PAINTINGCOATINGINSPECTIONSurfacepreparationforpaintingwillbecheckedforthefollowingattributesaccordingtothespecification:CleaningmethodPreparationgradeFreedomfromweldspatter,blowholesandotherdefects.HumidityandSteelTemperaturechecksp27、 riortopaintingPaintmanufactureztypandcolourofpainttoclientsspecificationDryfilmpaintthicknesstobecheckedaccordingtospecification.SGSRefNo.:14Rev.:0Page:7of9INSPECTIONGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/04Paintedsurfaceconditiontobefreefro28>mpin-holes,runs,damageorotherdiscontinuity5.5SPAREPARTSzLOOSEITEMSANDACCESSORIESSpareparts,looseitemsandaccessorieswillbecheckedvisuallyandfordimensionsmaterials,workmanshipandquantityaccordingtopurchaseorderspecificationtestmarksandtagswillbecheckedforcorrectident29、ification.5.6REPORTANDRELEASE5.6.1REPORTINGAfinalreportsummarisingtheactivitiescarriedoutwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthetimelimitslaiddowninthecontract.Thereportwillbeinaformatapprovedbytheclientandmustclearlyindicate30、 thefinalacceptanceorrejectionofthepump.5.6.2RELEASENOTEWhererequiredbythecontractareleasedocumentwillbeissuedtothemanufacturerwhenthepumpshavebeenfinallyaccepted.6.0SHIPPING6.1PREPARATIONANDPACKINGThefollowingpointsmustbechecked:AIIexteriormachinedsurfacesmustb31、 ecoatedwithrustpreventativeAllinternalsurfaceswhicharesusceptibletocorrosionmustbecoatedwithrustpreventativeAllflangedopeningsshouldbefittedwithmetalprotectorsinaccordancewiththespecificationAllthreadedconnectionsmustbeprovidedwithsteelplugsCheckmanualsandi32、nstructionsareincludedareincludedasthespecificationrequirementsPackingstyleandsuitabilityforoverseasshipmentShippingmarksarecorrectPre-assembledsystemsaremarkedasrequiredbythespecification7.0RECIPROCATINGCOMPRESSORSDATADOSSIERThefollowingfinaldocumentswillberevie33、wedandendorsedasnecessary.ManufacturersdatareportsMaterialCertificationDimensionaIrecordNDEreportsHydrostatictestreportsPerformancetestrequirementsNPSHreportsRun-testreportsStripdownreportsFinalinspectionreportMarkingsPackingIistSGSRefNo.:14Rev.:0Page:8of9INSPECTI0NGUIDELINESRECIPROCATINGCOMPRESSORSFORGENERALSERVICESDate:18/03/04SparepartsSGSRefNo.:14Rev.:0Page:9of91