-设备制造质量检验规程（Shell Boilers Welded Const）-.docx

”设备制造质量检验规程(SheilBoilersWeldedConst)l,1、SGSRefNo.:03Rev.:0Page:lof!INSPECTIONGIDELINESSHELLBoilersofweldedCONSTRUCTlc)NDate940304NSPECTIoNGuidelinesshellboilerofweldedconstrctionofoApproval04032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:03Rev.:0Page:2of11INSPEC2、TiONGuidelinesshellBoilersofweldedCONSTRUCTIONDate:04/03/04Cc)NTENTSlPURPoSE2SCOPE3PROCEDURE4DOCMENTS5INSPECTIONPROCESS6SHIPPING7SHELLBOILERDATADossierscertificateofconformity9nspectionchecklistsgsRefNo.:03Rev.:0Page:3of!INSPECTIONGUIDELINESSHELLBoilersofweldedcoNSTRUCTioNDate：043、03041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatethesupply,manufacture,andtestofallShellBoilers.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionoftheShellBoilerfromtheexaminationofcertificationfromprocur4、ementsourcestothefinalinspection,preservationandpackingtodespatchforsite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalShellBoiler.ExperiencedinspectorsmayinterprettheintentoftheinstructiontoaccommodateI5、ocaIornovelpracticesortoutilisetheinstructionforaone-offzoralternativedesignofboilerzthedesignhavingbeenapprovedbytheclient.AnysuchVariationsshouldbenotedontheinspectorsreport.Mostboilersareconstructedunderoneofthewellknownnationalcodeswhichrequireaninspect6、ingauthoritytosurveyProductionThisinstructionisbasedintherequirementsofsuchacode.ltassumesthatthedesignparametershavebeenreviewedandapproved.3.0PROCEDURES.IGENERALThisinstructiontogetherwithitsassociatedchecksheetmaybeusedonanycontractororder.ltisintendedto7、actasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionwillbespecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseOrderspecif8、 ications,purchasersorcompanystandards,andwithinthepracticesandrulesofthecountr½stateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreOnerousrequirementshallapplyunless9、 thepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSAppIicabIecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)EN12953:210、003ASMEIAS1229-1990SGSRefNo.:03Rev.:0Page:4of!INSPECTIONGuidelinesshellBoilersofweldedNSTRCTIONDate0403044.0DOCUMENTSTOBERECEIVED/AVAILABLEATINSPECTIONPurchaseorderorContractBoiIerInspectionandTestPlanITPBoiIerdataSheetApproveddrawings,(arrangements)Sub-assemblydra11 、WingsMateriaItestCertificatesWeIdproceduresandProcedureQualificationRecordsProductionweldtestrequirementsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsRepairproceduresNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsND12 、E/inspectorsqualificationsHeattreatmentprocedurecalibrationrecordsfortestingmeasuringequipmentHydrostatictestingprocedurezwaterqualitydocumentpreparationandpaintingprocedurePreservation,packingandshippingprocedureSpares/operatingmanualsSupplylist(packinglist)5.0INSPECTIONPROCES13 、S5.1MATERIAL5.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopiesofmillcertificateswillbeavailableatmanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings.Thereviewwillinclude:MakersnameandlocationMaterialSpecification14 、CertificateNo.,Grade,sizeandwallthicknessHeatorcastNo.ChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinishStructuralobservations,notabledefects5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesagainstprodu15 、ctmarkings.Materialsuppliedagainstdrawingzmateriallistandspecificationasappropriate.Transferidentificationtocutoffcomponents,(CastNotransfer)zasspecified.Visualanddimensionalcompliancewithspecification.5.1.3ADDITIONALSPECIALREQUIREMENTSMayapplyonspecialcomponents,checkto16、ensurethatcontractrequirementshavebeenmet.WitnessanyNDEexaminationasnecessary.SGSRefNo.:03Rev.:0Page:5of!INSPECTIONGuidelinesshellBoilersofweldedNSTRCTIONDate040304SGSRefNo.:03Rev.:0Page:6ofIiinspectionGuidelinesshellBoilersofweldedCONSTRUCTIONDate:04/03/045.1.4REPORT17、INGReportingonmaterialchecksmustinclude:ConfirmationofsatisfactorydocumentreviewRecordoftheendorsementofcertificatereviewed/witnessedRecordofallnon-conformitiesRecordoftestswitnessedandtheresult5.2FABRICATI0NOFSHELLBOILERSAfterclearanceofabovepointstosatisfaction18>oftheinspectorzthenthefabricatorwillproceedwiththemanufactureofsub-assembliesandcomponentsoftheShellBoilerJnspectorswillreviewthefollowingpointsonabasistobeoutlinedintheapplicableNationaIStandardzPurchasersdocumentation,qualityplan,tstandinspectionplan,orother19、document,asnotifiedtotheinspector.5.2.1PREPARATIONFORWELDINGCarryoutvisualanddimensionalchecktoensurecompliancewithWPSandspecification/Code.Wherespecifiedweldbevelswillbeexaminedbyrequiredcodemethodaftergrinding/machining.Edgesandweldbevelswillbeclean,dryandfre20、efromsurfacedefects.Laminations,cracks,voidsznotcheszetc.Thesewillbecauseforrejectionunlesssuitable/Satisfactoryremedialactioncanbetaken.WeldrepairsmustbecarriedinaccordancewithTheCoderequirementsandapprovedbytheclientbeforeweldingproceeds.SeriousOrExcessivedefectsm21、ustbereported.5.2.2WELDINSPECTION5.2.2.1EDGEPREPARATIONVisualanddimensionalcheckwillbeformedinaccordancewithWPSandspecificationsMTorPTshouldbecarriedoutinthecutedgesasrequired.Edgesmustbefreefromlaminations,cracks,notchesetc5.2.2.2FITUPINSPECTION.Shapes,dimen22、sionandalignmentswillbecheckedinaccordancewithapprovedWPSzClrawingandspecificationscode5.2.2.3VISUALCHECKANDNON-DESTRCTIVEEXAMINATIONThepreparedgrooveandadjacentareawillbecleanandfreefromforeignmaterials,oil,paint,waterandrust.Thepreparededgewillbere-examinedto23、 ensurenodefectshavebeenexposedduringfinalpreparation.TackweldswillbeproducedusingtheapplicableWPSconditionsandwillbevisualfreefromdefects.Nondestructiveexaminationwillbeperformedinaccordancewiththecoderequirements.5.2.2.4MONITORINGOFWELDCONDITIONSPreheatheat24、 temperatureandmethod,lnterpasstemperaturesweldmaterialcontrol,welderandprocessqualificationswillbecheckedforconformitytocoderequirementsandmonitoredSGSRefNo.:03Rev.:0Page:7of!INSPECTIONGUIDELINESSHELLBOILERSOFWELDEDNSTRCTIONDate0403045.2.2.5BACKGOUGINGINSPECTIONTh25、eshapeanddimensionofthebackgougedgrooveswillbecheckedforconformitytotheWPSrequirement.Thevisualappearancemustbecleanandfreefromdefects.NDEexaminationwillbeinaccordancewithcode/clientsrequirements5.2.2.6POSTWELDINSPECTIONAftercompletionofallweldingandgrinding26、 operationsavisualexaminationwillconfirmtherearenoharmfuldefectssuchascracksjackoffusion,surfaceporosityorexposedSlaginclusionsJncompIetePenetrationJncorrectprofileoftheweldjackofleglengthandOverIapJemporaryattachmentswillberemovedzgroundsmooth,andtheareasche27、ekedfordefectsbyMPorPT.5.2.2.7NONDESTRUCTIVEEXAMINATIONNDEwillbeperformedbyqualifiedpersonneltoapprovedtechniques.Thetechniquesavailablearedependentonvesselsclassificationandthematerialsused.Checkthatthecorrectmethodhasbeenusedandverifytheapprovedstatusofboth28、Techniquesandthepersonnel.5.2.2.8WELDREPAIRSWeIdrepairswillbecompletedusinganapprovedWPSmethodandretestedaccordingly.AIIrepairswillbeapprovedbeforeanyhydraulictestingiscarriedout.5.2.2.9DIMENSIONALMEASUREMENTSANDVISALLEXAMINATIONAdimensionalcheckcoveringallmajo29、rdimensionsandtheposition/orientationOfattachmentswillbecarriedoutinaccordancewiththecodeanddrawingrequirements.Inadditionafullvisualexaminationofbothinsidewherepracticableandoutsidesurfacesofthevesselwillbecompleted.Particularattentionshouldbepaidtotheclean30>Iinessoftheinteriorofthevessel,thecondition/appearanceofweldsandassociatedareasandtheconditionofsealingfaces.5.2.3.PNEUMATICTESTNozzlereinforcingpadszsupportssaddlesorotherattachmentsshallbeexaminedwhenspecifiedbyanapprovedlowpressurepneumatictestprocedureusing31、soapywaterastheindicatingmedium5.2.4HYDRAULICTESTINGCheckallpreviousitemshavebeenacceptedbyauthorisedbodies.CoderequirementswhichspecifytestingwillbewitnessedThefollowingitemswillbeverified.Calibrationstatusandcorrectworkingrangesofgauges.Aminimumof2pressure32agaugeswillbeattachedtoitemundertest.AdequateprovisionforventingofhighpointsanddrainswillbeprovidedTestpressureshallbeappliedasdirectedbyprocedureorcodeuntiltestlimitingpressureisreached.Duringholdperiod,amethodicalcheckforleakswillbeconducted.Testpressure,33、metalandwatertemperaturewillberecorded.SGSRefNo.:03Rev.:0Page:8ofIiinspectionGuidelinesshellBoilersofweldedNSTRCTIONDate040304Waterqualitywillbespecified.5.2.5POSTHYDRAULICTESTINGAfterdepressurisation,shellboilercomponentswillbedrainedanddriedtomeetspecifiedrequirements.StampingofInspectionAuthoritystampszwillbecarriedoutinapprovedarea,asrequiredb