-设备制造质量检验规程（Industrial Valves）-.docx

,设备制造质量检验规程(IndUStrialValVeS)Il1、SGSRefNo.:09Rev.:0Page:lof9INSPECTIONGIDELINESINDSTRIALVALVESDate:ll/03/04INSPECTIONGUIDELINESINDSTRIALVALVESOForApprovalll032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:09Rev.:0Page:2of9INSPECTI0NGIDELINESINDSTRIALVALVESDat2、e:ll/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCUMENTS5INSpectionprocess6Shipping7valvedataDosiersinspectioncheckLISTSGSRefNo.:09Rev.:0Page:3of9INSPECTI0NGUIDELINESINDSTRIALVALVESDate:ll/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovali3、datethesupply,manufactureandtestofvalves.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofavalvefromtheexaminationOfcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.ltisparticularlysuitablefortheinspe4、ctionofGatezGIobezBaIIandCheckvalves.Althoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalvalve.ExperienceciJnspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstruc5、tionforaone-off,oralternativedesignofvalve,thedesignhavingbeenapprovedbytheclient.Anysuchvariationsshouldbenotedontheinspectorsreport.3.0PROCEDURE3.IGENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonanyorderorcontract.ltisintendedtoactasag6、uidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionrequiredwillbespecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawingszpurchaseOrderspecifi7、 cations,purchasersorcompanystandardszandwithinthepracticesandrulesofthecountr½stateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreOnerousrequirementshallapplyunless8、thepurchaserorclientdirectsotherwiseinwriting.Therangeofvalvetypes,materials,sizesandpressureratingsincludedwithinstandardmanufacturerscataloguesislargeandinfinitelyvariedandexcludesthepossibilityofproducinganoverallinstruction,whichdefinespreciselytowhatextentin9、 spectionisrequiredonanyspecificitemorpurchaseorder.TheinspectorwillfirstestablishwhethertheextentOfinspectionisstipulatedwithinthebodyofthePurchaseOrderdocumentationorProjectinstructions.3.2SPECIALISEDVALVESFORCRITICALSERVICESWhensuchstipulationsarenotprovidedzas10、ageneralguidezallvalvesover8NBwillnormallybeindividuallywitnessedontest.Withverylargeorspecialvalveszsuchinspectionmaybeextendedtodetailedcomponentinspectionofmajorcomponents.SuchdetailinspectionWillalwaysapplytovalvesintendedforhighpressureSteam,cryogenic,nucl11、earorothercriticalservice,andinsuchinstances,willextendtovalvessmallerthan8NB.3.3GENERALPURPOSEVALVESWithquantityordersforgeneralpurposevalvesinthesmallersizesandpressureratingsinnon-criticalservicezreviewofthesuppliersmaterialandtestcertificationcoupledwitha12、 monitoringofvalvetestandpercentagestripandfinalinspectionwillnormallysufficetoestablishwhethertheorderrequirementsarebeingsatisfactorilymet.SGSRefNo.:09Rev.:0Page:4of9INSPECTIONGuidelinesindustrialVALVESDates03043.4REFERENCEDocuMENTSApplicablecodesandspecifications13、 .Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)API598ValveInspectionandTestAPI6D.PipelinevalvesAPI594.WafertypecheckvalvesASME/ANSIB16.5FIangeszVaIvesa14、 、ndFittingsAPI600,602,603,604.4.0DOCUMENTSTOBERECEIVED/AVAILABLEATINSPECTIONPurchaseorderinspectionandTestPlansITPDataSheetApproveddrawings,(arrangements)Sub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresandProcedureQualificationRecordsListofqualifiedweldersorweldi15、 ngOperatorsWeIdersqualificationsCalibrationcertificatesfortestandinspectionequipmentNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHeattreatmentProcedureHydrostatictestingprocedurezwaterqualitydocumentPrepa16、 rationandpaintingprocedurePreservationzpackingandshippingprocedureSpares/operatingmanualsSupplylist(packinglist)5.0INSPECTIONPROCESS5.1MATERIAL5.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopiesofmillcertificatesshallbeavailableatmanufacturerspremises.Theseshouldbeexam17、inedforcompliancewithspecificationsandwhereappropriatetodrawings.Thereviewwillincludecheckson:MakersnameandIocationSGSRefNo.:09Rev.:0Page:5of9INSPECTI0NGIDELINESINDSTRIALVALVESDate:ll/03/04CertificateNoMaterialSpecificationHeatorcastNoMakersNoorPlateNoChemicalc18、ompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinishStructuralobservations,notabledefects.Thiscoversbodystemmaterial,shellmaterial,trimmaterials,glandmaterials,anti-frictionmaterials,ball,wedgeorflapmaterials,operatingcomponentszsupportmateria19、I,WeIlendzflangesandanyotherspecifiedcomponent.5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspecificationasappropriate.Transferidentificationtocutoffcomponentsz(CastNotransf20、er),asspecified.Visualanddimensionalcompliancewithspecification.5.1.3ADDITI0NALSPECIALREQUIREMENTSMayapplyonspecialcomponentsze.g.thickcomponents,dissimilarmaterial,alloysteelsornon-ferrousalloys.Checktoensurecontract/specificationrequirementshavebeenmet.WitnessNDEe×aminati21 、onsasnecessary.5.1.AREPORTINGReportingonthematerialchecksshouldinclude:Confirmationofsatisfactorydocumentreview.Recordoftheendorsementofcertificationreviewed/witnessed.Recordofallnon-conformities.Recordofanytestswitnessedandtheresult.5.2VALVEFABRlCATIONA代erclearanceof22 、abovepointstosatisfactionoftheinspectorzthenthefabricatorwillproceedwiththemanufactureofsub-assembliesandcomponentsoftheValvesJnspectorswillreviewthefollowingpointsonabasistobeoutlinedinthePurchasersdocumentation,qualityplan,testandinspectionplan,orotherdocum23、ent,asnotifiedtotheinspector.5.2.1MACHINEDcomponents,subjectedtoWELDlNGCarryoutvisualanddimensionalchecktoensurecompliancewithWPSandspecification.WherespecifiedzweldbevelsshallbeexaminedbyMTorPTaftergrinding/machining.Edgesandweldbevelswillbeclean,dryandfreefrom24、surfacedefectsjaminations,cracks,voids,notches,etc.Theseshallbeacauseforrejectionunlesssuitable/satisfactoryremedialactioncanbetaken.Weldingrepairstobevelsarenotpermitted,withoutapprovalfromtheClientJnspectorsmustreportexcessiveorseriousdefects.5.2.2WELDINGSGSRefNo.:25、09Rev.:0Page:6of9INSPECTI0NGIDELINESINDUSTRIALVALVESDate:ll/03/04ThisstageinspectionwillbecarriedoutwhencomponentszhavebeentackedusingweldingconsumablesandparametersfromanapprovedWPS.InspectorsshallcheckandreportOni-Cleanlinessandfitupaccuracyofpreps.Roundnessoffo26、rmofcomponents.Applicationofpreheat.Weldinginprogress.Cleaningofwelds.Completionoftestcoupons,(wherespecified)NDE.Resultsshallmeetspecificationsorcoderequirements.Hardnesstests-whenspecifiedinthecontractimpacttests-whenspecifiedinthecontracts.2.3P0STWELDINsPECTIONSCarry27、 outdimensionalcheckandPWHTasspecified.WhenPWHThasbeencompletedthenportablehardnessmeasurementmaybeusedtoestablishhardnessofmaterial,heataffectedzoneorwelds,asmaybespecified.5.2.4VISUALANDDIMENSIONALINSPECTIONInspectionshallinclude,butnotnecessarilybelimitedto:To28、 >verifythatthemodelandvariousfeaturesandcomponentscomplywiththepurchaseorderdescriptionandvalvespecificationanddrawingsasapplicable.ToverifythatthedimensionsofvaIves,fIanges,fIangedrillingzborezstemzthreading,wallthicknessandanyotherdimensions,asapplicablezcomplywith29、 therequirementsofthespecificationandOtherWitnessingrequiredpressuretests.Witnessingfunctionaltestofactuatoronvalvezwhenactuatorsarespecified.RadiographicexaminationandotherNDEinaccordancewiththeapplicablereferencesnotedabove.5.2.5TESTING5.2.5.1LOWPRESSREAIRTESTSSpe30、 cialisedtestingofseatsztheseals,by-passes,etc.,mayberequired.DetailswillbeasrequiredbythePurchasersTechnicalspecification.Aminimumof2gaugeswithcorrectworkingrangesshallbeused.ThecalibrationOfthegaugeswillbechecked.5.2.5.2HYDRAULICTESTINGCheckallpreviousitemshave31、 beenacceptedbyauthorisedbodies.Thefollowingitemswillbeverified.SGSRefNo.:09Rev.:0Page:7of9INSPECTI0NGUIDELINESINDSTRIALVALVESDate:ll/03/04Bodytests,highpressureclosuretests,backseattestsasdetailedinapplicableprocedureandcodeSpecification.Calibrationstatusandcorrectw32、orkingrangesofgauges.Aminimumof2pressuregaugeswillbeattachedtoitemundertest.Adequateprovisionforventingofhighpointsanddrainingofthetestmediumwillbeprovided.Testpressureshallbeappliedasdirectedbyprocedureorcodeuntiltestlimitingpressureisreached.DuringholdP33、eriodzamethodicalcheckforIeakswillbeconducted.Testpressures,metalandwatertemperatureswillberecorded.Waterqualitywillbeasspecified.5.2.5.3POSTHYDRAULICTESTINGAfterdepressurisation,valvecomponentswillbedrainedanddriedtomeetSpecifiedrequirements.StampingofInspectionauthoritystampszwillbecarriedoutinapprovedarea,asrequiredbyclient/code.StampsusedshallbeIo