-设备制造质量检验规程（Water Tube Boilers）-.docx

,设备制造质量检验规程(WaterTubeBoilers)Il1、SGSRefNo.:02Rev.:0Page:lof9INSPECTIONGUIDELINESWATERTUBEBOILERSDate:04/03/04INSPECTIONGUIDELINESWATERTUBEBOILERSOForApproval04032022J.C.BrottonB.TremainBTremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:02Rev.:0Page:2of9INSPECTI0NGUIDELINESWATERTUBEBOILERSD2、ate:04/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCUMENTS5lNspectionprocess6Shipping7boilerdataDosierscertificateofC0NF0RMITY9INSPECTI0NCHECKLISTSGSRefNo.:02Rev.:0Page:3of9INSPECTI0NGUIDELINESWATERTUBEBOILERSDate:04/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificati3、onactivitiesrequiredtovalidatethesuppl½manufacture,andtestofWaterTubeBoilers.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofaWaterTubeBoilerfromtheexaminationOfcertificationfromprocurementsourcestothefinalinspection,preservationandpackingforde4、spatchtosite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheConstructionofatypicalWaterTubeBoiIenExperiencedinspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone5、-oforalternativedesignofboilei;thedesignhavingbeenapprovedbytheclient.Anysuchvariationsshouldbenotedontheinspectorsreport.MostboilersareconstructedunderoneofthewellknownNationalcodeswhichrequireanInspectingAuthoritytosurveyproduction.Thisinstructionisbased6、intherequirementsofsuchacode.ltassumesthatthedesignparametershavebeenreviewedandapproved.3.OPROCEDURES.IGENERALThisinstructiontogetherwithitsassociatedchecksheetmaybeusedonanyorderorcontract.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspector7 、programme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionrequiredwillbespecifiedonthechecksheet.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecificationszpurchasersorcompanystandards,andwithin8 、thepracticesandrulesoftheCountryzStateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreonerousrequirementWillapplyunlessthepurchaserorclientdirectsotherwiseinwriti9 、ng.3.2REFERENCEDocuMENTSAppIicabIecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)EN12952:2022ASMEIAS1229-1990SGSRefNo.:02Rev.:0Page:4o10 、f9INSPECTIONGuidelineswatertubeBOlLERSDate:04/03/044.0DOCUMENTStobeRECEIVED/AVAILABLEATINSPECTIONPurchaseorderorContractBoiIerInspectionTestPlanITPBoiIerdataSheetApproveddrawings,(arrangements)Sub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresandProcedureQualificati11、onRecordsProductionweldtestrequirementsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsRepairproceduresNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHeattreatmentprocedurecalibrationrecordsf12、 ortestingmeasuringequipmentHydrostatictestingprocedure,waterqualitydocumentpreparationandpaintingprocedurePreservation,packingandshippingprocedureSpares/operatingmanualsSupplylist(packinglist)5.0INSPECTIONPROCESS5.!MATERIALS.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopies13、 ofmillcertificateswillbeavailableatmanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings.ThereviewwillIncIudeiMakersnameandlocation.CertificateNo.Gradezsizeandwallthickness.MaterialSpecificationHeatorcastNo.Chemicalco14、 mposition.Mechanicalproperties.Heattreatedcondition.NDEappliedandresults.Surfacefinish.Structuralobservations,notabledefects.5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspecifica15、 、tionasappropriate.Transferidentificationtocutoffcomponents,(CastNotransfer)zasspecified.Visualanddimensionalcompliancewithspecification.SGSRefNo.:02Rev.:0Page:5of9INSPECTI0NGuidelineswatertubeBOILERSDate:04/03/045.1.3ADDITIONALSPECIALREQUIREMENTSIVIayapplyonspecialcomponents16、,checktoensurethatcontractrequirementshavebeenmet.WitnessanyNDEexaminationasnecessary.5.1.AREPORTINGReportingonmaterialchecksmustinclude:ConfirmationofsatisfactorydocumentreviewRecordoftheendorsementofcertificatereviewed/witnessedRecordofallnon-conformitiesRecordof17、testswitnessedandtheresult5.2WATERTUBEBOILERFABRICATIONAfterclearanceofabovepointstosatisfactionoftheinspectorzthenthefabricatorwillproceedwiththemanufactureofsub-assembliesandcomponentsoftheWaterTubeBoilerJnspectorswillreviewthefollowingpointsonabasistobeo18、utlinedintheapplicableNationalStandardzPurchasersdocumentation,qualityPlan,testandinspectionplanzorotherdocumentzasnotifiedtotheinspector.5.2.1WELDEDDRUMSANDHEADERSReviewweldingproceduretestsortestrecordandensurethatwelderapprovaltestsandwelderscertificatesarevalid19、 .Inspectcutplatevisuallyanddimensionallypayingparticularattentiontomaterialidentificationmarksandidentifymaterialtobeusedforthetestplates.Dimensionallyinspectweldsetupandalignment.Visuallyexamineedgesofweldpreparationtoensurethattheyarefreefromdefectswhichmay20、 affecttheweldedseam.Verify/witnessNDEofweldpreparationifrequiredbycode.Visuallyinspectalldrum/headerlongitudinalandcircumferentialweldseamsandreviewradiographandultrasonictestreports.Dimensionalcheckonattachmentsandcompensationplates,nozzlesetc.Verifycompletionofw21、eldingtoasatisfactorystandardandreviewrecordsofpostweldheattreatment.Verifythatallweldtestplateshavebeencompletedandproperlyidentified.WitnessHydraulicTestJnternaIandexternalexamination.Finalinspectionafteranymachiningoperationssubsequenttopressuretesting.SGSRef22、 No.:02Rev.:0Page:6of9INSPECTIONGIDELINESWATERTUBEBOILERSDate:04/03/045.2.2SEAMLESSDRUMSANDHEADERSReviewweldingproceduretestortestrecordsandensurethatwelderapprovaltestsandwelderscertificatesarevalid.Confirmmaterialidentitiesandensureproperidentificationofcomponents23、 .Inspectbeforeendclosurewhetherbyforgingorweldingonofseparateendclosures.Dimensionalcheckonattachmentsandcompensationplates,nozzlesetc.Verifycompletionofweldingtoasatisfactorystandardandreviewrecordsofpostweldheattreatment.Verifythatallweldtestpieceshavebeen24、completedandproperlyidentified.WitnessHydraulicTestJnternaIandexternalexamination.Finalinspectionafteranymachiningoperationssubsequenttopressuretesting.5.2.3TUBESANDINTEGRALPIPINGReviewweldingproceduretestortestrecordandensurethatthewelderapprovaltestsandweldersc25、ertificatesarevalid.Checkmaterialidentities.Witnesssetupatleast10%minimumoftubesandintegralpipesbeforewelding.VerifycompletionofweldingtoasatisfactorystandardandthattheNDEexaminationreports/recordshavebeencompletedandaccepted5.2.4HYDRAULICPRESSURETESTONindivid26、ALCOMPONENTSifrequiredorFINALASSEMBLEDBOILERUNITCheckallpreviousitemshavebeenacceptedbyAuthorisedbodies.CoderequirementswhichspecifytestingwillbeWitnessedThefollowingitemswillbeVerifiedCaIibrationstatusandcorrectworkingrangesofgauges.Aminimumof2pressuregauges27、willbeattachedtoitemundertestAdequateprovisionforventingofhighpointsanddrainingwillbeprovidedTestpressureshallbeappliedasdirectedbyprocedureorcodeuntiltestlimitingpressureisReached.Duringholdperiod,amethodicalcheckforleakswillbeconducted.Testpressures,metala28、ndwatertemperatureswillberecorded.WaterqualitywillbeasSpecifiedSGSRefNo.:02Rev.:0Page:7of9INSPECTIONGIDELINESWATERTUBEBOILERSDate:04/03/04SpecialrequirementsofthepurchasersspecificationfordeflectionorstraingaugesorPressure/time/temperaturerecordingswillbeexaminedb29、ytheinspectorandrecordsverified5.2.5POSTHYDRAULICTESTINGAfterdepressurisation,boilercomponentswillbedrainedanddriedtomeetspecifiedrequirements.StampingofInspectionauthoritystamps,willbecarriedoutinapprovedareazasrequiredbyclient/code.Stampsusedshallbelowstressty30、pe.Applicationofdesiccant/preservativewillbeasdirectedinclientsspecification.5.3FINALASSEMBLYAllassembliesW川becheckedforcleanlinessanddryness.Rechecknozzles,supportandbracketlocationsandorientationsagainstassemblydrawings.Checkfordeformationoftubeszattachments,flange31、s,etc.andreportifnecessary.5.4MARKINGMatchmarks,identificationmarkswillbecheckedandlowstresstypestampmustbeusedonallpressureparts.5.5NAMEPLATEMateriaIshallbecheckedforcompatibility.Contentsofmarkingtobecheckedinaccordancewithapproveddrawingandspecificationsanda32、Uthoritystampedasrequired.Checkmountingofnameplateonabracketweldedtoaspecifiedareaofboiler,inaccordancewiththecoderequirement.5.6PAINTINGSurfacepreparationforpaintingwillbecheckedforthefollowingpoints,accordingtospecification.Cleaningmethod(Blastorscrapingandwir33、ebrushing)PreparationgradesFreedomfromweldspatter;blow-holesandotherdefectsHumidityandSteelTemperaturestobecheckedpriortopaintingPaintmanufacturezTypeandColourtocheckedtoclientsspecificationDryfilmthicknesstobecheckedaccordingtospecificationsurfaceconditiontobefreefrompin-holes,runsdamageandotherdiscontinuity.5.7SPAREPARTS,LOOSEITEMSJOOLSANDACCESS