-设备制造质量检验规程 Water Turbines-.docx

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1、设备制造质量检验规程WaterTurbines1、SGSRefNo.:20Rev.:0Page:lof8INSPECTIONGIDELINESWAERTURBINEDate:19/03/041NSPECTloNGIDELINESWATERTURBINEOForApprovall9032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:20Rev.:0Page:2of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/0

2、4CON2、TENTS1PURPOSE2SCOPE3PROCEDURE4DOCUMENTS5INSPECTIONPROCESS6SHIPPING7WATERTURBINEDATAD0SSIER8INSPECTI0NCHECK1.ISTSGSRefNo.:20Rev.:0Page:3of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatet3、hesupply,manufac

3、tureandtestofaWaterTurbineforgeneraluse.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofaWaterTurbinefromtheexaminationofcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.Althoughthe4methodologyincompilingthisinstructionistosystematicallyp

4、rogressthroughIheconstructionofatypicalWaterTurbine.ExperiencedJnspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone-off,oralternativedesignofTur5、bine.Thedesignhavingbeenapprovedbytheclient.AnySuchvariationsshouldbenotedontheinspectorsrepo

5、rt.3.0PROCEDURES.1GENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonanycontractororder.ltisintendedtoactasaguidetotheinspectorinthecourseofthe6、inspectionprogramme.AnypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofInspectionrequiredwillbeasspecifiedonthechecklist.A

6、IItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecifications,purchasersorcompanystandards7、,andwithinthepracticesandrulesofthecountrstateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovet

7、henthemoreOnerousrequirementwillapplyunlessthepurchaserorclientdirectsOtherwis8、einwriting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleo

8、nly)JISB81034.0DOCUMENTSTOBEREC日VED/AVAILABLEA9、TINSPECTIONPurchaseOrderorContractinspectionandTestPIanDatasheetSub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresandProcedureQualificationRecordsListofqualifiedweldersorweldingOperatorsSGSRefNo.:20Rev.:0Page:4of8INSPECTI0NGUIDELINESWATERTURBI

9、NEDate:19/03/04Welder10squalificationsCalibrationofmeasuringandtestequipmentNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHydrostatictestingprocedureperformancetestprocedurepreparationandpaintingprocedurePreservationzpackingand11

10、shippingproceduresupplylist(packinglist)5.0INSPECTIONPR0CESS5.1MATERIALS.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings:Ther12、eviewwillincludechecksOni-Ma

11、nufacturersnameandlocationCertificateNoMaterialSpecificationHeatorcastNoMakersNoorPlateNoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinish5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentifi13、cationoncertificatesagainstproductmarkings.Materialsuppliedagai

12、nstdrawing,materiallistandspecificationasappropriate.Visualanddimensionalcompliancewithspecification.5.1.3ADDITIONAL/SPECIALREQUIREMENTSMayapplyonspecialcomponents.Checktoensurespecificationcontractrequiremen14、tshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialcheck

13、sshouldinclude:ConformationofsatisfactorydocumentreviewRecordofendorsementofcertificationreviewed/witnessedRecordofallnon-conformitiesRecordofanytestswitnessedandtheresultSGS15、RefNo.:20Rev.:0Page:5of8INSPECTI0NGIDELINESWATERTURBINEDate:19/03/045.2WATERTURBINEMANUFACTUREAfterclearanceoftheabovepoint

14、stothesatisfactionoftheinspector,thefabricatorwillproceedwiththemanufactureofthesubassembliesandcomponentsfortheWaterTurbine.5.2.!FABRICATION16INSPECTIONFollowingthecompletionofweldingandmachiningoperationstheTurbinepartswillbeinspectedasrequiredbythespecificationorcontract.Theinspectionwillconsisto

15、f:VisualinspectionfordamageDimensionalchecktodrawingrequirementInspectionofparts,forcleanlinessVisualexami17、nationofweldedonconnectionsReviewofwelderqualificationsReviewofweldprocedurerecordConfirmationofsatisfactoryNDEProperdocumentationofthematerialsusedExamination/inspectionofintegralpartssuchas

16、reductiongears5.2.2HYDROSTATICTESTSTheturbinecasingandotherpressurecont18、ainingpartswillbehydrostaticallytested.Theinspectormustverifythatthecorrecttestpressurehasbeenappliedtotherelevantpartsdependingonspecificationrequirements.5.2.3CLEARANCECHECKSAftercompletionoffabricationtherequiredclearancesw

17、illbecheckedinaccordancewiththespecif19、icationrequirementinparticulartheareastobeexaminedare:RadialclearancebetweenrotorandcasingAxialclearancebetweentherotorbladesandstationaryparts5.2.4MECHANICALRUNNINGTESTManyturbinesaresubjectedtoamechanicalrunningtest.WhererequiredbythecontractOrpurchaseordert

18、20、hefollowingitemswillbeCheckediCriticaIspeedBearingtemperaturesVibrationNoisetest5.2.5FINALVISUALEXAMINATIONAftercompletionofalltestingavisualexaminationincludingapartialstripdownoftheunitisusuallyrequiredbytheSpecificationTheparticularareasofinterestare:Surface21 、roughnessVaneprofilesInternalcle

19、anlinessLocation/orientationofterminalflangesSGSRefNo.:20Rev.:0Page:6of8INSPECTI0NGUIDELINESWATERTURBINEDate:19/03/045.3NAMEPLATEContentstobecheckedinaccordancewiththeapproveddrawingsandspecificationsandstamped/markedinaccordancetoclien22 、tsrequirements.5.4PAINTINGCOATINGINSPECTIONSurfacepreparatio

20、nforpaintingwillbecheckedforthefollowingattributesaccordingtothespecification:CleaningmethodblastingzscrapingandwirebrushingPreparationgradeFreedomfromweldspatter,blowholesandotherdefects.Humidityandsteelte23、mperaturestobecheckedpriortopaintingPaintmanufacture,typeandcolourtobecheckedagainstclients

21、specificationDryfilmpaintthicknesstobecheckedaccordingtospecification.Surfaceconditiontobefreefrompin-holes,runs,damageorotherdiscontinuity.5.5SPAREPARTS,LOOSEItemsandacc24ESSORIESSpareparts,looseitemsandaccessorieswillbecheckedvisuallyandfordimensionsmaterials,workmanshipandquantityaccordingtopurch

22、aseorderspecificationtestmarksandtagswillbecheckedforcorrectidentification.5.6REPORTANDRELEASE5.6.1REPORTINGAfinalreportsummarisingtheact25Nivitiescarriedoutwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthetimelimitslaiddowninthecontract.Thereportwillbeinaformatapprovedbythec

23、lientandmustclearlyindicatethefinalacceptanceorrejectionofthewaterturbine.5.6.2RELEASENOTEWherer26、equiredbythecontractareleasedocumentwillbeissuedtothemanufacturerwhenthewaterturbinehasbeenfinallyaccepted.6.0SHIPPING6.1PREPARATIONANDPACKINGThefollowingpointsmustbechecked:AIIexteriormachinedsurfaces

24、mustbecoatedwithrustpreventativeAllinternalsurfaceswhichare27susceptibletocorrosionmustbecoatedwithrustpreventativeAllflangedopeningsshouldbefittedwithmetalprotectorsinaccordancewiththespecificationAllthreadedconnectionsmustbeprovidedwithsteelplugsCheckmanualsandinstructionsareincludedasthespecifica

25、tionrequirementsPack28ingstyleandsuitabilityforoverseasshipmentShippingmarksarecorrectPre-assembledsystemsaremarkedasrequiredbytheSpecificationSGSRefNo.:20Rev.:0Page:7of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/047.0WATERTURBINESDATADOSSIERThefollowingfinaldocumentswillbereviewedande29、ndorsedasne

26、cessary.ManufacturersdatareportsMaterialCertificationDimensionaIrecordNDEreportsHydrostatictestreportsRotorbalancereportclearancecheckreportRun-testreportsPerformancetestFinalinspectionreportMarkingsPackinglistSparePartsSGSRefNo.:20Rev.:0Page:8ofSinspectionguideli30、NeswaterTURBINEDate:19/03/048.01N

27、SPECTloNCHECKLISTINSPECTIONCHECKList(I)VISUALinspection/witnessingbybuyerREPRESENTATIVE(2)CERTIFICATESRECORDSTOBECHECKEDBYBUYERREPRESENTATIVE(3)CERTIFICATESDATATOBEPROVIDEDBYVENDORSPPLIERMANUFACTRERPre-FabricationProductionRequirementsSpec31、ificationDetails/NotesPurchaseOrderRequirementsInspection&

28、TestPIan(ITP)WeIdProceduresSpecification(WPS)SProcedureQualificationRecords(PClR)WeIderQualificationRecordsNDTPersonnelandProceduresPumpPerformanceProceduresln-ProcessInspection&TestingRequirementsMateriaITestCertificates&ld32、entificationTurbineCasingInspectionSHydrauIicTestsRotorInspectionSBaIanci

29、ngMechanicaIRunningTestFinaIVisualExaminationNDERecords(ifapplicable)NameplateIdentityReviewCalibrationCertificatesPaintingCoatingInspectionSparesWeIdFitUpsandConditions(ifapplicable)FinalInspection&TestingRequirementsVisual&DimensionalCheckMarkingShippingReviewofDataDocumentationPackageAdditionalZSuppIementaryRequirementsPreparationSPacking