设备制造质量检验规程（Heat Exchangers Shell.Tube）.docx

1、l,设备制造质量检验规程(HeatEXChangerSShelLTube)1、SGSRefNo.:04Rev.:0Page:lof121NSPECTloNGIDELINESHEATExchangersofshellandtubeTYPEDate950304NSPECTlC)NGuidelinesheatExchangersofshellandtubetypeofoApproval05032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:04Rev.:0

2、Page:2of12IN2、SpectionGuidelinesheatExchangersofshellandtubeTYPEDate:05/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCUMENTS5INSPECTI0NPROCESS6SHIPPING7VESSELDATADossiersinspectionchecklistsgsRefNo.：04Rev.：OPage：3Of12INSPECTI0NGIDELINESHEATEXCHANGERSOFSHELLANDTUBETYPEDate:05/03/041.0PURPOSEThisi3、nstruct

3、ioncoverstheinspection,testandverificationactivitiesrequiredtovalidatethesupply,manufactureandtestofaShellandTubeHeatExchanger.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionoftheShellandTubeHeatExchangerfromtheexaminationofcertification4、fromprocurementsourcestothefinalinspection,pre

4、servationandpackingtodespatchtosite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalShellandTubeHeatExchangerExperiencedJnspectorsmayinterprettheintentofthei5、nstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone-off,or

5、alternativedesignofHeatExchangerThedesignhavingbeenapprovedbytheclient.Anysuchvariationsshouldbenotedontheinspectorsreport.3.0PROCEDURES.1GENERALThisinstructiontogetherwiththea6、ssociatedchecksheetmaybeusedonanycontractororder.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramm

6、e.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionrequiredwillbeasspecifiedonthechecklist.AIItest7、sandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecifications,purchasersorcompanystandardszandwithinthepracticesandrulesofthecountry,stateorprovince

7、andanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionssh8、ouldbeapparentinanyoftheabovethenthemoreonerousrequirementwillapplyunlessthepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications.Designcode(tobestatedoninspection

8、report)PurchaseorderspecificationPurchasersstandardsApp9 、roveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)EN16812:2022ASMEVlllDivision1TEMAClassR,BorCAPI660,605AS1210JISB8249SGSRefNo.:04Rev.:0Page:4of12INSPECTIONGuidelinesheatExchangersofshellandtubeTYPEDate:05/03/044.0DOCUMEN

9、TSTOBEREC日VED/AVAIL10 、ABLEATINSPECTIONPurchaseOrderorContractinspectionandTestPlanITPDataSheetSub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresandProcedureQualificationRecordsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsCalibrationofmeasuringandtestequipmentNDEproc11、edure

10、s,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHeattreatmentdocumentpreparationandpaintingprocedurepreservation,packingandshippingproceduresupplylist(packinglist)5.0p rocedu re H yd rostatictestingprocedurewaterquality12、INSPECTIONPROCESS5.1M

11、ATERIALS.1.1REVIEWOFCERTlFICATIONOnginaIorauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.TheseshouldbeexaminedforcompliancewithspecificationsandWhereappropriate,drawings:Thereviewwillincludecheckson:-Manufacturersname13 、andlocationCertificateNoMaterialSpecificationHeat

12、orcastNoMakersNoorPlateNoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinishStructuralobservations,notabledefects5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationo14、ncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistands

13、pecificationasappropriate.Transferidentificationtocutoffcomponentsz(CastNotransfer)zasspecified.Visualanddimensionalcompliancewithspecification.5.1.3ADDITIONAL/SPECIALREQUIREMENTSMayapplyo15 、nspecialcomponentsze.g.thickcomponents,cladordissimilarmaterialzalloysteelsornonferrousmaterials.Checktoensu

14、respecificationContractSGSRefNo.:04Rev.:0Page:5of12INSPECTI0NGUIDELINESHEATExchangersofshellANDTUBETYPEDate:05/03/04requirementshavebeenmet.WitnessNDEexaminations16 、asnecessary.5.1.4REPORTINGReportingonthematerialchecksshouldincludeConformationofsatisfactorydocumentreviewRecordofendorsementofcertif

15、icationreviewed/witnessedRecordofallnon-conformitiesRecordofanytestswitnessedandtheresult5.2FABRICATIONOFHEATEXCHANGERS(SHELLANDT17、UBETYPE)Afterclearanceofabovepointstosatisfactionoftheinspector;thenthefabricatorwillproceedwiththemanufacturerofsub-assembliesandcomponentsoftheheatechanger.lnspectors

16、willreviewthefollowingpointsonabasistobeoutlinedintheapplicableNationalStandard,purchasers18、documentationzinspectionandtestplanorotherdocuments,asnotifiedtotheinspector.5.2.1PREPARATIONFORWELDINGCarryoutvisualanddimensionalchecktoensurecompliancewithWPSandSpecification.WherespecifiedzWeIdbevelsshal

17、lbeexaminedbyMTorPTaftergrinding/machining.Edgesandweld19、bevelswillbeclean,dryandfreefromsurfacedefects,laminations,cracks,voids,notches,etc.Theseshallbeacauseforrejectionunlesssuitable/satisfactoryremedialactioncanbetaken.Weldingrepairstobevelsarenotpermitted,withoutapprovalfromtheClientJnspectors

18、mustreportexcessiveors20eriousdefects.5.2.2WELDINSPECTION5.2.2.1EDGEPREPARATIONVisualanddimensionalcheckswillbeperformedinaccordancewiththeWPSandspecification.MTorPTwillbemadeoncutedgeasrequiredandedgesshallbefreefromIaminationzCrack,notch,etc.5.2.2.2FIT-UPINSPECTIONShapes,alignmentand21、 dimensions

19、willbecheckedinaccordancewithapprovedWPSanddrawings.5.2.2.3VISUALCHECKANDNDEGrooveandadjacentareawillbecleanandfreefromforeignmaterialszoil,paint,waterandrustzandwillalsobefreefrominjuriousdefectssuchascracks,andIaminationsJackweldswillbeperforme22、 dusingthesameprocedureofapplicableWPSandwillbefree

20、fromdefects.NDEwillbeperformedasrequiredforedgeandtackweld.5.2.2.4MONITORINGOFWELDPreheattemperatureandmethod,interpasstemperaturezweldmaterialcontrolzqualifiedWPSandqualifiedwelderemployed,weldingOperationzCleanIi23、nesswillconformtoapprovedWPSandspecifications.5.2.2.5BACKGOUGINGINSPECTIONSGSRefNo.

21、04Rev.:0Page:6of12INSPECTIONGIDELINESHEATExchangersofshellandtubeTYPEDate650304ShaPeanddimensionswillbecheckedinaccordancewithWPSandfreefromdefectandclean.NDEwillbeperformedif24、 required(MTorPT).5.2.2.6INSPECTIONOFCOMPLETEDWELDVisuaIinspectionwillbeperformedonthesurfaceofwelds.Checkareastobefreefr

22、omundercuts,overlaps,blow-holes,cracks,abruptridgesorvalleysandtobemergedsmoothlywiththeSurfacesjointed.5.2.2.7NONDESTRUCTIVEExAMINATIONNDEwiII25、 beperformedbyqualifiedpersonnelandtoqualifiedproceduresforweldjoint,tubetotube-sheetweldszandsurfacesafterremovaloftemporaryattachmentwelds.Rootandfinalw

23、eldsinallmaterialswillbeexaminedasrequiredbytheclient.Chemicalanalysisjerritecheckwillbemadeasrequiredb26、ythecontract.5.2.2.8WELDREPAIRAIIunacceptabledefectsshallberepairedbyapprovedproceduresbeforePWHT.5.2.3POSTWELDHEATTREATMENTPWHTrecordwillbereviewedinaccordancewithapplicablecodeandapprovedproce

24、dureforidentificationnumberzdatezheatingandcoolingrate,soakingtemperatur27andtime.5.2.4HARDNESSTESTHardnessofweldmetalandheataffectedzoneofpressureretainingweldsshallbeexaminedasrequired.5.2.5MOCK-UPTESTOFTUBETOTUBE-SHEETWELDMock-uptestwillbemadewhenrequired.Identification,visualappearanceanddimensi

25、ons,weldcontrol,Psectionofweld,Macro28、-observation,hardnesscheckofweldmetalandheataffectedzonewillbecheckedasrequired.5.2.6VISALANDDIMENSIONALINSPECTIONOFTUBES,TUBEBUNDLEANDSHELLVisualanddimensionalcheckwillbemadetothefollowingitemsateachstageoffabrication.Tubesafterbendingforthinningparticularly29

26、onthebackofbends.Tubesheetandbaffleplatejncludingtubehole,heads,flanges,tubes,flangefacingfinish.Channel,SheIIJIoatinghead,cover,tubebundleassembly.Templatecheckofshellwillbeperformedinaccordancewiththeapplicablespecificationsasrequired.Sizeandconstructionoftemplate30、aretobecheckedzandthetemplatem

27、ustpasssmoothlyzwithoutbindingthroughthefulllengthoftheSheILDirectionandorientationofnozzle,impingementbaffles,lugsandexternal,internalfittingswillbechecked.SGSRefNo.:04Rev.:0Page:7of12INSPECTIONGIDELINESHEATExchangersofshellandtubet31、YPEDate:05/03/04Outofroundness,diameterjength,wallthicknesszstra

28、ightnessofshellwillbechecked.Expansionratiooftubeendstobechecked.tubestobecheckedforthinningafterexpansion.U-tubewillbeformedfromasinglelengthhavingnocircumferentialwelds,andflatteningshallnotexceed132、0%ofthenominalODoftube.Tubesheetflatnessongasketcontactsurfacewillbecheckedasrequired.5.2.7TUBEBUN

29、DLEINSERTIONTubebundleinsertionwillbecheckedasrequired.Cleanlinesszinsertionwithoutbindingzcontactoftubesheetandshellflangeandgasketusedshallbeconfirmed.5.2.8TEST33ING5.2.8.1PNEUMATICTESTNozzIereinforcingpadsztubetotubesheetjointsandshellflangetotubesheetwillbeexaminedwhenspecifiedbyanapprovedlowpressurepneumatictestprocedureusingsoapywaterastheindicatingmedium.Aminimumof2gaugeswithcorrectworkingrangeswillbeused,thecalibrationofthegaugeswillbechecked.5.2.8.2HYDRAULICTESTINGCheckallpreviousitemshavebeen