设备制造质量检验规程 Storage Tanks Site Erection.docx

1、设备制造质量检验规程StorageTanksSiteErection1、SGSRefNo.:10ARev.:0Page:lof7INSPECTIONGIDELINESSTORAGETankssiteEREeTloNDate:11/03/041NSPEcnoNGuidelinesstorageTankssiteerectionofoApprovalll032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:10ARev.:0Page:2of7INSPEC

2、TI0NGUIDELINESS2、TORAGETankssiteERECTIONDate:ll/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCumentssinspectionprocess6StoragetankdataD0SSIER7INSPECTI0NCHECKLISTSGSRefNo.:10ARev.:0Page:3of7INSPECTI0NGUIDELINESSTORAGETANKSSITEERECTIONDate:ll/03/041.0PURPOSEThisinstructioncoverstheinspection,testandv3、erif

3、icationactivitiesrequiredtovalidatethesupply,manufactureandtestofstoragetanksforgeneraluseinrefineriesandchemicalplants.Thisinstructionisprimarilyforsiteerection2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofthestoragetankfromtheexaminati4onofcertificationfromprocurementsourcestothe

4、finalinspectionatsite.Althoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalstoragetank.Experienced,inspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalo5、rnovelpracticesortoutilisetheinstructionforaone-offdesignofstoragetank,thedesign

5、havingbeenapprovedbytheclient.AnysuchVariationsshouldbenotedontheinspectorsreport.3.0PROCEDURES.1GENERALThisinstructiontogetherwithitsassociatedchecksheetmaybeusedonanyorderor6、contract.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthes

6、ectionstobeusedandthelevelofinspectionrequiredwillbespecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheap7、proveddrawings,purchaseOrderspecificationszPurchasersorcompanystandardszandwithinthepracticesandrulesofthecountry,stateorprovinceandanygovernmentdecreeszlawszordinanceorreg

7、ulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreo8、nerousrequirementwillapplyunlessthepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasers

8、standardsApproveddrawingsSGScompanyStandardsAppIicabIecodes9、andstandards(sampleonly)BS2654BS2594BS7777API620API650API653EEMUA159SGSRefNo.:10ARev.:0Page:4of7INSPECTIONGUIDELINESSTORAGETankssiteERECTloNDate：ii/03/044.0documentstobeREC日VED/AVAILABLEATINSPECTION4.1SITECONSTRUCTIONPurchaseOrderorContrac

9、tInspectionandtestpla10nITPDataSheetConstructionSiteSafetyPlanApprovedDrawingsarrangementsSub-assemblydrawingsMaterialtestcertificatesShopReleaseNotesWeldproceduresandProcedureQualificationsRecordsListofQualifiedweldersorweldingoperatorsWelderqualificationsCalibrationofmeasuringandtes11、tequipmentND

10、EProceduresappropriatetomaterialofconstructionListofqualifiedNDEoperators/inspectorsHeatTreatmentprocedureHydrostaticTestingProcedureBase&TankPneumaticTestingProceduresPaintingProcedure5.0INSPECTIONPR0CESS5.1MATERIAL5.1.1REVIEWOFCERTlFICATIONOriginaIoraut12、henticatedcopiesofcertificatesshouldbeavai

11、lableatthemanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings:Thereviewwillincludecheckson:-ManufacturersnameCertificateNoMaterialSpecificationHeatorcastNoMakersNoorPlate13、NoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandre

12、sultsSurfacefinishStructuralobservations,notabledefects5.1.2VISUALANDDIMENSIONALVERIFICATIONMaterialidentificationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materialIi14standspecificationasappropriate.Transferidentificationtocutoffcomponentsz(CastNotransfer),asspecified.Visu

13、alanddimensionalcompliancewithspecification.ShopreleasenotescoveringcomponentssuppliedfromfabricatorsWorksSGSRefNo.:10ARev.:0Page:5of7INSPECTI0NGuidelinesstorageta15、NKSSITEERECTIONDate:ll/03/045.1.3ADDITIONAL/SPECIALREQUIREMENTSMayapplyonspecialcomponents,e.g.thickComponentszChecktoensurespecificat

14、ioncontractrequirementshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialchecksshouldincludeConformationof16satisfactorydocumentreviewRecordofendorsementofcertificationReviewedRecordofanynon-conformitiesRecordofanytestswitnessedandtheresultComponentssuppliedfromfabric

15、atorsworks5.2ERECTIONOFSTORAGETANKSAfterclearanceofabovepointstosatisfactionoftheinspector,thenthe17、fabricatorwillproceedwiththeerectionofstoragetankThesiteinspectorwillberesponsibleforallsiteoperationsuptoandincludingfinaltestingandcertificationofstoragetanksandwillpayattentiontofollowingpointsCli

16、maticconditionsandmetaltemperaturesduringweldingandcareful18、storageandhandlingOfmateriaIsJobsiterecordsofweldersqualifications,approvedweldproceduresandsitestorageandhandlingofweldingconsumablesshouldbecarefullymonitored.5.2.IMATERIALSTheinspectorwillcross-checkallincomingplatezfabricationsandmater

17、ialagainstcertification.Hew19illensureallmaterialisclearlyidentifiedandduringconstructionwillmonitortransferOfmarkingszWhichwillbemadetoensureallmaterialofthecompletedtankisidentifiablebysuchmarkings.lnthecaseofthinplateszmarkingwillbebypaintingoretching.AIImaterialwillbeinspectedprior20toincorporat

18、ioninthetanktoensurecorrectdimensionsandfreedomfromunacceptableflaws,especiallyinedgepreparations5.2.2WELDPROCEDURESANDWELDERSQuALIFICATIONSTheinspectorwillensurethatonlyapprovedproceduresareusedandthatallweldersandoperatorsaresuitablyqualified.AII21、weldswillbeclearlyidentifiedwithweldersstamporpai

19、ntmarking,asdirectedbythespecification.5.2.3WELDINGANDTESTINGAIIweldswillbemadetoapprovedWPSandwillbeinspectedforconformitytofinishprofile.ExtentofNDEandallNDErequirementswillbemonitored.Radiographswillberevi22、ewedandsignedoffwhensatisfactory.AIIdefectsrequiringrepairzwillbeloggedandreportedandthei

20、nspectorwillensurethatonlyapprovedweldproceduresareutilised.5.2.4TANKERECTIONTheinspectorwillensurethatanyrequiredoffsetsorstaggeringofweldsisCorrectlyincorporatedtocodeor23、projectrequirements.AllfittingsandfabricationwillbecheckedforSGSRefNo.:10ARev.:0Page:6of7INSPECTI0NGUIDELINESSTORAGETANKSSITEE

21、RECTIONDate:ll/03/04conformitytotankcurvaturezpriortoattachment.Majordimensionalcheckswillbewitnessedtoensurecompliancewithinspecifiedtolerances24、ofdiameters,heights,circularityetc.5.2.5TESTINGAIIpre-testprocedureswillbemonitored,includingcrackdetectionwhererequired.Hydrostaticandpneumatictestswill

22、beobservedandreportedjncludingvacuumboxtesting.5.SMARKINGNamepIatesifattachedshouldbeinaccordancewiththeapproveddr25、awings5.4PAINTINGINSPECTION5.4.1SURFACEPREPARATIONSurfacepreparationforpaintingwillbecheckedforthefollowingpoints,accordingtospecification.CleaningmethodBlastorscrapingandwirebrushing

23、PreparationgradesFreedomformweldsplatter,blowholesandotherdefectsHumidityandsteelt26、 emperaturestobecheckedpriortopaintingPaintmanufacture,typeandcolourtobecheckedagainstclientsrequirementsDryFilmthicknesstobecheckedaccordingtospecificationsurfaceconditiontobefreefrompin-holes,runs,damagesandotherd

24、iscontinuity5.5REPORTANDFINALCERTIFICATION5.5.1REPO27、 RTINGAfinalreportsummarisingtheactivitiescarriedoutwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthelaiddowntimeIimitsJhereportwillbeintheformrequiredbytheclientandwillclearlyindicatethefinalacceptanceorrejectionofthegood

25、s.5.5.2FIN28、 、ALCERTlFlCATIONCertificationofcompletedtanksforcompliancetocodeandspecificationrequirementswillbepreparedandcountersignedbythesiteinspectorzpriortodistribution,inaccordancewithprojectrequirements.6.0STORAGETANKDATAD0SSIER6.1SITEERECTIONDOCUMENTSThefollowingdocuments29、shallberevieweda

26、ndsignedofftothecontractrequirementsAsBuiltDrawingsFabricatorsDataReportsMateriaICertificatesorcertifiedmilltestreportsMaterialListormapWelderrecordforeachSeamHeatTreatmentrecordsTemperature-timerecordchartduringPWHTDimensionaIrecordsNDErecordsHard30、nesstestrecordsHydrostaticrecordstank-pneumatic&v

27、acuumboxtestingFinalcertificationSGSRefNo.:10ARev.:0Page:7of7INSPECTI0NGuidelinesstoragetankssiteERECTIONDate:ll/03/047.0INSPECTIONCHECKLISTINSPECTIONCHECKLIST(1)VISALinspection/witnessingbybuyerREPRESENTATIVE(2)CERTIFICATESRE31、CORDSTOBECHECKEDBYBUYERREPRESENTATIVE(3)CERTIFICATESDATATOBEPROVIDEDBYV

28、ENDOR/SUPPLIER/MANUFACTURERPre-Fabrication/ProductionRequirementsSpecificationDetails/NotesPurchaseOrderRequirementslnspectionSTestPIan(ITP)ApprovedDrawings(Arrangements)Sub-AssembIyDrawingsWeIdProceduresSpec32ification(WPS)&ProcedureQualificationRecords(PQR)WeIderQualificationRecordsNDTPersonnelRec

29、ordsandProceduresHeatTreatmentProceduresln-ProcessInspection&TestingRequirementsMateriaITestCertificates&ldentificationWeldandEdgePreparationFitUplnspection(ShellCoursePlatesorBaseplates33、Manwaysetc)HeatTreatmentofHotFormedComponentsMonitoringWeldConditionsWeIdBackGougingInspectionPostWeldInspectionNDEExaminationWeIdRepairsPostWeldHeatTreatmentVisual&DimensionalExaminationHydrostaticPneumaticTestingVisuaIandDimensionaIVacuumBoxTesting(BasePlateWeldJoints)FinalInspection&TestingRequirementsVisual&DimensionalCheckMarkingPaintingZCoatingInspectionReview