设备制造质量检验规程Columns.docx

1、设备制造质量检验规程Columns1、SGSRefNo.:35Rev.:0Page:lofIOINSPECTIONGIDELINESLMNSDate310404INSPECTIONGIDELINESCOLMNSOForApproval31032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:35Rev.:0Page:2ofIOINSPECTIONGIDELINESCOLMNSDate310404NTENTSlPRPOSE2SC2、OPE3PROCED

2、RE4DOCMENTS5INSPECTIONPROCESS6SHIPPING7COLUMNSDATAD0SSIER8INSPECTI0NCHECKLISTSGSRefNo.:35Rev.:0Page:3ofIOINSPECTIONGIDELINESCOLUMNSDate3104041.0PRPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatethesupply,manufactureandtest3、ofcolumns.2.OSCOPEThisinstructioncover

3、sallnecessarystagesintheproductionofcolumnsfromtheeaminationofcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalColumns.ExperiencedJnspectorsmayinter

4、prettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone-off,Oralternativedesignofcolumns,thedesignhavingbeenapprovedbytheclient.AnySuchvariations5、shouldbenotedontheinspectorsreport.3.0PROCEDURE3.IGENERALThisinstructiontogetherwithitsassociatedchecksheetmaybeu

5、sedonanyorderorcontract.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthese6、ctionstobeusedandthelevelofinspectionrequiredwillbespecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecif

6、ications,purchasersorcompanystandardszandwithinthepracticesandrulesOfthecountryzStateorprovinceandan7ygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreOnerousrequirementwillapplyunlessthepurchaserorclientdirectsotherwiseinw

7、riting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications.Des8、igncode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)ENPED5500.ETCASMEVlllDivision1or2ASMEV,ASMEIXAS1210BSEN287z2884.0DOCUMENTSTOBE

8、REC日VED/AVAILABLEATINSPEC9、TlONInspectionTestPlanITPDataSheetApproveddrawings,arrangementsSub-assemblydrawingsSGSRefNo.:35Rev.:0Page:4ofIOINSPECTIONGIDELINESCOLMNSDate310404MaterialtestcertificatesWeldproceduresandProcedureQualificationRecordListofqualifiedweldersorweldingOperatorsWeIdersqualifi10、C

9、ationsNDEproceduresz(appropriatetomaterialofConstructionJListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHeattreatmentprocedurecalibrationcertificatesfortestequipmentHydrostatictestingprocedure,waterqualitydocumentpreparationandpaintingprocedurepreservation,11、packingandshippingpro

10、cedureSpares/operatingmanualsSupplylist(packinglist)5.0INSPECTIONPROCESS5.1MATERIAL5.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopiesofmillcertificatesshallbeavailableatmanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsan12dwhereappropriate,drawings.Thereviewwillincludec

11、hecksonMakersnameandlocation.CertificateNoMaterialSpecification.HeatorcastNo.MakersNoorPlateNo.Chemicalcomposition.Mechanicalproperties.Heat-treatedcondition.NDEappliedandresults.Surfacefinish.Structuralobservations,notabl13、edefects.5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncerti

12、ficatesagainstproductmarkings.Materialsuppliedagainstvesseldrawingdatasheetzmateriallistandspecificationasappropriate.Transferidentificationtocutoffcomponentsz(CastNotransfer),asspecified.Visualan14ddimensionalcompliancewithspecification.5.1.3ADDITIONALSPECIALREQUIREMENTSMayapplyonspecialcomponentsz

13、e.g.thickcomponentszdishedheads,cladordissimilarmaterialszalloysteelsornon-ferrousalloys.Thesecomponentsmayrequireformalacceptanceoftestsbeforefurtherpreparationcanconti15Nnue.Checktoensurethatspecification/contractrequirementshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonma

14、terialchecksshouldincludeSGSRefNo.:35Rev.:0Page:5ofIOINSPECTIONGUIDELINESCLUMNSDate310404ConfirmationofsatisfactorydocumentreviewRecordof16、theendorsementofcertificationreviewed/witnessedRecordofallnon-conformitiesRecordofanytestswitnessedandtheresult5.2COLUMNFABRICZVriONAfterclearanceofabovepointst

15、osatisfactionoftheinspector,thenthefabricatorwillproceedwiththemanufactureofsub-assembliesandcomponentso17、faColumnJnspectorswillreviewthefollowingpointsonabasistobeoutlinedinthePurchasersdocumentationJnspectionandtestplan,orotherdocumentzasnotifiedtotheinspector.5.2.!PREPARATIONFORWELDINGCarryoutvi

16、sualanddimensionalchecktoensurecompliancewithWPSandspecification.W18、herespecified,weldbevelswillbeexaminedbyrequiredcodemethodaftergrinding/machining.Edgesandweldbevelswillbecleanzdryandfreefromsurfacedefects,laminations,cracks,voids,notches,etc.Thesewillbeacauseforrejectionunlesssuitable/satisfact

17、oryremedialactioncanbetaken.Weldrep19、airsmustbecarriedoutinaccordancewiththecoderequirementsandapprovedbytheclientbeforeweldingproceeds.Seriousorexcessivedefectsmustbereported.5.2.2WELDINSPECTION5.2.2.1EDGEPREPARATIONVisualanddimensionalcheckwillbeperformedinaccordancewithWPSandspecificationsMTor20

18、PTshallbecarriedoutinthecutedgesasrequired.Edgesmustbefreefromlaminations,cracks,notchesetc.5.2.2.2FIT-UPINSPECTIONShapeszalignmentanddimensionswillbecheckedinaccordancewiththeapprovedWPSanddrawing.5.2.2.3VISUALCHECKANDNON-DESTRUCTIVEEXAMINATIONThepreparedgroove21、andadjacentareawillbecleanandfreef

19、romforeignmaterials,oil,paint,waterandrust.Thepreparededgewillbere-examinedtoensurenodefectshavebeenexposedduringfinalpreparation.TackweldswillbeproducedusingtheapplicableWPSconditionsandwillbevisualfreefromdefects.Nondestru22、ctiveexaminationwillbeperformedinaccordancewiththecoderequirement.5.2.2.4

20、MONITORINGOFWELDCONDITIONSPreheatheattemperatureandmethod.Interpasstemperaturesweldmaterialcontrol,welderandprocessqualificationswillbecheckedforconformitytocoderequirements.5.2.2.5BACKGOUGING23、INSPECTIONTheshapeanddimensionsofthebackgougedgroovewillbecheckedforconformitytotheWPSrequirements.Thevis

21、ualappearancemustbecleanandfreefromdefects.NDEexaminationwillbeinaccordancewiththecode/clientrequirementsSGSRefNo.:35Rev.:0Page:6ofioinspectionGuidelinescol24、UMNSDate3104045.2.2.6POSTWELDINSPECTIONAftercompletionofallweldingandgrindingoperationsavisualexaminationwillconfirmtherearenoharmfuldefectss

22、uchascracks,lackoffusion,surfaceporosityorexposedSlaginclusionsJncompIetePenetrationJncorrectprofileoftheweldjackofleg25、lengthandOverIapJemporaryattachmentswillberemovedzgroundsmooth,andtheareascheckedfordefectsbyMPorPTfordefects.5.2.2.7NONDESTRUCTIVEEXAMINATIONNDEwillbeperformedbyqualifiedpersonne

23、ltoapprovedtechniques.Thetechniquesavailablearedependentonvesselclassificationandt26、hematerialsused.Checkthatthecorrectmethodhasbeenusedandverifytheapprovedstatusofboththetechniqueandthepersonnel.5.2.2.8WELDREPAIRWeIdrepairswillbecompletedusinganapprovedWPSmethodandretestedaccordingly.Allrepairswil

24、lbeapprovedbeforeanypostweldheattreatment27、iscarriedout.5.2.2.9POSTWELDHEATTREATMENTThepostweldheattreatmentrecordoftemperatureandtimeshouldbereviewedinaccordancewiththeapprovedcode/procedure.Similarlytheresultsofhardnesstestsshouldbereviewedinaccordancewiththecoderequirements,5.2.2.10DIMENSIONALME

25、ASUREM28、ENTANDVISUALEXAMINATIONAdimensionalcheckcoveringallmajordimensionsandtheposition/orientationofattachmentsandinternaltrayringswillbecarriedoutinaccordancewiththecodeanddrawingrequirements.Inadditionafullvisualexaminationofbothinside(wherepracticable)andoutsides29urfacesofthevesselwillbecompl

26、eted.ParticularattentionshouldbepaidtothecleanlinessoftheInteriorofthecolumn,thecondition/appearanceofweldsandassociatedareasztheconditionofsealingfaces.5.2.3PNEUMAICTESTNozzIereinforcingpadszsupportsaddlesorotherattachmentsshallbeea30、minedWhenspecifiedbyanapprovedlowpressurepneumatictestprocedureu

27、singsoapywaterastheindicatingmedium.Aminimumof2gaugeswithcorrectworkingrangesasdescribedbythecodeshallbeused.5.2.4HYDRAULICTESTINGCheckallpreviousitemshavebeenacceptedbyauthorisedbodies.Coderequ31、irementsWhichspecifytestingwillbewitnessed.ThefollowingitemswillbeVerified.Calibrationstatusandcorrectw

28、orkingrangesofgauges.Aminimumof2pressuregaugeswillbeattachedtoitemundertest.Adequateprovisionforventingofhighpointsanddrainingwillbeprovided.Testpressuresha32、Ilbeappliedasdirectedbyprocedureorcodeuntiltestlimitingpressureisreached.Duringholdperiod,amethodicalcheckforleakswillbeconducted.Testpressur

29、es,metalandwatertemperatureswillberecorded.Waterqualitywillbeasspecified.SGSRefNo.:35Rev.:0Page:7ofIOINSPECTIONGUIDELINE33、SCOLUMNSDate:31/04/04Specialrequirementsofthepurchasersspecificationfordeflectionorstraingaugesorpressure/time/temperaturerecordingswillbeexaminedbytheinspectorandrecordsverified.5.2.5P0STHYDRAULICTESTINGA代erdepressurisationzcolumncomponentswillbedrainedanddriedtomeetspecifiedrequirements.StampingofInspectionauthoritystamps,willbecarriedoutinapprovedarea