设备制造质量检验规程（Storage Tanks Shop Fabrication）.docx

1、设备制造质量检验规程(StorageTanksShopFabrication),1、SGSRefNo.:10Rev.:0Page:lof8INSPECTI0NGIDELINESSTORAGETanksprefabricationinmanufacturersWORKSDate:ll/03/04INSPECTIONGUIDELINESSTORAGETanksprefabricationinmanufacturersworksofoApprovalll032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedChe

2、ckedApprovedDateSGSRefN2、o.:10Rev.:0Page:2of8INSPECTI0NGUIDELINESSTORAGETANKSPREFABRICATIONINMANUFACTURERSWORKSDate:ll/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCUMENTS5INSPECTI0NPROCESS6SHIPPING7STORAGETANKDATADossiersinspectionchecklistsgsRefNO.：ioRev.：OPage：3Of8INSPECTI0NGUIDELINESSTORAGETANKSPREFA

3、BRICATI3、ONINMANUFACTURERSWORKSDate:ll/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatethesupply,manufactureandtestofstoragetanksforgeneraluseinrefineriesandchemicalplants.Thisinstructionisprimarilyformillandprefabricationst4、 agesatfabricatorsworks2.

4、0SCOPEThisinstructioncoversallnecessarystagesintheproductionofthestoragetankfromtheexaminationofcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.Althoughthemethodologyincompilingthisinstruct!5、 onistosystematicallyprogressthroughIheconstructionofatypical

5、storagetank.Experienced,inspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone-offdesignofstoragetank,thedesignhavingbeenapprovedbytheclient6、 .AnysuchVariationsshouldbenotedontheinspectorsreport.3.0PROCEDURES.1GENERALThisinstructiontogether

6、withitsassociatedchecksheetmaybeusedonanyorderorcontract.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmay7、 beinvokedandthesectionstobeusedandthelevelofInspectionrequiredwillbespecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheap

7、proveddrawings,purchaseorderspecifications,purchasersorcompanystandardszandwithinthepracticesandrulesofthecountry,sta8teorprovinceandanygovernmentdecreesjaws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreOnerousrequirementwillapplyunlessthepur

8、chaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSApplicablecodes9、andspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)BS2654BS2594BS7777API620API650API653EEMUA159S

9、GSRefNo.:10Rev.:0Page:4of8INSPECTI0NGUIio、DelinesstorageTanksprefabricationinmanufacturersWORKSDate：ii/O3/O44.oDOCUMENTSTOBEREC日VED/AVAILABLEATINSPECTIONPurchaseOrderorContractinspectionandTestPlanITPDataSheetApproveddrawingszarrangementsSub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresand

10、ProcedureQualific11、ationRecordsListofqualifiedweldersorweldingOperatorsWeIdersqualificationslnspectionandtestplanCalibrationofmeasuringandtestequipmentNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHeattreatment3procedureP12、repa

11、rationandpaintingprocedurePreservation,packingandshippingproceduresupplylist(packinglist5.0INSPECTIONPR0CESS5.1MATERIALS.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.Theseshouldbeexaminedforcompliance13 、withspecificationsandwhereappr

12、opriate,drawings:ThereviewwillincludechecksOni-ManufacturersnameCertificateNoMaterialSpecificationHeatorcastNoMakersNoorPlateNoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinishStructuralob14 、servations,notabledefects.5.1.2VISUALANDDIMENSIONALVERIFICATIONMa

13、terialidentificationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspecificationasappropriate.Transferidentificationtocutoffcomponents,(CastNotransfer)zasspecified.Visual15 、anddimensionalcompliancewithspecification.SGSRefNo.:10Rev.:0Page:5of8INSPECTI0NGUIDELINESS

14、TORAGETANKSPREFABRICATIONINMANUFACTURERSWORKSDate:ll/03/045.1.3ADDITIONAL/SPECIALREQUIREMENTSMay applyonspecial components,e.g.thickcomponents.Checktoensurespecificationcontractrequirement16、shavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialchecksshouldincludeConform

15、ationofsatisfactorydocumentreviewRecordofendorsementofcertificationReviewedRecordofanynon-conformitiesRecordofanytestswitnessedandtheresult5.2STORAGETA17、 NKFABRICATIONAfterclearanceofabovepointstosatisfactionoftheinspector,thenthefabricatorwillproceedwiththemanufactureofsub-assembliesandcomponentso

16、fthestoragetank.lnspectorswillpayattentiontothefollowingpointsonabasistobeoutlinedinthePurchasersdocumentationJnsp18、ectionandtestplan,orotherdocument,asnotifiedtotheinspectors.2.1PLATEPREPARATIONCarryoutvisualanddimensionalchecktoensurecompliancewithWPSandspecification.Wherespecified,weldbevelsshal

17、lbeexaminedbyMTorPTaftergrinding/machining.Edgesandweldbevelswillbeclean,dry19、 andfreefromsurfacedefects,laminations,cracks,voids,notches,etc.Theseshallbeacauseforrejectionunlesssuitable/satisfactoryremedialactioncanbetaken.Weldingrepairstobevelsarenotpermitted,withoutapprovalfromtheengineer/inspec

18、tor.lnspectorsmustreportexcessiveorseriousdefect20、 s.Platessubjecttoforming,rollingordishingmayrequireadditionalheattreatmentzNDEtomeetcoderequirements.5.2.2SHELLCOURSESORBASEPLATES,CONTAININGWELDEDSEAMSThiSstageinspectionWillbecarriedoutwhenplateshavebeentackedusingweldingconsumablesandparametersf

19、romanapproved21、WPS.InspectorsshallcheckandreportOni-Cleanlinessandfitupaccuracyofweldpreparation.Flatnessofplates,methodsofpreventingdistortion,e.gsequencedwelding,strongbacks,backstep,etc.Applicationofpreheat.StorageandhandlingofweldingConsumabIesJnterpassconditionwhereweldingisin22、 progress.Clea

20、ningofwelds.Completionoftestcoupons,(wherespecified)NDE.Resultsshallmeetspecificationsorcoderequirements.Hardnesstests-whenSpecifiedJmpacttests-whenspecified.SGSRefNo.:10Rev.:0Page:6of8INSPECTI0NGUIDELINESSTORAGETANKSPREFABRICATIONINMANUFACTURERSWORKSDatell0323、045.2.3REPAIRWELDSRepairweldsmaybeperm

21、ittedinaccordancewiththecoderequirementsandmustbeCarriedoutonlyafterinvestigationoftheprobablecauseandinaccordancewithapprovedWPSdocuments.AIIweldrepairsshouldbereportedtotheclient.5.2.4POSTWELDHEATTREATMENTOFHOTFORMED24、COMPONENTSCarryoutdimensionalcheckandreviewfurnacerecordcharttoensureheattreatm

22、entwascarriedoutasspecified.Hardnessmeasurementmaybeusedtoestablishconditionofmaterialzheataffectedzoneorwelds,asmaybespecified.Checkdimensions,curvaturezetc.,afterPWHT.5.3Assemblyinspe25CTIONStoragetanksmaysometimesbeassembledpriortodespatch,thisshouldbewitnessedandtheresultsofanyfillingtestrecorde

23、d.Thenumberandthicknessoftheplatesshouldbecheckedifnotrialassemblyhasbeenpossible.Plateswithaccessholeszmanwaysandvalveopeningsmustbevisuallyand26、dimensionallychecked.5.3.1MARKINGMatchmarksjdentificationmarkswillbecheckedtothedrawingrequirement.Nameplatesifattachedshouldbeinaccordancewiththeapprove

24、ddrawing.5.4PAINTINGINSPECTION5.4.1SURFACEPREPARATloNSUrfaCepreparationforpaintingwillbecheckedforthefollowingpo27ints,accordingtospecification.Cleaningmethod(Blastorscrapingandwirebrushing)PreparationgradesFreedomfromweldspatter,blow-holesandotherdefectsHumidityandsteeltemperaturetobecheckedpriorto

25、paintingPaintManufacturestypeandcolourtobecheckedagainstclientsrequirementsDry28、 filmthicknesstobecheckedaccordingtospecificationsurfaceconditiontobefreefrompin-holeszrunsdamageandotherdiscontinuity.5.5ADDITIONALITEMS5.5.1QANTITYQUALITYCHECKSpareparts,looseitems,toolsandaccessoriestobecheckedvisual

26、lyandfordimensions,materials,workmanshipandqua29、 ntityaccordingtopurchaseorderspecificationandsupplylist.Markingand/orTagshallbecheckedforidentification.SGSRefNo.:10Rev.:0Page:7of8INSPECTIONGuidelinesstorageTanksprefabricationinmanufacturersWORKSDate:ll/03/045.6REPORTANDRELEASE5.6.1REPORTINGAfinalr

27、eportsummarisingthe30、activitiescarriedoutwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthelaiddowntimeIimitsThereportwillbeintheformrequiredbytheclientandwillclearlyindicatethefinalacceptanceorrejectionofthegoods.5.6.2RELEASENOTESWhererequiredbythecont31、ractaReleaseDocument

28、willbeissuedtothemanufacturerwhenthestoragetankhasbeenfinallyaccepted.6.0SHIPPINGPREPARATIONANDPACKING6.1PREPARATIONANDPACKINGThefollowingpointsshallbecheckedtoensuretheymeetwithcontractrequirementsandacceptedstandardsofgoodpractice.Cleanlin32、 essanddrynessofcomponentsRustpreventionforallmachinedsu

29、rfacesandweldingbevelsProtectionandcoversforallopeningsandprotrudingpartsSpacingofplatesSecurityfromwarping/transitdamagePackingstyleandsuitabilityfortransportationincludingslingingpointsShippingmarksand33、 、othermarkings7.0DOCUMENTATIONPACKAGE7.1FABRICATIONSHOPDOCUMENTSThefollowingfinaldocumentsshallbereviewedandsignedofftothecontractrequirement.Thesemayapplytobothshopandsiteoperations.ComponentdetailClrawingsManufacturersdatareportsMaterialcertificateorcertifiedmilltestreportsMateriallistormapWelderrecordforeachSeamHeattreatmentrecords(Temperature-timereco