1、设备制造质量检验规程(WaterTubeBoilers)Il1、SGSRefNo.:02Rev.:0Page:lof9INSPECTIONGUIDELINESWATERTUBEBOILERSDate:04/03/04INSPECTIONGUIDELINESWATERTUBEBOILERSOForApproval04032022J.C.BrottonB.TremainBTremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:02Rev.:0Page:2of9INSPECTI0NGUIDELINESWATERT
2、UBEBOILERSD2、ate:04/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCUMENTS5lNspectionprocess6Shipping7boilerdataDosierscertificateofC0NF0RMITY9INSPECTI0NCHECKLISTSGSRefNo.:02Rev.:0Page:3of9INSPECTI0NGUIDELINESWATERTUBEBOILERSDate:04/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificati3、onact
3、ivitiesrequiredtovalidatethesupplmanufacture,andtestofWaterTubeBoilers.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofaWaterTubeBoilerfromtheexaminationOfcertificationfromprocurementsourcestothefinalinspection,preservationandpackingforde4、spatchtosite.Althoughthemethodologyincompili
4、ngthisinstructionistosystematicallyprogressthroughtheConstructionofatypicalWaterTubeBoiIenExperiencedinspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone5、-oforalternativedesignofboilei;thedesignhavingbeenapprovedbytheclient.Anysuchvariati
5、onsshouldbenotedontheinspectorsreport.MostboilersareconstructedunderoneofthewellknownNationalcodeswhichrequireanInspectingAuthoritytosurveyproduction.Thisinstructionisbased6、intherequirementsofsuchacode.ltassumesthatthedesignparametershavebeenreviewedandapproved.3.OPROCEDURES.IGENERALThisinstruction
6、togetherwithitsassociatedchecksheetmaybeusedonanyorderorcontract.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspector7 、programme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionrequiredwillbespecifiedonthechecksheet.AIItestsandinspectionswillbecarriedoutagai
7、nsttheapproveddrawings,purchaseorderspecificationszpurchasersorcompanystandards,andwithin8 、thepracticesandrulesoftheCountryzStateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreonerousrequirementWillapplyu
8、nlessthepurchaserorclientdirectsotherwiseinwriti9 、ng.3.2REFERENCEDocuMENTSAppIicabIecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)EN12952:2022ASMEIAS1229-1990SGSRe
9、fNo.:02Rev.:0Page:4o10 、f9INSPECTIONGuidelineswatertubeBOlLERSDate:04/03/044.0DOCUMENTStobeRECEIVED/AVAILABLEATINSPECTIONPurchaseorderorContractBoiIerInspectionTestPlanITPBoiIerdataSheetApproveddrawings,(arrangements)Sub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresandProcedureQualificati1
10、1、onRecordsProductionweldtestrequirementsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsRepairproceduresNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHeattreatmentprocedurecalibrationrecordsf12、 ortestingmeasuringeq
11、uipmentHydrostatictestingprocedure,waterqualitydocumentpreparationandpaintingprocedurePreservation,packingandshippingprocedureSpares/operatingmanualsSupplylist(packinglist)5.0INSPECTIONPROCESS5.!MATERIALS.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopies13、 ofmillcertificateswillbeavailableatman
12、ufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings.ThereviewwillIncIudeiMakersnameandlocation.CertificateNo.Gradezsizeandwallthickness.MaterialSpecificationHeatorcastNo.Chemicalco14、 mposition.Mechanicalproperties.Heattreatedcondition.NDEappliedandres
13、ults.Surfacefinish.Structuralobservations,notabledefects.5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspecifica15、 、tionasappropriate.Transferidentificationtocutoffcomponents,(CastNotransfer)zasspecified
14、Visualanddimensionalcompliancewithspecification.SGSRefNo.:02Rev.:0Page:5of9INSPECTI0NGuidelineswatertubeBOILERSDate:04/03/045.1.3ADDITIONALSPECIALREQUIREMENTSIVIayapplyonspecialcomponents16、,checktoensurethatcontractrequirementshavebeenmet.WitnessanyNDEexaminationasnecessary.5.1.AREPORTINGReporting
15、onmaterialchecksmustinclude:ConfirmationofsatisfactorydocumentreviewRecordoftheendorsementofcertificatereviewed/witnessedRecordofallnon-conformitiesRecordof17、testswitnessedandtheresult5.2WATERTUBEBOILERFABRICATIONAfterclearanceofabovepointstosatisfactionoftheinspectorzthenthefabricatorwillproceedwi
16、ththemanufactureofsub-assembliesandcomponentsoftheWaterTubeBoilerJnspectorswillreviewthefollowingpointsonabasistobeo18、utlinedintheapplicableNationalStandardzPurchasersdocumentation,qualityPlan,testandinspectionplanzorotherdocumentzasnotifiedtotheinspector.5.2.1WELDEDDRUMSANDHEADERSReviewweldingproc
17、eduretestsortestrecordandensurethatwelderapprovaltestsandwelderscertificatesarevalid19、 .Inspectcutplatevisuallyanddimensionallypayingparticularattentiontomaterialidentificationmarksandidentifymaterialtobeusedforthetestplates.Dimensionallyinspectweldsetupandalignment.Visuallyexamineedgesofweldprepar
18、ationtoensurethattheyarefreefromdefectswhichmay20、 affecttheweldedseam.Verify/witnessNDEofweldpreparationifrequiredbycode.Visuallyinspectalldrum/headerlongitudinalandcircumferentialweldseamsandreviewradiographandultrasonictestreports.Dimensionalcheckonattachmentsandcompensationplates,nozzlesetc.Veri
19、fycompletionofw21、eldingtoasatisfactorystandardandreviewrecordsofpostweldheattreatment.Verifythatallweldtestplateshavebeencompletedandproperlyidentified.WitnessHydraulicTestJnternaIandexternalexamination.Finalinspectionafteranymachiningoperationssubsequenttopressuretesting.SGSRef22、 No.:02Rev.:0Page
20、6of9INSPECTIONGIDELINESWATERTUBEBOILERSDate:04/03/045.2.2SEAMLESSDRUMSANDHEADERSReviewweldingproceduretestortestrecordsandensurethatwelderapprovaltestsandwelderscertificatesarevalid.Confirmmaterialidentitiesandensureproperidentificationofcomponents23、 .Inspectbeforeendclosurewhetherbyforgingorweldi
21、ngonofseparateendclosures.Dimensionalcheckonattachmentsandcompensationplates,nozzlesetc.Verifycompletionofweldingtoasatisfactorystandardandreviewrecordsofpostweldheattreatment.Verifythatallweldtestpieceshavebeen24、completedandproperlyidentified.WitnessHydraulicTestJnternaIandexternalexamination.Fina
22、linspectionafteranymachiningoperationssubsequenttopressuretesting.5.2.3TUBESANDINTEGRALPIPINGReviewweldingproceduretestortestrecordandensurethatthewelderapprovaltestsandweldersc25、ertificatesarevalid.Checkmaterialidentities.Witnesssetupatleast10%minimumoftubesandintegralpipesbeforewelding.Verifycomp
23、letionofweldingtoasatisfactorystandardandthattheNDEexaminationreports/recordshavebeencompletedandaccepted5.2.4HYDRAULICPRESSURETESTONindivid26、ALCOMPONENTSifrequiredorFINALASSEMBLEDBOILERUNITCheckallpreviousitemshavebeenacceptedbyAuthorisedbodies.CoderequirementswhichspecifytestingwillbeWitnessedThe
24、followingitemswillbeVerifiedCaIibrationstatusandcorrectworkingrangesofgauges.Aminimumof2pressuregauges27、willbeattachedtoitemundertestAdequateprovisionforventingofhighpointsanddrainingwillbeprovidedTestpressureshallbeappliedasdirectedbyprocedureorcodeuntiltestlimitingpressureisReached.Duringholdperi
25、od,amethodicalcheckforleakswillbeconducted.Testpressures,metala28、ndwatertemperatureswillberecorded.WaterqualitywillbeasSpecifiedSGSRefNo.:02Rev.:0Page:7of9INSPECTIONGIDELINESWATERTUBEBOILERSDate:04/03/04SpecialrequirementsofthepurchasersspecificationfordeflectionorstraingaugesorPressure/time/temper
26、aturerecordingswillbeexaminedb29、ytheinspectorandrecordsverified5.2.5POSTHYDRAULICTESTINGAfterdepressurisation,boilercomponentswillbedrainedanddriedtomeetspecifiedrequirements.StampingofInspectionauthoritystamps,willbecarriedoutinapprovedareazasrequiredbyclient/code.Stampsusedshallbelowstressty30、pe
27、Applicationofdesiccant/preservativewillbeasdirectedinclientsspecification.5.3FINALASSEMBLYAllassembliesW川becheckedforcleanlinessanddryness.Rechecknozzles,supportandbracketlocationsandorientationsagainstassemblydrawings.Checkfordeformationoftubeszattachments,flange31、s,etc.andreportifnecessary.5.4MA
28、RKINGMatchmarks,identificationmarkswillbecheckedandlowstresstypestampmustbeusedonallpressureparts.5.5NAMEPLATEMateriaIshallbecheckedforcompatibility.Contentsofmarkingtobecheckedinaccordancewithapproveddrawingandspecificationsanda32、Uthoritystampedasrequired.Checkmountingofnameplateonabracketweldedto
29、aspecifiedareaofboiler,inaccordancewiththecoderequirement.5.6PAINTINGSurfacepreparationforpaintingwillbecheckedforthefollowingpoints,accordingtospecification.Cleaningmethod(Blastorscrapingandwir33、ebrushing)PreparationgradesFreedomfromweldspatter;blow-holesandotherdefectsHumidityandSteelTemperaturestobecheckedpriortopaintingPaintmanufacturezTypeandColourtocheckedtoclientsspecificationDryfilmthicknesstobecheckedaccordingtospecificationsurfaceconditiontobefreefrompin-holes,runsdamageandotherdiscontinuity.5.7SPAREPARTS,LOOSEITEMSJOOLSANDACCESS
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