1、设备制造质量检验规程(SheilBoilersWeldedConst)l,1、SGSRefNo.:03Rev.:0Page:lof!INSPECTIONGIDELINESSHELLBoilersofweldedCONSTRUCTlc)NDate940304NSPECTIoNGuidelinesshellboilerofweldedconstrctionofoApproval04032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:03Rev.:0Pa
2、ge:2of11INSPEC2、TiONGuidelinesshellBoilersofweldedCONSTRUCTIONDate:04/03/04Cc)NTENTSlPURPoSE2SCOPE3PROCEDURE4DOCMENTS5INSPECTIONPROCESS6SHIPPING7SHELLBOILERDATADossierscertificateofconformity9nspectionchecklistsgsRefNo.:03Rev.:0Page:3of!INSPECTIONGUIDELINESSHELLBoilersofweldedcoNSTRUCTioNDate：043、03
3、041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatethesupply,manufacture,andtestofallShellBoilers.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionoftheShellBoilerfromtheexaminationofcertificationfromprocur4、ementsourcestothefinalinspection,pre
4、servationandpackingtodespatchforsite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalShellBoiler.ExperiencedinspectorsmayinterprettheintentoftheinstructiontoaccommodateI5、ocaIornovelpracticesortoutilisetheinstructionforaone-offzoralternatived
5、esignofboilerzthedesignhavingbeenapprovedbytheclient.AnysuchVariationsshouldbenotedontheinspectorsreport.Mostboilersareconstructedunderoneofthewellknownnationalcodeswhichrequireaninspect6、ingauthoritytosurveyProductionThisinstructionisbasedintherequirementsofsuchacode.ltassumesthatthedesignparameter
6、shavebeenreviewedandapproved.3.0PROCEDURES.IGENERALThisinstructiontogetherwithitsassociatedchecksheetmaybeusedonanycontractororder.ltisintendedto7、actasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionwillbespecified
7、onthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseOrderspecif8、 ications,purchasersorcompanystandards,andwithinthepracticesandrulesofthecountrstateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparen
8、tinanyoftheabovethenthemoreOnerousrequirementshallapplyunless9、 thepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSAppIicabIecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesa
9、ndstandards(sampleonly)EN12953:210、003ASMEIAS1229-1990SGSRefNo.:03Rev.:0Page:4of!INSPECTIONGuidelinesshellBoilersofweldedNSTRCTIONDate0403044.0DOCUMENTSTOBERECEIVED/AVAILABLEATINSPECTIONPurchaseorderorContractBoiIerInspectionandTestPlanITPBoiIerdataSheetApproveddrawings,(arrangements)Sub-assemblydra
10、11 、WingsMateriaItestCertificatesWeIdproceduresandProcedureQualificationRecordsProductionweldtestrequirementsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsRepairproceduresNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsND12 、E/inspectorsqualifi
11、cationsHeattreatmentprocedurecalibrationrecordsfortestingmeasuringequipmentHydrostatictestingprocedurezwaterqualitydocumentpreparationandpaintingprocedurePreservation,packingandshippingprocedureSpares/operatingmanualsSupplylist(packinglist)5.0INSPECTIONPROCES13 、S5.1MATERIAL5.1.1REVIEWOFCERTlFICATIO
12、NOriginaIorauthenticatedcopiesofmillcertificateswillbeavailableatmanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings.Thereviewwillinclude:MakersnameandlocationMaterialSpecification14 、CertificateNo.,Grade,sizeandwallthicknessHeatorcastNo.Chemicalcom
13、positionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinishStructuralobservations,notabledefects5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesagainstprodu15 、ctmarkings.Materialsuppliedagainstdrawingzmateriallistandspecificationasappropriate.Transferi
14、dentificationtocutoffcomponents,(CastNotransfer)zasspecified.Visualanddimensionalcompliancewithspecification.5.1.3ADDITIONALSPECIALREQUIREMENTSMayapplyonspecialcomponents,checkto16、ensurethatcontractrequirementshavebeenmet.WitnessanyNDEexaminationasnecessary.SGSRefNo.:03Rev.:0Page:5of!INSPECTIONGuid
15、elinesshellBoilersofweldedNSTRCTIONDate040304SGSRefNo.:03Rev.:0Page:6ofIiinspectionGuidelinesshellBoilersofweldedCONSTRUCTIONDate:04/03/045.1.4REPORT17、INGReportingonmaterialchecksmustinclude:ConfirmationofsatisfactorydocumentreviewRecordoftheendorsementofcertificatereviewed/witnessedRecordofallnon-
16、conformitiesRecordoftestswitnessedandtheresult5.2FABRICATI0NOFSHELLBOILERSAfterclearanceofabovepointstosatisfaction18oftheinspectorzthenthefabricatorwillproceedwiththemanufactureofsub-assembliesandcomponentsoftheShellBoilerJnspectorswillreviewthefollowingpointsonabasistobeoutlinedintheapplicableNati
17、onaIStandardzPurchasersdocumentation,qualityplan,tstandinspectionplan,orother19、document,asnotifiedtotheinspector.5.2.1PREPARATIONFORWELDINGCarryoutvisualanddimensionalchecktoensurecompliancewithWPSandspecification/Code.Wherespecifiedweldbevelswillbeexaminedbyrequiredcodemethodaftergrinding/machinin
18、g.Edgesandweldbevelswillbeclean,dryandfre20、efromsurfacedefects.Laminations,cracks,voidsznotcheszetc.Thesewillbecauseforrejectionunlesssuitable/Satisfactoryremedialactioncanbetaken.WeldrepairsmustbecarriedinaccordancewithTheCoderequirementsandapprovedbytheclientbeforeweldingproceeds.SeriousOrExcessi
19、vedefectsm21、ustbereported.5.2.2WELDINSPECTION5.2.2.1EDGEPREPARATIONVisualanddimensionalcheckwillbeformedinaccordancewithWPSandspecificationsMTorPTshouldbecarriedoutinthecutedgesasrequired.Edgesmustbefreefromlaminations,cracks,notchesetc5.2.2.2FITUPINSPECTION.Shapes,dimen22、sionandalignmentswillbech
20、eckedinaccordancewithapprovedWPSzClrawingandspecificationscode5.2.2.3VISUALCHECKANDNON-DESTRCTIVEEXAMINATIONThepreparedgrooveandadjacentareawillbecleanandfreefromforeignmaterials,oil,paint,waterandrust.Thepreparededgewillbere-examinedto23、 ensurenodefectshavebeenexposedduringfinalpreparation.Tackwel
21、dswillbeproducedusingtheapplicableWPSconditionsandwillbevisualfreefromdefects.Nondestructiveexaminationwillbeperformedinaccordancewiththecoderequirements.5.2.2.4MONITORINGOFWELDCONDITIONSPreheatheat24、 temperatureandmethod,lnterpasstemperaturesweldmaterialcontrol,welderandprocessqualificationswillbe
22、checkedforconformitytocoderequirementsandmonitoredSGSRefNo.:03Rev.:0Page:7of!INSPECTIONGUIDELINESSHELLBOILERSOFWELDEDNSTRCTIONDate0403045.2.2.5BACKGOUGINGINSPECTIONTh25、eshapeanddimensionofthebackgougedgrooveswillbecheckedforconformitytotheWPSrequirement.Thevisualappearancemustbecleanandfreefromdefe
23、cts.NDEexaminationwillbeinaccordancewithcode/clientsrequirements5.2.2.6POSTWELDINSPECTIONAftercompletionofallweldingandgrinding26、 operationsavisualexaminationwillconfirmtherearenoharmfuldefectssuchascracksjackoffusion,surfaceporosityorexposedSlaginclusionsJncompIetePenetrationJncorrectprofileofthew
24、eldjackofleglengthandOverIapJemporaryattachmentswillberemovedzgroundsmooth,andtheareasche27、ekedfordefectsbyMPorPT.5.2.2.7NONDESTRUCTIVEEXAMINATIONNDEwillbeperformedbyqualifiedpersonneltoapprovedtechniques.Thetechniquesavailablearedependentonvesselsclassificationandthematerialsused.Checkthatthecorre
25、ctmethodhasbeenusedandverifytheapprovedstatusofboth28、Techniquesandthepersonnel.5.2.2.8WELDREPAIRSWeIdrepairswillbecompletedusinganapprovedWPSmethodandretestedaccordingly.AIIrepairswillbeapprovedbeforeanyhydraulictestingiscarriedout.5.2.2.9DIMENSIONALMEASUREMENTSANDVISALLEXAMINATIONAdimensionalcheck
26、coveringallmajo29、rdimensionsandtheposition/orientationOfattachmentswillbecarriedoutinaccordancewiththecodeanddrawingrequirements.Inadditionafullvisualexaminationofbothinsidewherepracticableandoutsidesurfacesofthevesselwillbecompleted.Particularattentionshouldbepaidtotheclean30Iinessoftheinterioroft
27、hevessel,thecondition/appearanceofweldsandassociatedareasandtheconditionofsealingfaces.5.2.3.PNEUMATICTESTNozzlereinforcingpadszsupportssaddlesorotherattachmentsshallbeexaminedwhenspecifiedbyanapprovedlowpressurepneumatictestprocedureusing31、soapywaterastheindicatingmedium5.2.4HYDRAULICTESTINGChecka
28、llpreviousitemshavebeenacceptedbyauthorisedbodies.CoderequirementswhichspecifytestingwillbewitnessedThefollowingitemswillbeverified.Calibrationstatusandcorrectworkingrangesofgauges.Aminimumof2pressure32agaugeswillbeattachedtoitemundertest.Adequateprovisionforventingofhighpointsanddrainswillbeprovide
29、dTestpressureshallbeappliedasdirectedbyprocedureorcodeuntiltestlimitingpressureisreached.Duringholdperiod,amethodicalcheckforleakswillbeconducted.Testpressure,33、metalandwatertemperaturewillberecorded.SGSRefNo.:03Rev.:0Page:8ofIiinspectionGuidelinesshellBoilersofweldedNSTRCTIONDate040304Waterqualitywillbespecified.5.2.5POSTHYDRAULICTESTINGAfterdepressurisation,shellboilercomponentswillbedrainedanddriedtomeetspecifiedrequirements.StampingofInspectionAuthoritystampszwillbecarriedoutinapprovedarea,asrequiredb
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