设备制造质量检验规程（Reciprocating Compressors）.docx

1、设备制造质量检验规程(ReCiProCatingCompressors),1、SGSRefNo.:14Rev.:0Page:lof9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/04INSPECTIONGIDELINESRECIPROCATINGCompressorsforgeneralservicesofoApprovall8032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprove

2、dDateSGSRefNo.:14Rev.:02、Page:2of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOCUmentssinspectionprocess6Shipping7ReciprocatingCOMPRESSORSDATAD0SSIER8INSPECTI0NCHECKLISTSGSRefNo.:14Rev.:0Page:3of9INSPECTI0NGuidelinesreciprocatingcompre

3、ssorsforgen3、ERALSERVICESDate:18/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatethesupply,manufactureandtestofaReciprocatingCompressorforgeneraluse.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionoftheReciprocatin4、gCompressorfromtheexa

4、minationofcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalReciprocatingCompressorExperienc5、ed,inspectorsmayinterprettheintentoftheinstructiontoacc

5、ommodatelocalornovelpracticesortoutilisetheinstructionforaone-off,oralternativedesignofcompressor.Thedesignhavingbeenapprovedbytheclient.Anysuchvariationsshouldbenotedontheinspectorsreport,3.0PROCEDURES.16、GENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonanycontractororder.ltisint

6、endedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionrequiredwil7、Ibeasspecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecifications,purchasersorcompanys

7、tandardszandwithinthepracticesandrulesofthecountrstateorprovinceandanygovernmentdecreeszlaws,ordinanceorregulationasm8、ayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreOnerousrequirementwillapplyunlessthepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSAp

8、plicablecodesandSpecifications.Designcode(tobestatedoninspectionreport)Purchase9、orderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)API618JISB83414.0DOCUMENTSTOBEREC曰VED/AVAILABLEATINSPECTIONPurchaseOrderorContractinspectionandTestplansData

9、sheetSub-assemblydrawingsSGSRefNo.:14Rev.:0Page:410 、of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/04MaterialtestCertificatesWeIdproceduresandProcedureQualificationRecordsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsCalibrationofmeasuringandtestequipment

10、NDEproceduresz(appropriateto11 、materialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHydrostatictestingprocedurepreparationandpaintingprocedurePreservationzpackingandshippingproceduresupplylist(packinglist)5.0INSPECTIONPR0CESS5.1MATERIALS.1.1REVIEWOFCERTlFICATIONO

11、riginaI12orauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings:Thereviewwillincludecheckson:-ManufacturersnameandlocationCertificateNoMaterialSpecificationHeatorcastNo13、MakersNoorPlateNoChemica

12、lcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinish5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspecificationa14、sappropriate.Visualanddimensionalcompliancewithspecifica

13、tion.5.1.3ADDITI0NALSPECIALREQUIREMENTSMayapplyonspecialcomponents.Checktoensurespecificationcontractrequirementshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialchecksshouldinclude15、:ConformationofsatisfactorydocumentreviewRecordofendorsementofcertificationreviewed

14、/witnessedRecordofallnon-conformitiesRecordofanytestswitnessedandtheresultSGSRefNo.:14Rev.:0Page:5of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/045.2RECIPROCA16、TINGCOMPRESSORMANUFACTUREAfterclearanceoftheabovepointstothesatisfactionoftheinspectothefabricatorwillproceed

15、withthemanufactureofthesubassembliesandcomponentsforareciprocatingcompressor.5.2.!FABRICATIONINSPECTIONFollowingthecompletionofweldingandmachiningoperat17、ionsthecompressorpartswillbeinspectedasrequiredbythespecificationorcontract.Theinspectionwillconsistof:VisualinspectionfordamageDimensionalcheckt

16、odrawingrequirementInspectionofparts,particularlycastinpassagesandpipingforcleanlinessVisualexaminationofweldedonco18、nnectionsReviewofwelderqualificationsReviewofweldprocedurerecordConfirmationofsatisfactoryNDE5.2.2HYDROSTATICTESTSThecompressorandotherpressurecontainingpartswillbehydrostaticallytes

17、ted.Themainitemsbeing:CylinderCoolingJacketsPipingPressurevesselsFiltersCooIersThei19、nspectormustverifythatthecorrecttestpressurehasbeenappliedtotherelevantpartsdependingonspecificationrequirements.5.2.3PRESSURETESTInadditiontothehydrostatictestitmaybenecessarytocarryoutapressuretestusingheliumasth

18、etestmedium.TheinspectorWiIkWitnesspressure20、testasrequiredReviewtestmethodtoensureitisacceptabletothecodespecificationrequirement.5.2.4ASSEMBLYINSPECTIONDuringcompressorassemblyandwhenrequiredbythePurchaseorderorcontractinspectionwillbecarriedoutpayingparticularattentiontothefollowingitems:Pistone

19、ndclear21、anceCrankshaftdeflectionRun-outCheckPropermatchmarkingprotectionofmachinedSurfacesSGSRefNo.:14Rev.:0Page:6of9INSPECTI0NGuidelinesreciprocatingcompressorsforgeneralSERVICESDate:18/03/045.2.5MECHANICALRUNNINGTESTCertaintypesofcompressormaybesubjectedtoamechanicalrunningtest.T22、hisParticular

20、lyappliestoskidmountedunits.Whererequiredbythepurchaseordertheinspectorwillcheckforthefollowingattributesduringthetestperiod.Lubricatingoil-temperature,pressureflowrateCoolingwater-temperature,pressureflowrateCriticalspeedBearingtemperaturesVibrationGas23、 ketcondition/leakageProperoperationofpressu

21、rereliefvalvesspeedgovernorsandoverspeedshutdowndevices5.2.6DISMANTLINGINSPECTIONSomepurchasersmayrequireastripdowninspectionaftertesting.Wherethereisaninspectionthefollowingpointswillbecheckedasaminimum:Visualconditionof24、 cylinderlinerSurfaceconditionofcrossheadguidepistonrodsandbearingsValveplat

22、esValvespringsPistons5.2.7FINALVISUALANDDIMENSIONALINSPECTIONAftercompletionofallmanufactureandtesttheinspectorwillundertakefinalinspectionofthecompressorpayingparticularattentionto:Main25NdimensionstodrawingrequirementsSkiddimensionsMatchmarksforre-assemblyPositionofoutsideconnectionpointsInspectio

23、nofworkmanshipDirectionofrotationmarkedcorrectly5.3NAMEPLATEContentstobecheckedinaccordancewiththeapproveddrawingsandspecificationsandstamped/markedina26、 ccordancetoclientsrequirements.5.4PAINTINGCOATINGINSPECTIONSurfacepreparationforpaintingwillbecheckedforthefollowingattributesaccordingtothespeci

24、fication:CleaningmethodPreparationgradeFreedomfromweldspatter,blowholesandotherdefects.HumidityandSteelTemperaturechecksp27、 riortopaintingPaintmanufactureztypandcolourofpainttoclientsspecificationDryfilmpaintthicknesstobecheckedaccordingtospecification.SGSRefNo.:14Rev.:0Page:7of9INSPECTIONGuideline

25、sreciprocatingcompressorsforgeneralSERVICESDate:18/03/04Paintedsurfaceconditiontobefreefro28mpin-holes,runs,damageorotherdiscontinuity5.5SPAREPARTSzLOOSEITEMSANDACCESSORIESSpareparts,looseitemsandaccessorieswillbecheckedvisuallyandfordimensionsmaterials,workmanshipandquantityaccordingtopurchaseorder

26、specificationtestmarksandtagswillbecheckedforcorrectident29、ification.5.6REPORTANDRELEASE5.6.1REPORTINGAfinalreportsummarisingtheactivitiescarriedoutwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthetimelimitslaiddowninthecontract.Thereportwillbeinaformatapprovedbytheclientand

27、mustclearlyindicate30、 thefinalacceptanceorrejectionofthepump.5.6.2RELEASENOTEWhererequiredbythecontractareleasedocumentwillbeissuedtothemanufacturerwhenthepumpshavebeenfinallyaccepted.6.0SHIPPING6.1PREPARATIONANDPACKINGThefollowingpointsmustbechecked:AIIexteriormachinedsurfacesmustb31、 ecoatedwithr

28、ustpreventativeAllinternalsurfaceswhicharesusceptibletocorrosionmustbecoatedwithrustpreventativeAllflangedopeningsshouldbefittedwithmetalprotectorsinaccordancewiththespecificationAllthreadedconnectionsmustbeprovidedwithsteelplugsCheckmanualsandi32、nstructionsareincludedareincludedasthespecificationr

29、equirementsPackingstyleandsuitabilityforoverseasshipmentShippingmarksarecorrectPre-assembledsystemsaremarkedasrequiredbythespecification7.0RECIPROCATINGCOMPRESSORSDATADOSSIERThefollowingfinaldocumentswillberevie33、wedandendorsedasnecessary.ManufacturersdatareportsMaterialCertificationDimensionaIrecordNDEreportsHydrostatictestreportsPerformancetestrequirementsNPSHreportsRun-testreportsStripdownreportsFinalinspectionreportMarkingsPackingIistSGSRefNo.:14Rev.:0Page:8of9INSPECTI0NGUIDELINESRECIPROCATINGCOMPRESSORSFORGENERALSERVICESDate:18/03/04SparepartsSGSRefNo.:14Rev.:0Page:9of91