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1、Zhenjiang JinMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：1 of 12Manufacturing and Examination Procedure制 造 和 检 验 程 序 Prepared by Date _ 编 制： 日期： Approved by _Date _ 批 准： 日期： Accepted by _Date _ 认 可： 日期：Zhenjiang JinMen Industrial Co., LtdA
2、SME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：2 of 121Scope 范围1.1This procedure establishes the inspection, testing and examination requirements during the fabrication process of pressure vessels which constructed to the ASME Code Section，B31.1and VIII Div.1. 本程序在锅
3、炉/压力容器的制造过程中，规定了检验、测试和检验要求， 满足ASME规范第卷，B31.1和第卷第分册。1.2The manufacturing process mentioned in this procedures including material preparation (cutting, edge preparation, machining), forming, welding and final testing, etc. The inspection mentioned in this procedure mainly means the visual inspection a
4、nd dimensional measuring check. 在本过程中提及的制造过程，包括材料准备（切割、边缘整理、机加工），成型、焊接和最后测试等。在本过程中提及的检验主要地意味着目测和尺寸测量检测。2Responsibility: 责任2.1The QC Manager shall be responsible to train and qualify the Examiners who engaged in the manufacturing process inspection on pressure vessels, and shall control the quality.
5、质量管理经理应负责培训和考试检验员，以便他在压力容器上，从事制造过程的检验，并控制产品质量。2.2 The Examiner shall conduct inspection and examination based on the items listed in Process Check List (PCL), procedures and the applicable Code Section requirements.检验员应基于在PCL、程序和所应用的规范要求上列出的条款执行检验和测试。2.3 After inspection, Examiner shall record the r
6、esults in the “Inspection and Examination Record” forms and keep them in file.在检验之后，检查员应将检验结果记录在”检验记录表”里并将它们保存在档案里。2.4 Any unacceptable items or quality related problems found during the inspection shall be handled as nonconformity.在检验过程中，任何不合格的产品或发现质量相关的问题应按照不符合项来处理。3Preparation for Inspection 检验前的
7、准备Zhenjiang JinMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：3 of 123.1Examiner shall have an annual vision test. 检验员定期进行视力测试。3.2Direct visual examination may be conducted when the parts can be examined at an angle not less than 30 degree. M
8、irrors may be used to assist examination when deemed necessary. 当部件能被在一个不低于30度时检测，直接的视力检验应被执行。当认为必要时，镜子应被帮助来检验。3.3The material, part, component etc. under visual examination shall be sufficiently illuminated. Flashlight or other auxiliary lighting devices shall be employed is necessary. 材料、部件、零件等，在视
9、力检验下应足够地照明，必要时，闪光灯或其它辅助照明设备应被使用。3.4 In some cases, remote visual examination may have to be substituted for direct examination. Remote visual examination may use visual aids such as mirrors, telescopes, borescopes, fiber optics, cameras, or other suitable instruments. Such systems shall have a resol
10、ution capability at least equivalent to that obtainable by direct observation. 在一些情况下，远程的视力检验可能不得不代替直接检验。远程的视力检验可以使用视力辅助工具，如镜子、望远镜、管道镜、纤维光学镜、照相机、或其它适当的工具。像这样的体系应有解决能力至少等于直接观察获得的。3.5All the examined surfaces shall be clean. Irregular shapes covering and mixing surface defects shall be washed away. 所有
11、被检验的表面应被清理。不规则的遮盖物和混合表面的缺陷应被清除。4Inspection during Material Cutting 在材料切割时检验4.1After lay-out but before cutting, the Examiner shall verify and examine the accurate transfer of Material Coded Mark. 在划线切割之前，检验员应确认材料编号标识被准确地进行了移植。4.2When plates, components, and other parts, may be cut to shape and size
12、by oxygen or arc cutting for carbon and low alloy steel and by plasma cutting machine for austenitic stainless steel. After cutting, the edges to be welded shall be uniform and smooth and shall be free of all loose scale and slag accumulations before welding. The detrimental discoloration of materia
13、l which has been molten shall be removed prior to further fabrication or use. 钢板、零件和其它部件应用氧或电弧切割碳钢和低合金钢成型和尺寸，用等离子机切割奥氏体不锈钢。在切割后，所有的熔渣和已经被熔化的有害的变色材料应在深度加工或使用之前移除。Zhenjiang JinMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：4of 124.3Ends of nozz
14、les or manhole necks which are to remain unwelded in the completed vessel may be cut by shearing provided sufficient additional material is removed by any other method that produces a smooth finish. Exposed inside edges shall be chamfered or rounded. 倘若用其它的方法能够去除足够的额外添加的材料，以使成品的表面光滑，那么，在完成的容器中，不需要焊接
15、的管口端或检修孔管颈可以用修剪的办法去除。精整地镀铴薄板。暴露在外的内部边缘应被斜切或磨圆。4.4The Examiner shall examine the shapes and dimensions of cut parts by steel ruler, band tape or model. 检验员应用钢尺、卷尺或模子，检查切割部件的形状和尺寸。4.5 Cutting edge of being cut parts shall be examined by direct visual examination or by magnifying glass when deemed nece
16、ssary in order to disclose possible lamination, shearing crackle, or other defects. 认为必要时，为了揭露可能得迭片结构，被切割的部件的切割边缘应被检验通过直接目测检验或放大镜、剪切裂纹 或其它的缺陷。5Forming Examination 成型检验5.1If the plates are to be rolled, the adjoining edges of longitudinal joints of cylindrical vessels shall first be shaped to the pro
17、per curvature by preliminary rolling or forming in order to avoid having objectionable flat spots along the completed joints. 如果要滚轧钢板，圆柱容器的纵缝连接的相邻边应先被预先滚轧成形，以具有适当的曲率。这样可以避免完成的焊缝周围有不必要的、未弯曲的部分。5.2The shell of an internal pressure vessel shall be substantially round. The difference between the maximum
18、 and minimum inside diameters at any cross section shall not exceed 1% of the nominal diameter at the cross section under consideration. 内部压力容器的壳应被充分地弄成圆形。在任何横截面，最大与最小的内径差异都不应超过在考虑中的横截面的直径的1%。When the cross section passes through an opening or within 1 ID of an opening or within 1ID of the opening m
19、easured from the center of the opening, the permissible difference in inside diameters given above, may be increased by 2% of the inside diameter of the opening. Zhenjiang JinMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：5of 12当横截面通过一个开口，或从开
20、口的中心测量，该横截面在一个开口的1ID范围内，在以上给出的内部直径的允许公差范围可能会变大，变大范围为开口内部直径的2%。When the cross section passes through any other location normal to the axis of the vessel, including head to shell junctions, the difference in diameters shall not exceed 1 %. For vessels with longitudinal lap joints, the permissible diff
21、erence in inside diameters may be increased by the nominal plate thickness. Roundness measurement shall be completed inside vessels, and be vertical to the rolling shaft by special gauge, instrument steel rule, band tape, caliber etc. Each shell shall be examined at least in three cross sections, tw
22、o at ends and one at midst section.对于有纵向焊接缝的容器，内部直径可能会不同，这种不同可能随钢板的正常厚度而增加。圆度测量应该在容器内部完成，并且与辊轴垂直。可采用特殊标准尺、钢尺、卷尺和卡尺等测量。至少在三处横截面处检验每一壳体，两处分别在两端，一处在中部。5.3The shell of a completed vessel to operate under external pressure shall not exceed the out-of-roundness limitation described in paragraph 5.2 and ma
23、ximum plus-or-minus deviation from the true circle form, measured radially on the outside or inside of the vessel, shall not exceed the maximum permissible deviation obtained from Fig. UG-80.1. 在外部压力下工作的完整的容器的壳体，变形程度不应超过5.2中描述的限制。通过测量容器外部或内部半径所得的、其偏离圆环形状的最大值，不应超过图UG-80.1中的可允许最大偏离值。5.4The inner surfa
24、ce of a torispherical , hemispherical, or ellipsoidal head shall not deviate outside of the specified shape by more than 1-1/4 % of D nor inside the specified shape by more than 5/8 % of D, where D is the nominal inside diameter of vessel shell at the point of attachment. The knuckle radius shall no
25、t be less than that specified. The deviation shall be measured perpendicular to the specified shape and shall not be abrupt.准球、半球或椭球体的接头，大于规定外形的量不超过直径的1-1/4%，小于规定外形的量不超过直径的5/8%。此处直径指容器壳体在附件连接处的正常内部直径。接头范围不得少于规定。应垂直于规定外形测量偏离值，该偏离值不应是突变的。5.5 Hemispherical heads or any spherical portion of a torispheri
26、cal or ellipsoidal head designated for external pressure shall, in addition to satisfying the requirements of paragraph 5.4, meet the tolerance specified for spheres in UG-80(b) using a value of 0.5 for L/D0.为外部压力设计的半球状接头，或准球、椭球体的接头的任意球状部分，除满足5.4中的要求外，应为L/D0使用0.5的值，满足UG-80（b）中规定的球体的容许公差。Zhenjiang Ji
27、nMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：6of 125.6The skirt of heads shall be sufficiently true to round so that the difference between the max. and min. inside diameter shall not exceed 1 % of the normal diameter.5.7 The marks on the
28、cylindrical shell and heads shall be examined after formation to make sure they are clear. 在柱形壳上和接头上的标志应被在成型之后进行检验以确认它们清楚。6Machining Examination 机加检验6.1Examiner shall attach material identification tag or make marking on all machined parts. 检验员应贴上材料识别标签或在所有机加部件上做记号。6.2The shape, dimensions of being
29、machined parts shall be measured by straightedge, caliper, caliber, angle square etc. 机加部件的形状和尺寸应用直尺、卡钳、卡尺、角尺等测量。6.3Examining for the roughness of the being machined surfaces shall be carried out by surface roughness measuring devices. 机加表面的粗糙程度的检验应用表面粗糙程度测量仪器实施。6.4For screw parts, examined by closi
30、ng screw (ring screw gauge, screw plug gauge) etc. 对于螺丝零件，用螺纹规检验（环头螺纹规，螺旋塞规）等。7Fabrication Process Examination 制作过程检验7.1Alignment of sections at edges to be butt welded shall be checked, the maximum offset is not greater than applicable amount for the weld joint category under consideration as liste
31、d in Table 1. The section thickness t is the normal thickness of the thinner section at the joint. 对于对接焊缝边缘的截面线形应被检查最大的偏移量不大于在考虑中的焊缝种类的应用量（见表1）。截面厚度是在接缝处叫薄截面的公称厚度。Zhenjiang JinMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：7of 12Table 1 Maxim
32、um Alignment Tolerance for Butt-weld表1 对接焊缝最大错边量公差Section Thickness截面厚度Joint Categories 接缝种类in. A B C and D至Up to 1/2,incl1/4t1/4t超过Over 1/2 to 3/4, incl1/8 in (3mm) 1/4t 超过over 3/4 to 1.5,incl1/8 in(3mm)3/16 in. (5mm)超过over 1.5 to 2,incl1/8 in (3mm)1/8 t 超过Over 2 lesser of 1/16 t or 3/8 in (10mm)较小
33、的lesser of 1/8 t or 3/4in (19mm)较小的7.2 Any offset within the allowable tolerance provided above shall be faired at a three to one taper over the width of the finished weld or if necessary by adding additional weld metal beyond what would other wise be the edge of the weld. Such additional weld metal
34、 build up shall be subject to the requirement of following :在上述允许公差范围内的偏移量，可以在完成的焊接的宽处按照3比1的锥度使其成为流线型，或如有必要，可在焊接的边缘添加额外的焊接金属。额外焊接金属的喷镀应符合下述要求。a) A butt welding procedure qualification in accordance with provision of ASME Section IX must be performed for the thickness of weld metal deposited, prior t
35、o production welding. 在产品焊接前，应对喷镀的焊接金属的厚度进行符合ASME第IX卷条款的对接焊程序的质检。b) All weld metal buildup must be examined the full surface of the deposit by liquid penetrate examination to the requirements ASME Code Section VIII, Division 1.所有喷镀的焊接金属的都应按照ASME第VIII、第1分册的要求，用液体渗透检验的方法检验其喷镀表面。c) When such surface we
36、ld metal buildup is used in welded joints which require full or spot radiographic examination, the weld metal buildup shall be included in the examination.如果在要求全部或定点X光检验的焊缝处使用表面焊接金属喷镀，该焊接金属喷镀也应被包括在检验。7.3A tapered transitive having a length not less than three times of the offset between the adjacent
37、 Zhenjiang JinMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：8of 12surfaces of abutting section shall be provided at joints between sections that differ in thickness by more than 1/4 of the thickness of the thinner or by more then 1/8 in .在厚度
38、不同的截面间（厚度的不同大于薄者的1/4，或大于1/8英寸）的焊缝，应提供锥形过渡。其长度不少于临近截面的相邻表面偏移量的3倍。7.4Except when the joints are examined by RT for 4 in. on each side of circumferential welded intersection, vessels made up of two or more course shall have the centers of the welded longitudinal joints of adjacent course staggered or s
39、eparated by a distance of at least five (5) times thickness of the thicker plate.除非X光检验的每一边的圆周焊接横截面焊接缝为4英寸，否则，在由两个或多个部分构成的容器中，相邻部分的纵向焊接的中心点应被错开或分开，距离至少是较厚钢板厚度的5倍。7.5All lugs, brackets, saddle type nozzles, manhole frames, reinforcement around openings, and other appurtenances shall be formed and fit
40、ted to conform reasonably to the shell surface to which they are attached when pressure parts extend over pressure retaining welds, such welds shall be ground flash for the portion of the weld to be covered. 当壳体的压力部件超出保持压力的焊接时，这种焊接需要覆盖的部分应接地、用火花处理。所有的接线片、鞍形管口、检修孔铁口框架、开口周围的加固和其他附属物，应该合理地成形加工和安装，以适合它们
41、所安装的壳体表面。7.6Fabricate dimensions and shapes shall be examined by template.用模板检验制造尺寸和外形。7.7The surface to be welded shall be clean and free to scale, rust, oil, grease or other deleterious foreign material. The cleaning distance from the edge of welding joint shall be at least 1 in. (25 mm) for ferro
42、us metal and 2 in. (50 mm) for non-ferrous metals.将要进行焊接的表面应干净，无剥落、生锈、机油、油脂或其他损害性外界物质。从焊缝的边缘算起，对于铁类金属，清洁范围不少于1英寸（25毫米），非铁类金属不少于2英寸（50毫米）。8Welding Process Examination 焊接过程检验8.1Examiner shall examine the surface cleanness of being welded parts. 检验员应检验将被焊接部分表面的清洁度。8.2Examiner shall verify the correct W
43、PS as specified by the drawing has been available and all welders have been qualified. 检验员应核实制图规定的正确的WPS是否可以得到利用，并检验所有的焊接工是否合格。Zhenjiang JinMen Industrial Co., LtdASME ProceduresJM/ASME-07Manufacturing and Examination ProcedureRev. No.: 0.0Page：9of 128.3Tack weld shall be carried out by the qualifie
44、d welders following the qualified WPS used for production welding. Tack weld shall be at least 1/2 in. (13mm) in length at the interval of not longer than 16 in. (400 mm). 预焊应由合格的焊接工按照针对产品焊接的合格WPS进行。预焊的长度至少为2/1英寸（13毫米），间距不长于16英寸（400毫米）。8.4Prior to welding, the groove surface shall be cleaned for a d
45、istance of at least 1 in. (25 mm) from the welding joint edge. The welding joint shall be preheated by either torch or electrical method to the specified temperature with a range of 3 in. (75 mm) from the welding joint. It is recommended that the welding can not be done when the temperature of base
46、metal is lower than 0 F (-20 C). At temperatures between 32 F (0 C) and 0 F (-20 C), the surface of all areas within 3 in. (75 mm) of the point where a weld is to be started should be heated to a temperature above 60 F (15 C) before welding is started. It is recommended also that no welding be done
47、when surface are wet. The preheated temperature shall be checked by the thermometer. 焊接前，从焊缝边缘算起，至少1英寸（25毫米）之内的表面纹路都应被清洁。焊缝周围3英寸（75毫米）之内的范围应用焊炬或其他工具预热到规定温度。当壳体金属温度低于华氏0 F (摄氏-20 C)时，推荐不要进行焊接。温度在华氏32 F (摄氏0 C) 和0 F (-20 C)之间时，焊缝周围3英寸（75毫米）范围内所有表面应预热至华氏60 F (15 C)以上。当表面是湿的时，推荐不要进行焊接。应用温度计检查预热温度。 8.5 The Shop Supervisor shall assign the experienced and qualified welders to perform welding. H