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1、 Inspection and Test Procedurefor Construction of RPLC ProjectRPLC项目检查和测试程序 DOC. No.: F074-PI-0310-0001Revision Status:C18-07-13Issue for ApprovalB28-05-13Issue for ApprovalA17-04-13Issue for ApprovalRev.DateDescriptionPrepared ByChecked ByApproved ByHYUNDAI-WISONClientQin YongShi XiangquanZhang Sho
2、uyueTable of Contents1INTRODUCTION简介31.1Purpose31.2Scope31.3Definitions and Abbreviations32PROCESS 53GENERAL NOTICE54OVERVIEW75STEEL STRUCTURE96PAINTING, BLASTING, GALVENIZING147PIPING178EQUIPMENT279ELECTRICAL2910INSTRUMENT2911WEIGHTING3012LOAD OUT3013 DELIVERY 311 INTRODUCTION简介This document presen
3、ts the Wison (Nantong) Heavy Industry (BUILDER) Project Fabrication Inspection and Test Plan (ITP) for the module of RPLC Deep Conversion Project.本程序介绍的是惠生重工RPLC项目的关于生产检查和试验计划。The ITP is prepared and managed by the Project Quality Assurance Manager in accordance with the Project Specifications.本程序是项
4、目质量保证经理根据项目的特殊说明而啊指定的。1.1 Purpose目的To describe the inspection and test items during the project construction period and define the “Hold point”or “Witness point”or “Review Point”or “Surveillance Point” to ensure that the quality of each product item can meet the requirement of contract, specificatio
5、ns and drawings. This Inspection Test Plan (ITP) shall be issued for HIWIN (CONTRACTOR) and/or PDVSA (COMPANY) approval as required.本程序是在项目施工期间，为了描述检查和测试项目以及定义“节点控制”或者“见证点”、“检查点”、“监测点”来确保产品质量满足合同需要，满足图纸的说明。此ITP程序文件必须经过HWIN和PDVSA的批准。1.2 Scope前景展望This ITP covers all BUILDER Fabrication yard inspection
6、 and test items for the piperack module of RPLC Deep Conversion Project. The ITP must ensure compliance with the requirements of Production drawings, specifications, contract and relevant standards. 此ITP包含RPLC项目部管廊模块所有预制厂房的检查和测试项目。此ITP必须确保遵守生产图纸，说明以及合同相关标准的需要。1.3 Definitions and Abbreviations 定义和缩写代
7、码1.3.1 Definitions定义 The following definitions apply to this Project Inspection and Test Plan:下面的定义适用于此项目的检查和测试计划COMPANYPetroles De Venezuela, S.A. (PDVSA)CONTRACTORA consortium formed by HYUNDAI ENGINEERING & CONSTRUCTION CO., LTD., HYUNDAI ENGINEERING CO., LTD., and WISON ENGINEERING LTD.VENDORWis
8、on (Nantong) Heavy Industry (WHI) also referred to as “Wison”CLIENTCOMPANYCONTRACTORHoldBuilder is not allowed to proceed with the inspection/test unless a written release is issued by the Contractor.必须有总包批准方可检查WitnessBuilder can proceed with the inspection/test when Contractors representatives is n
9、ot present at the notified time.可以在通知时间自行检查 SurveillanceBuilder is not requested to notify Contractor / COMPANY. The Contractor / COMPANY inspector will monitor work in progress, test and inspections during his visit or periodical inspection. 不需要通知总包和甲方，总包和甲方的检查员将会周期性的监督工作的进程测验和检查ReviewBuilder shall
10、 provide Contractor and or Company with certificates, reports and records as applicable for review.分包需要提供可用的证书，报告和记录给甲方和总包1.3.2 Abbreviations缩写代码 The following abbreviations apply to this ITP document:下面的缩写代码适用于本ITP程序文档APIAmerican Petroleum Institute美国石油组织ASMEAmerican Society of Mechanical Engineers
11、美国机械工程师学会ASNTAmerican Society of Non-Destructive Testing美国无损检测学会AISCAmerican Institute of Steel Construction美国钢结构施工协会ASTMAmerican Society for Testing and Materials美国材料检测学会AWSAmerican Welding Society美国焊接学会DCDigital Control数位控制DFTDry Film Thickness干膜厚度DWGDrawing图纸E&IElectrical & Instrumentation电气仪表RPL
12、CRefinery Puerto La CruzIDIdentityISOInternational Organization for Standardization国际组织标准ITPInspection and Test Plan检查测试计划MPIMagnetic Particle Inspection磁粉检查NCRNon Conformance Record现场质量询问单NDTNon Destructive Testing无损检测PEPProject Execution Plan项目执行计划PMIPositive Material Identification光谱分析PQRProcedur
13、e Qualification Record工艺评定记录PTPenetration Testing渗透PWHTPost Weld Heat Treatment焊接热处理QAQuality Assurance质量保证QCQuality Control质量控制RTRadiographic Testing射线探伤UTUltrasonic Testing超声探测WHIWison Heavy Industry惠生重工WOMWison Offshore & Marine惠生海洋WPSWelding Procedure Specification焊接工艺评定2 PROCESS过程The following
14、Fabrication ITP Work sheets identify the following processes:下面的ITP制作工作表印证了下面的程序； Overview概况 Steel Structure钢结构 Painting/Blasting/Galvanizing涂漆、喷砂和镀锌 Piping管道 Equipment设备 Electrical电气 Instrument仪表 Insulation保温 Load out外运 Delivery运送3 GENERAL 一般3.1 All inspection and testing items are to be performed
15、in accordance with Project Specification, relevant rules and Regulations specified in Specification。所有的检查和检验项目必须与工程的相关说明，相关特殊的规章制度保持一致。3.2 According to the construction schedule, QA/QC shall notify the CONTRACTORs and/or COMPANYs representative to attend the inspection and/or testing as the followin
16、g procedure:根据施工日程表，质量检查和控制人员必须通知总包和业主的代表去参加检查和检验根据以下程序；a. ”Daily inspection application form” shall be submitted to CONTRACTORs and/or COMPANYs representative before 17:00 by email one day before yard carried out inspection or test. Inspections scheduled on Weekend or during National Holiday have t
17、o be submitted two days before. 日常的检查申请表必须在检查的前一天下午5点之前通过邮件发送给总包或业主代表；检查计划在周末和假期的需要提前两天申报； b. If schedule changed, QA/QC shall notify the CONTRACTORs and/or COMPANYs representative as early as possible. 如果检查日期变更，QA/QC人员需尽早通知业主和总包代表；3.3 The CONTRACTORs and/or COMPANYs representative shall sign on the
18、 “inspection record” with result and comments. The yard shall proceed next step or repair according to the result of survey. In order to enhance effectively working progress, re-inspection will be based on the comments of first inspection.业主和总包代表需要检查签字做好记录以及备注。根据检查结果，对产品进行下一步的推动工作或修改。为了加强工作效率，二次检验将会
19、根据第一次检查的备注来实施。3.4 The CONTRACTORs and/or COMPANYs representative shall attend inspection and testing as”H”, and “W”, in plan. 业主和总包方将会根据检查计划表里的“H”和“W”来参加价差测试3.5 Builder shall provide all the notification to CONTRACTORs and/or COMPANYs representative as”H” and “W” in plan.过程中，生产方必须给出业主和总包方“H”和“W”3.6
20、The CONTRACTORs and/or COMPANYs representative inspection shall be carried out after internal inspection of WHI.业主和总包方将会在惠生自检之后进行检查测验； Remark: H: Hold W: Witness S:Surveillance R: Review 4.0 Overview概述4.1Welding Procedure Specification焊接工艺评定l PQRl WPSl Welding Control ProcedureF074-PI-0310-0002l AWS
21、 D1.1/1.8l ASME section IXl Client SPEC.l 30510-02 Rev.2HHRYY:YES4.2Welder Qualification焊工资质l Welder qualification testl Review/ approval of welders qualificationl Welder Management ProcedureF074-PI-0310-0003l AWS D1.1/1.8l ASME section IXl Client SPEC.l 30510-03Rev.1HWS4.3 Material Control材料控制l Mat
22、erial receiving inspectionl Material inspectionl GB materials retest inspection by 3rd partyl Material traceability for membersl Layout for material storagel Inspection of Incoming Materials ProcedureF074-PI-0310-0004Positive Material Identification Procedure F074-PI-0310-0005l Material Identificati
23、on and Traceability ProcedureF074-PI-0310-0035l Client SPEC.l 30503-41 Rev.1l 30503-47 Rev.0l 30516-02 Rev.3l 30516-03 Rev.4l 30516-04 Rev.3l 30516-01 Rev.3l 30516-06 Rev.3l 30508-01 Rev.2HWSYY:YES4.3NDT personnel无损检测人员l Review / approval of NDT operators qualificationl NDT personnel qualification P
24、rocedureF074-PI-0310-0006l Client SPEC.l 30528-02Rev.0HRR4.5Final submission终交l Shop drawings / NDT drawingsl Quality plan and ITPl Relevant procedures WPS and PQRl Register of qualified welders and NDT operatorsl As-built Inspection and test reports with summery listl As-built drawings Material cer
25、tificatesl Project As-built Documents Control ProcedureF074-PI-0310-0007l Client SPEC.l N/AHRR5.0 Steel Structure钢结构5.1Material receiving材料接收l Material ID/ markingl Quantityl Visual (surface , cut edge )l Mill certificatesl Material gradeSizel Heat No., Batch No.l Mill sheetl Inspection of Incoming
26、Materials ProcedureF074-PI-0310-0004 l Positive Material Identification ProcedureF074-PI-0310-0005l Client SPEC.l GB/T 700-2006l GB/T 1591-2008 l 30503-65 Rev.0HWSYY:YES5.2Material Re-testing inspection材料二次测试检验l Re-testing (high-strength steel)l GB materials retest inspection by 3rd partyl Project p
27、rocurement quality planF074-PI-0305-0002l Client SPEC.l 30516-02Rev.3HWSYY:YES5.3Cutting , beveling , transfer of identification , marking and material traceabilityl Machiningl Cuttingl Bevelingl Transfer of identificationl Material traceabilityl Positive Material Identification ProcedureF074-PI-031
28、0-0005l Client SPEC.l 30516-01Rev.3HSS5.4Fit-up inspectionl Preparation of edgel Piece No. l WPS No.l Tack weldl Alignment and straightnessl Assembly dimensionl Weld butteringl Structure Fit-up & visual Inspection ProcedureF074-PI-0310-0009l Inspection Criteria Table F074-PI-0310-0055l Approved WPSl
29、 Client SPEC.l 30503-36 Rev.2l 30503-39 Rev.1HWS5.5Welding Controll WPS approvedl Welding consumable controll Welding equipmentl Preheat & post heat , if necessaryl Run-on & run-off plates usedl Cleaning of welded surfacel Workmanshipl Weld profile/ Tack weldl Weld Repair: Removal of defect, l Weldi
30、ng Control ProcedureF074-PI-0310-0002l Welding Consumables Control ProcedureF074-PI-0310-0010l Client SPEC.l Approved PQR/WPSl N/AHSS5.6Weld Visual Inspectionl Joint No./ Welder No.l Date of weldedl Crack/ Undercutl Porosity/ Arc strike/ Spatterl Reinforcementl Lack of root surfacel Concave root l W
31、elding Control ProcedureF074-PI-0310-0002l Client SPEC.l 30503-44 Rev.2HWSYY:YES5.7NDTl Ultrasonic Testing is applicable to all weld types;l Ultrasonic examination extentl UT performancel Ultrasonic examination procedureF074-PI-0310-0011l Client SPEC.l ASME Section V l 30506-01Rev.2HWSYY:YES5.8NDTl
32、Radiographic Testing is applicable to butter welds only;l Radiography inspection extentl RT performancel Identification of filml Radiographic film evaluationl Radiography procedureF074-PI-0310-0012l Client SPEC.l ASME Section V l 30507-01Rev.2HRSYY:YES5.9NDTl Magnetic particle and Liquid penetration
33、 inspection is applicable to the weld surfaces of each type of joints;l Magnetic particle inspection procedureF074-PI-0310-0013l Liquid penetration procedureF074-PI-0310-0014l Client SPEC.l ASME Section V l 30506-02Rev.2l 30505-01Rev.1HWSYY:YES5.10Weld repairl Approval of repair welding procedurel R
34、emoval of defective weldsl Repair record , (if any NDT required after repair)l Welding Repair ProcedureF074-PI-0310-0015l Client SPEC.l ASME Section Vl ASME Section IX l Approved PQR/WPSl 30506-02 Rev.2l 30507-01 Rev.2l 30506-01 Rev.2HWSYY:YES5.11Dimensional controll Rolled tubularl Nodes l Panelsl
35、Assembled blocksl Completed jacketl Piles and legsl Flatnessl Erection dimensional l Structure and Pipeline Dimensional Control ProcedureF074-PI-0310-0016l Heat Straightening ProcedureF074-PI-0310-0017l Client SPEC.l Inspection CriteriaTable F074-PI-0310-0055l 30503-39 Rev.1HWSYY:YES5.12Release chec
36、kl Before blasting: l Overall visual / Dimensionl NDT/ Any tests requiredl Delivery checkl Overall visual/ Dimensionl Paintingl NCR clearancel Release Check ProcedureF074-PI-0310-0018l Control of Non-conforming ProcedureF074-PI-0310-0019l Client SPEC.N/AHWSYY:YES5.13PWHT( if applicable )l Equipmentl
37、 Performancel Records & curve chartl Post Weld Heat Treatment ProcedureF074-PI-0310-0020l Client SPEC.l ASME B31.3 l 30503-13 Rev.2HWSYY:YES6.0 Painting/Blasting/Galvanizing6.1Receiving inspection of coating materiall Paint batch No. Paint manufacturers specificationsl Paint certificatesl Abrasive m
38、ateriall Packing conditionl Inspection of Incoming Materials ProcedureF074-PI-0310-0004l Client SPEC.l 30503-47 Rev.0HWSYY:YES6.2Surface preparationl Cleanliness : SSPC-SP5 -SP6 SSPC-SP7 -SP10 SSPC-SP11l Blasting method: Dry blastingl Blasting condition l Surface Preparation and Painting Inspection
39、ProcedureF074-PI-0310-0021l Client SPEC.l ISO8501l SSPC-SP5/SP6 -SP7/SP10 -SP11l 30517-02 Rev.2HWSYY:YES6.3Painting Inspection andCoating thickness(D.F.T)l Applicable area Coat Systeml Film Thickness (D.F.T)l Defect repairl Surface Preparation and Painting Inspection ProcedureF074-PI-0310-0021l Colo
40、r coding ProcedureF074-PI-0310-0022l Client SPEC.l SSPC-PA 2l 30517-02 Rev.2HWSYY:YES6.4Inspection of adhesionl Adhesion test shall be checked at 3 pointsl Surface Preparation and Painting Inspection ProcedureF074-PI-0310-0021l Client SPEC.l ASTM D 3359l SSPCl 30517-02Rev.2HWSYY:YES6.5Inspection of
41、Holidayl Holiday check with a Holiday Detectorl Repair defects and re-inspectl Painting Repair ProcedureF074-PI-0310-0023l Client SPEC.l ASTM G 62l SSPCl NACEl 30517-02Rev.2HWSYY:YES6.6Repairl Damaged portion shall be thoroughly cleaned by blasting , power tools or sandpaperl Painting Repair Procedu
42、reF074-PI-0310-0023l Client SPEC.l SSPCl NACE30517-02 Rev.2After repair, re-inspectionHWSYY:YES6.7Handlingl Protection of coated surface during lifting and handling operationsl Surface Preparation and Painting Inspection ProcedureF074-PI-0310-0021l Client SPEC.N/AWSS6.8Hot-Dip Galvanizingl Structure
43、 preparing before galvanizingl Galvanizingl Repair the damaged surface:l Washing with fresh water;l Cleanliness: SSPC-SP3;l Cleaning by solvent washing;l Brush the specified paint.l Galvanizing control procedureF074-PI-0310-0024l Client SPEC.l AASTM A 53/A 53Ml ASTM A 153/A 153Ml ASTM A 123/A123Ml 30583-01 Rev.1HWSYY:YES7.0 Piping7.1Material receiving SUPPLYBY CONTRACTORl Material ID/ markingl Quantityl Visual (surface , cut edge )l Material gradeSizel Heat No., Batch No.l Material test certificatel Materials and Equipments of client Inspection ProcedureF074-PI-0310-0025 l Client SPECl ASME
