《-设备制造质量检验规程（Heat Exchangers Air Cooled）-.docx》由会员分享，可在线阅读，更多相关《-设备制造质量检验规程（Heat Exchangers Air Cooled）-.docx（9页珍藏版）》请在三一办公上搜索。
1、l,设备制造质量检验规程(HeatEXChangerSAirCooled),1、SGSRefNo.:05Rev.:0Page:lofIOINSPECTIONGIDELINESAIRCOOLEDHEATEXCHANGERDate:09/03/04INSPECTIONGUIDELINESAIRCOOLEDHEATEXCHANGEROForApproval09032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:05Rev.:0Page:2ofIOINSPE
2、CTIONGUIDELINESAIRC2、OoledheatEXCHANGERDate:09/03/04CONTENTSlPURPOSE2SCOPE3PROCEDURE4DOcumentssinspectionprocess6Shipping7aircooledheatEXCHANGERDATAD0SSIER8INSPECTI0NCHECKLISTSGSRefNo.:05Rev.:0Page:3ofIOINSPECTIONGUIDELINESAIRCOOLEDHEATEXCHANGERDate:09/03/041.0PURPOSEThisinstructioncoverstheinspect!
3、3、on,testandverificationactivitiesrequiredtovalidatethesupplmanufactureandtestofanAirCooledHeatExchanger.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofanAirCooledHeatExchangerfromtheexaminationofcertificationfromprocurementsourcestothefinal4、inspection,preservationandpackingtodespa
4、tchtosite.AlthoughthemethodologyincompilingthisinstructionistosystematicallyprogressthroughtheconstructionofatypicalAirCooledHeatExchanger.Experiencedinspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovel5、practicesortoutilisetheinstructionforaone-offzoralternativedesignofHeatExcha
5、ngenThedesignhavingbeenapprovedbytheclient.Anysuchvariationsshouldbenotedontheinspectorsreport.3.0PROCEDURES.1GENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonany6 、contractororder.ltisintendedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybe
6、invokedandthesectionstobeusedandthelevelofinspectionrequiredwillbeasspecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutag7 、ainsttheapproveddrawingszpurchaseorderspecificationszpurchasersorcompanystandards,andwithinthepracticesandrulesofthecountrstateorprovinceandanygovernmentdecrees,laws
7、,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethe8 nthemoreOnerousrequirementwillapplyunlessthepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications.Designcode(tobestatedoninspectionreport)Purchaseorderspecific
8、ationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppI9 、icablecodesandstandards(sampleonly)EN13706:2000API661ASMEVlllDivision14.0DOCUMENTSTOBEREC曰VED/AVAILABLEATINSPECTIONPurchaseOrderorContractinspectionandTestPlanITPDataSheetApproveddrawings,(arrangements)Sub-assemblyClrawingsMateriaItes
9、tCertificatesSGSRefNo.:05Rev.:0Pageio、:4ofioinspectionGuidelinesairCooledheatEXCHANGERDate：09/03/04TeStdataforfanszfanmotors,gearboxesetc.WeldproceduresandProcedureQualificationRecorcIsListofqualifiedweldersorweldingOperatorsWeIdersqualificationsCalibrationofmeasuringandtestequipmentNDEproceduresz(a
10、ppropriate11、tomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHeattreatmentprocedureHydrostatictestingprocedurewaterqualitydocumentpreparationandpaintingprocedurePreservationzpackingandshippingproceduresupplylist(packinglist)5.0INSPECTIONPR0CESS5.12、1MATERIA
11、L5.1.1REVIEWOFCERTIFICATIONOriginalorauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings:Thereviewwillincludecheckson:-ManufacturersnameandlocationCer13 、tificateNoMaterialSpecificationHeatorcas
12、tNoMakersNoorPlateNoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinishStructuralobservations,notabledefects.5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentificationoncertificatesa14 、gainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspec
13、ificationasappropriate.Transferidentificationtocutoffcomponentsz(CastNotransfer)zasspecified.Visualanddimensionalcompliancewithspecification.5.1.3ADDITIONAL/SPECIALREQUIREMENTSMayapplyonspecialcompon15 、ents,e.g.thickComponentszCladordissimilarmaterial,alloysteelsornonferrousmaterials.Checktoensures
14、pecificationcontractrequirementshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialchecksshouldinclude:-Conformationofsatisfactorydocumentrevi16 、ewRecordofendorsementofcertificationreviewed/witnessedSGSRefNo.:05Rev.:0Page:5ofIOINSPECTIONGUIDELINESAIRCOOLEDHEATEXCHANGE
15、RDate:09/03/04Recordofallnon-conformitiesRecordofanytestswitnessedandtheresult5.2HEATEXCHANGERFABRICATIONAfterclearanceofabovepointstosatisfac17、tionoftheinspectorzthenthefabricatorwillproceedwiththemanufactureofsub-assembliesandcomponentsoftheheatexchanger.lnspectorswillreviewthefollowingpointsonab
16、asistobeoutlinedinthePurchasersdocumentationJnspectionandtestplan,orotherdocumentzasnotifiedtotheinspect18or.5.2.1PREPARATIONFORWELDINGCarryoutvisualanddimensionalchecktoensurecompliancewithWPSandspecification.WherespecifiedzweldbevelsshallbeexaminedbyMTorPTaftergrinding/machining.Edgesandweldbevels
17、willbeclean,dryandfreefromsurfacedefects,laminations,cracks,voids,notch19es,etc.Theseshallbeacauseforrejectionunlesssuitable/satisfactoryremedialactioncanbetaken.Weldingrepairstobevelsarenotpermitted,withoutapprovalfromtheClientJnspectorsmustreportexcessiveorseriousdefects,5.2.2WELDINSPECTION5.2.2.1
18、EDGEPREPARATIONVisualanddimensionalch20、eckswillbeperformedinaccordancewiththeWPSandspecification.MTorPTwillbemadeoncutedgeasrequiredandedgesshallbefreefromIaminationzCrack,notch,etc.5.2.2.2FIT-UPINSPECTIONShapes,alignmentanddimensionswillbecheckedinaccordancewithapprovedWPSanddrawings.5.2.2.3VISUA2
19、1、LCHECKANDNDEGrOOVeandadjacentareamustbecleanandfreefromforeignmaterials7oil,paint,waterandrust,andwillbefreefrominjuriousdefectssuchascracks,andIaminationsJackweldswillbeperformedusingthesameprocedureofapplicableWPSandwillbefreefromdefects.NDEwillbeperfor22、medasrequiredforedgeandtackweld,5.2.2.4M
20、ONITORINGOFWELDPreheattemperatureandmethod,interpasstemperature,weldmaterialControLquaIifiedWPSandqualifiedwelderemployedzweldingOPeration,cleanlinesswillconformtoapprovedWPSandspecifications.5.2.2.5BACKGOUGINGINsPECTIONShapeand23、dimensionswillbecheckedinaccordancewithWPSandfreefromdefectandclean.N
21、DEwillbeperformedifrequired(MTorPT).5.2.2.6INSPECTIONOFCOMPLETEDWELDVisuaIinspectionwillbeperformedonthesurfaceofwelds.Checkareastobefreefromundercuts,overlaps,blow-holes,cracks,abruptridges24、orvalleysandtobemergedSmoothlywiththesurfacesjointed.5.2.2.7NONDESTRUCTIVEExaminationsgsRefNo.95Rev.:OPage：
22、6OfioinspectionGuidelinesairCooledheatEXCHANGERDate:09/03/04NDEWiIlbeperformedbyqualifiedpersonnelandtoqualifiedproceduresforweldjoint,tubetotube-sheetwelds,a25NndsurfacesafterremovaloftemporaryattachmentweldRootandfinalweldsinallmaterialseitherofsolidalloyoralloy-cladplatewillbeexaminedasrequiredby
23、theContract.Chemicalanalysis,ferritecheckorfreeironcheckwillbemadeasrequiredbythecontract.5.2.2.8WELDREPAIRAIIunacce26、ptabledefectsshallberepairedbyapprovedproceduresbeforePWHT.5.2.3POSTWELDHEATTREATMENTPWHTrecordWiIlbereviewedinaccordancewithapplicablecodeandapprovedprocedureforidentificationnumbG
24、date,heatingandcoolingrate,soakingtemperatureandtime.5.2.4HARDNESSTESTHardnessofwel27、dmetalandheataffectedzoneofpressureretainingweldsshallbeexaminedasrequired.5.2.5MOCK-PTESTOFTUBETOTUBE-SHEETWELDMock-uptestwillbemadewhenrequired.Identification,visualappearanceanddimensions,weldControIzPXsectionof
25、WeIdzMacro-Observation,hardnesscheckofweldmetal28、andheataffectedzonewillbecheckedasrequired.5.2.6VISUALANDDIMENSIONALINSPECTIONOFTUBES,TUBEBUNDLEANDSHELLVisuaIanddimensionalinspectionofTubeszTubeBundleandSheILVisuaIanddimensionalcheckwillbemadetothefollowingitemsateachstageoffabrication.Tubesheetan
26、dbaffle29、 plate,includingtubehole,heads,flanges,tubes,flangefacingfinish.Tubesafterbendingforthinningparticularlyonthebackofbends.Finnedtubeswillbevisuallyinspectedtoconfirmthatthetypeoffinningisinaccordancewiththecontractrequirementandtoensurethatassembledtubeshavenodam30、 ageinthefinnedareas.Dama
27、gedtubeswillberejectedforstraighteningorcorrectionbeforefinaltest.Channel,shell,floatinghead,coverztubebundleassembly.Templatecheckofshellwillbeperformedinaccordancewiththeapplicablespecificationsasrequired.Sizeandconstructionoftemplatearet31、Obecheckedzandthetemplatemustpasssmoothlwithoutbindingthr
28、oughthefulllengthoftheSheILDirectionandorientationofnozzle,impingementbaffles,lugsandeternal,internalfittingswillbechecked.Outofroundness,diameterjength,wallthickness,straightnessofshellwillbechecked.Expans32、ionratiooftubeendstobechecked.tubestobecheckedforthinningafterexpansion.SGSRefNo.:05Rev.:0P
29、age:7ofIOINSPECTIONGUIDELINESAIRCOOLEDHEATEXCHANGERDate:09/03/04U-tubewillbeformedfromasinglelengthhavingnocircumferentialwelds,andflatteningshallnotexceed10%ofthenominal33ODoftube.Tubesheetflatnessongasketcontactsurfacewillbecheckedasrequired.5.2.7TUBEBUNDLEINSERTIONTubebundleinsertionwillbecheckedasrequired.CleanIinessJnsertionwithoutbinding,contactoftubesheetandshellflangeandgasketusedshallbeconfirmed.5.2.8FANTESTAfterinstallationeachfanwillbetestedtoensurethatitiscorrectlyinstalled(correctdirectionofrotation)a
