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    设备制造质量检验规程 Water Turbines.docx

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    设备制造质量检验规程 Water Turbines.docx

    1、设备制造质量检验规程WaterTurbines1、SGSRefNo.:20Rev.:0Page:lof8INSPECTIONGIDELINESWAERTURBINEDate:19/03/041NSPECTloNGIDELINESWATERTURBINEOForApprovall9032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:20Rev.:0Page:2of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/0

    2、4CON2、TENTS1PURPOSE2SCOPE3PROCEDURE4DOCUMENTS5INSPECTIONPROCESS6SHIPPING7WATERTURBINEDATAD0SSIER8INSPECTI0NCHECK1.ISTSGSRefNo.:20Rev.:0Page:3of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatet3、hesupply,manufac

    3、tureandtestofaWaterTurbineforgeneraluse.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofaWaterTurbinefromtheexaminationofcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.Althoughthe4methodologyincompilingthisinstructionistosystematicallyp

    4、rogressthroughIheconstructionofatypicalWaterTurbine.ExperiencedJnspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone-off,oralternativedesignofTur5、bine.Thedesignhavingbeenapprovedbytheclient.AnySuchvariationsshouldbenotedontheinspectorsrepo

    5、rt.3.0PROCEDURES.1GENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonanycontractororder.ltisintendedtoactasaguidetotheinspectorinthecourseofthe6、inspectionprogramme.AnypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofInspectionrequiredwillbeasspecifiedonthechecklist.A

    6、IItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecifications,purchasersorcompanystandards7、,andwithinthepracticesandrulesofthecountrstateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovet

    7、henthemoreOnerousrequirementwillapplyunlessthepurchaserorclientdirectsOtherwis8、einwriting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleo

    8、nly)JISB81034.0DOCUMENTSTOBEREC日VED/AVAILABLEA9、TINSPECTIONPurchaseOrderorContractinspectionandTestPIanDatasheetSub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresandProcedureQualificationRecordsListofqualifiedweldersorweldingOperatorsSGSRefNo.:20Rev.:0Page:4of8INSPECTI0NGUIDELINESWATERTURBI

    9、NEDate:19/03/04Welder10squalificationsCalibrationofmeasuringandtestequipmentNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHydrostatictestingprocedureperformancetestprocedurepreparationandpaintingprocedurePreservationzpackingand11

    10、shippingproceduresupplylist(packinglist)5.0INSPECTIONPR0CESS5.1MATERIALS.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings:Ther12、eviewwillincludechecksOni-Ma

    11、nufacturersnameandlocationCertificateNoMaterialSpecificationHeatorcastNoMakersNoorPlateNoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinish5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentifi13、cationoncertificatesagainstproductmarkings.Materialsuppliedagai

    12、nstdrawing,materiallistandspecificationasappropriate.Visualanddimensionalcompliancewithspecification.5.1.3ADDITIONAL/SPECIALREQUIREMENTSMayapplyonspecialcomponents.Checktoensurespecificationcontractrequiremen14、tshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialcheck

    13、sshouldinclude:ConformationofsatisfactorydocumentreviewRecordofendorsementofcertificationreviewed/witnessedRecordofallnon-conformitiesRecordofanytestswitnessedandtheresultSGS15、RefNo.:20Rev.:0Page:5of8INSPECTI0NGIDELINESWATERTURBINEDate:19/03/045.2WATERTURBINEMANUFACTUREAfterclearanceoftheabovepoint

    14、stothesatisfactionoftheinspector,thefabricatorwillproceedwiththemanufactureofthesubassembliesandcomponentsfortheWaterTurbine.5.2.!FABRICATION16INSPECTIONFollowingthecompletionofweldingandmachiningoperationstheTurbinepartswillbeinspectedasrequiredbythespecificationorcontract.Theinspectionwillconsisto

    15、f:VisualinspectionfordamageDimensionalchecktodrawingrequirementInspectionofparts,forcleanlinessVisualexami17、nationofweldedonconnectionsReviewofwelderqualificationsReviewofweldprocedurerecordConfirmationofsatisfactoryNDEProperdocumentationofthematerialsusedExamination/inspectionofintegralpartssuchas

    16、reductiongears5.2.2HYDROSTATICTESTSTheturbinecasingandotherpressurecont18、ainingpartswillbehydrostaticallytested.Theinspectormustverifythatthecorrecttestpressurehasbeenappliedtotherelevantpartsdependingonspecificationrequirements.5.2.3CLEARANCECHECKSAftercompletionoffabricationtherequiredclearancesw

    17、illbecheckedinaccordancewiththespecif19、icationrequirementinparticulartheareastobeexaminedare:RadialclearancebetweenrotorandcasingAxialclearancebetweentherotorbladesandstationaryparts5.2.4MECHANICALRUNNINGTESTManyturbinesaresubjectedtoamechanicalrunningtest.WhererequiredbythecontractOrpurchaseordert

    18、20、hefollowingitemswillbeCheckediCriticaIspeedBearingtemperaturesVibrationNoisetest5.2.5FINALVISUALEXAMINATIONAftercompletionofalltestingavisualexaminationincludingapartialstripdownoftheunitisusuallyrequiredbytheSpecificationTheparticularareasofinterestare:Surface21 、roughnessVaneprofilesInternalcle

    19、anlinessLocation/orientationofterminalflangesSGSRefNo.:20Rev.:0Page:6of8INSPECTI0NGUIDELINESWATERTURBINEDate:19/03/045.3NAMEPLATEContentstobecheckedinaccordancewiththeapproveddrawingsandspecificationsandstamped/markedinaccordancetoclien22 、tsrequirements.5.4PAINTINGCOATINGINSPECTIONSurfacepreparatio

    20、nforpaintingwillbecheckedforthefollowingattributesaccordingtothespecification:CleaningmethodblastingzscrapingandwirebrushingPreparationgradeFreedomfromweldspatter,blowholesandotherdefects.Humidityandsteelte23、mperaturestobecheckedpriortopaintingPaintmanufacture,typeandcolourtobecheckedagainstclients

    21、specificationDryfilmpaintthicknesstobecheckedaccordingtospecification.Surfaceconditiontobefreefrompin-holes,runs,damageorotherdiscontinuity.5.5SPAREPARTS,LOOSEItemsandacc24ESSORIESSpareparts,looseitemsandaccessorieswillbecheckedvisuallyandfordimensionsmaterials,workmanshipandquantityaccordingtopurch

    22、aseorderspecificationtestmarksandtagswillbecheckedforcorrectidentification.5.6REPORTANDRELEASE5.6.1REPORTINGAfinalreportsummarisingtheact25Nivitiescarriedoutwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthetimelimitslaiddowninthecontract.Thereportwillbeinaformatapprovedbythec

    23、lientandmustclearlyindicatethefinalacceptanceorrejectionofthewaterturbine.5.6.2RELEASENOTEWherer26、equiredbythecontractareleasedocumentwillbeissuedtothemanufacturerwhenthewaterturbinehasbeenfinallyaccepted.6.0SHIPPING6.1PREPARATIONANDPACKINGThefollowingpointsmustbechecked:AIIexteriormachinedsurfaces

    24、mustbecoatedwithrustpreventativeAllinternalsurfaceswhichare27susceptibletocorrosionmustbecoatedwithrustpreventativeAllflangedopeningsshouldbefittedwithmetalprotectorsinaccordancewiththespecificationAllthreadedconnectionsmustbeprovidedwithsteelplugsCheckmanualsandinstructionsareincludedasthespecifica

    25、tionrequirementsPack28ingstyleandsuitabilityforoverseasshipmentShippingmarksarecorrectPre-assembledsystemsaremarkedasrequiredbytheSpecificationSGSRefNo.:20Rev.:0Page:7of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/047.0WATERTURBINESDATADOSSIERThefollowingfinaldocumentswillbereviewedande29、ndorsedasne

    26、cessary.ManufacturersdatareportsMaterialCertificationDimensionaIrecordNDEreportsHydrostatictestreportsRotorbalancereportclearancecheckreportRun-testreportsPerformancetestFinalinspectionreportMarkingsPackinglistSparePartsSGSRefNo.:20Rev.:0Page:8ofSinspectionguideli30、NeswaterTURBINEDate:19/03/048.01N

    27、SPECTloNCHECKLISTINSPECTIONCHECKList(I)VISUALinspection/witnessingbybuyerREPRESENTATIVE(2)CERTIFICATESRECORDSTOBECHECKEDBYBUYERREPRESENTATIVE(3)CERTIFICATESDATATOBEPROVIDEDBYVENDORSPPLIERMANUFACTRERPre-FabricationProductionRequirementsSpec31、ificationDetails/NotesPurchaseOrderRequirementsInspection&

    28、TestPIan(ITP)WeIdProceduresSpecification(WPS)SProcedureQualificationRecords(PClR)WeIderQualificationRecordsNDTPersonnelandProceduresPumpPerformanceProceduresln-ProcessInspection&TestingRequirementsMateriaITestCertificates&ld32、entificationTurbineCasingInspectionSHydrauIicTestsRotorInspectionSBaIanci

    29、ngMechanicaIRunningTestFinaIVisualExaminationNDERecords(ifapplicable)NameplateIdentityReviewCalibrationCertificatesPaintingCoatingInspectionSparesWeIdFitUpsandConditions(ifapplicable)FinalInspection&TestingRequirementsVisual&DimensionalCheckMarkingShippingReviewofDataDocumentationPackageAdditionalZSuppIementaryRequirementsPreparationSPacking


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