Outline for Safety Performance Supervisory Inspection.docx

Outline for Safety Performance Supervisory Inspection.docx

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OutlineforSafetyPerformanceSupervisoryInspection

AppendixI

OutlineforSafetyPerformanceSupervisoryInspection

ofBoilerandPressureVesselProducts

A.BOILER

I.Applicablescope

Thisoutlineisthegeneralrequirementsforsupervisoryinspectionofthesafetyperformanceofstationarypressure-containingboilerswithwatermediumandorganicfluidHeatersandtheirparts.Thesupervisoryagencymayadjusttheitemsandcontentsbasedontheactualsituation.

II.Contentsofsupervisoryinspection

1.Supervisoryinspectingtheitemsrelatedtothesafetyperformanceoftheproductduringboilermanufacturing.

2.Supervisoryexaminingtheimplementationofthequalitysystemofthesupervisedmanufacturer

III.Itemsandmethodsofsupervisoryinspection

1.Drawinganddatareview

（1）Reviewthedesigndataoftheboilerproducts,

（2）Examinethestandardsandtechnologyforboilermanufactureandinspection;

（3）Reviewthestandardsandtechnologyfornon-destructiveexamination（NDE）;

（4）Reviewtheapprovalformalitiesofdesignchange（includingmaterialsubstitution）.

2.Manufacturequalityofdrum（shell）,furnace,tube-plate,reversecombustionchamber,verticalflueandlowersupportring

（1）Checkmaterialcertificateandmaterialre-testreport

（2）Checktheselectionandformalitiesofsubstitutematerials

（3）Checkthetransplantationofmaterialidentification

（4）Appearanceexamination（includingbasemetalsandwelds）

（5）Examineweldpositionandstaggerbetweentheabuttingwelds

（6）Checktheidentificationsteelstampofweldersandweldingoperators

（7）Spot-checkgeometricdimension（includingdifferencebetweenthemaximumandtheminimuminnerdiametersofcylinder,angularity,straightness,misalignmentandlocationofopening）

（8）Measurewallthicknessofcylindersandheads（tubeplate）（ifnecessary）

（9）Examinethenumberandmanufacturingmethodofweldingtestplate

（10）Checkpropertytestreportsofweldingproducttestplateandverifythetestresults

（11）CheckNDEreportandspot-checkthex-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthetotalnumberoffilms（filmsatcrossjoint,T-jointandatdoubtfulpositionandweldingrepairshouldbeincluded.

（12）Checkheattreatmentrecordsandreport

（13）Checkhydrostatic（pressure）test（includingtestingpressure,temperaturesoftestmediumandofenvironment,pressureraisingrate,pressuredwellingtimeandvalidationofpressuregaugecalibration）

（14）Checkthedimensionsandappearanceofopeningsfortube,therectificationoftubejointsandmachiningquality.

3.Supervisoryinspectionofmanufacturingqualityforheader

（1）Checkmaterialcertificateandmaterialre-testingreport

（2）Checktheselectionofsubstitutematerialsandmaterialsubstitutionformalities

（3）Examinethetransferofmaterialidentification

（4）Examinesurfacequality（includingweld）

（5）Wall-thicknessmeasurement（ifnecessary）

（6）Checktheidentificationsteelstampofwelders

（7）Checkspectrumanalysisreportofalloysteeltube,weldandofcomponentsandparts

（8）Verifyingthenumberandmanufacturingmethodofweldingtestplate

（9）Checkthemechanicalpropertytestreportoftheproductweldingtestplateandverifythetestresult

（10）CheckNDEreportandspotcheckx-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthetotalnumberoffilms

（11）Checkheattreatmenttechnologyandreport

（12）Checkhydrostatic（pressure）test（includingtestingpressure,temperaturesoftestingmediumandofenvironment,pressureraisingrate,dwellingtimeandthevalidationofcalibrationforpressuregauges）

（13）Examinetheopeningdimensionandsurfacequalityoftubehole,rectificationoftube-jointsandmachiningquality

4.Supervisoryinspectionofmanufacturingqualityfortubes

（1）Checkmaterialcertificateandmaterialre-testingreport

（2）Checktheselectionofsubstitutematerialsandmaterialsubstitutionformalities

（3）Checkthetransferofmaterialidentification

（4）Appearanceexamination（includingweld）

（5）Spot-checkgeometry（includingbendingqualityoftubesanddifferencebetweenthemaximumandtheminimuminnerdiameters）

（6）Reviewthespectrumanalysisreportforalloysteeltube,welds,componentsandparts

（7）Verifyingthenumberandmanufacturingmethodtubetestsamplesmadebyeithercuttingfromtubesorattachingwithtubes

（8）Checkthemechanicalpropertytestreportoftheproductweldingtestplateandverifythetestresult

（9）CheckNDEreportandspotcheckx-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthetotalnumberoffilms

（10）Conductsoundingoftubebyballs

（11）Checkhydrostatic（pressure）test（includingtestingpressure,temperaturesoftestmediumandofenvironment,pressureraisingrate,dwellingtimeandvalidationofcalibrationforpressuregauges）

5.Safetyappurtenance

Thenumber,specifications,typesandcertificatesofcomplianceofsafetyappurtenanceshouldmeettherelevantrequirements.

6.Thermaladjustingtestforsafetyperformanceofcompactoil-firedorgas-firedboilersinmanufacturer

（1）Checkifthetypesandspecificationsofsafetyvalves,pressuregaugesandwaterlevelindicatorsmeettherequirements.

（2）Checkifthewaterlevelcontroldevicesaresensitive

（3）Checkiftheover-pressureprotectiondevicesaresensitive

（4）Checkiftheignitionprogramcontrollersandfireextinguishprotectiondevicesaresensitive

（5）Checkiftheburnermatchestheboiler

7.Examinationofdeliverytechnicaldocumentofboilers

（1）Checkthedeliverytechnicaldocuments

（2）Checkthecontentsonnameplateandstampthesupervisoryinspectionsymbolonit

8.Supervisoryinspectiondata

Oncetheproducthaspassedthesupervisoryinspection,thesupervisoryinspectorshouldsummarizethedataandverifyingpapersintimeaccordingtotheSupervisoryInspectionItemsforSafetyPerformanceofBoilerProductsandissuetheSupervisoryInspectionCertificate.

9.Thesupervisoryinspectorshouldcheckthefollowingdocumentsofthesupervisedcompanies

（1）Qualitymanual

（2）Thelistofappointmentanddismissalofqualitysystempersonnel

（3）Thelistofqualifiedweldersandweldingoperatorsengagedinboilerwelding（includingqualifieditems,termofvalidityintheircertificatesandidentificationsteelstamp）

（4）ThelistofpersonnelengagedinNDE（includingqualifieditems,levelandtermofvalidityintheircertificates）

（5）Thelistofinspectorsengagedinboilerqualityinspection

（6）Boilerdesigndata,technologicaldocumentandinspectionandtestingreportandrecordandasummarizedtableofweldingprocedurequalification

（7）Supervisedmanufacturerproductionplanforboilers

（8）Sub-contractsforboilerproduction

B.PressureVessel

I.Applicablescope

Thisoutlineisappliedtothesupervisoryinspectiononsafetyperformanceofpressurevesselexceptforgascylinders.

II.Contentsofsupervisoryinspection

1.Supervisoryinspectingtheitemsrelatedtothesafetyperformanceoftheproductduringpressurevesselmanufacturing.

2.Supervisoryexaminingtheimplementationofthequalitysystemofthesupervisedmanufacturer

III.Itemsandmethodsofsupervisoryinspection

1.Drawinganddata

（1）Examinethecertificationofpressurevesseldesigner,conformtheeffectivenessofitsqualification

（2）Reviewtheeffectivenessofstandardsonmanufactureandinspectionforpressurevessel

（3）Reviewtheapprovalformalitiesfordesignchange（includingmaterialsubstitution）.

2.Materials

（1）Checkmaterialcertificateandmaterialre-testreport

（2）Checkthetransplantationofmaterialidentification

（3）Checktheselectionandformalitiesofsubstitutematerialsformainpressureparts

3.Welding

（1）Checktheweldingprocedurequalificationandtheirrecords,verifythattheweldingtechnologyusedinproductproductionisinaccordancewiththerelevantstandardsandcodes.

（2）Confirmthenumberandmanufacturingmethodoftheweldingtestplate.

（3）Checkthepropertytestreportoftheproductweldingtestplatesandconfirmthetestresults.

（4）Checkidentificationsteelstampsofweldersandweldingoperators.

（5）Checkformalitiesandproceduresforweldingrepair.

4.Visualanddimensionalexamination

（1）Examinetheappearanceofweldedjoints.

（2）Checkthemechanicaldamageonthesurfaceofbasemetal

（3）Checkthedifferencebetweenmaximumandminimumdiametersofshell.Checkthestraightnessofthecylinderofverticalvesselwithheightmorethan30meters,Checkthearrangementofweldsandthedeviationoffigureinheadandrecordtheiractualdimensions.Checkthemaindimensionsoftheformingpetalforsphericalvessels.

5.Non-destructiveexamination

（1）Checkx-rayfilmarrangementmapandNDEreport.VerifytheproportionandpositionofNDE.Forthespot-NDEpressurevessel,checktheextensionRTfortherepairedwelds.AsfortheUTorsurfaceflawdetection,thesupervisoryinspectorshouldconductrandomon-sitesupervisoryinspectioninadditioncheckingthereport.

（2）Checkthex-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthewholeandshouldnotlessthan10films（includingthex-rayfilmsatT-joint,doubtfulareaandattherepairedarea）.

6.Heattreatment

Checkandconfirmthecorrespondencebetweenheattreatmentcurveandactualheattreatmentparameterandprocedure.

7.Pressuretest

Beforepressuretest,confirmthatallrequireditemshavepassedthesupervisoryinspectionandthesupervisedmanufacturerhaskeptthetestimonyofthewhole-completedwork.Duringpressuretest,thesupe