Outline for Safety Performance Supervisory Inspection.docx

1、Outline for Safety Performance Supervisory InspectionAppendix IOutline for Safety Performance Supervisory Inspection of Boiler and Pressure Vessel ProductsA. BOILERI. Applicable scopeThis outline is the general requirements for supervisory inspection of the safety performance of stationary pressure-

2、containing boilers with water medium and organic fluid Heaters and their parts. The supervisory agency may adjust the items and contents based on the actual situation.II. Contents of supervisory inspection1. Supervisory inspecting the items related to the safety performance of the product during boi

3、ler manufacturing.2. Supervisory examining the implementation of the quality system of the supervised manufacturerIII. Items and methods of supervisory inspection1. Drawing and data review(1) Review the design data of the boiler products,(2) Examine the standards and technology for boiler manufactur

4、e and inspection;(3) Review the standards and technology for non-destructive examination (NDE);(4) Review the approval formalities of design change (including material substitution).2. Manufacture quality of drum (shell), furnace, tube-plate, reverse combustion chamber, vertical flue and lower suppo

5、rt ring(1) Check material certificate and material re-test report(2) Check the selection and formalities of substitute materials(3) Check the transplantation of material identification(4) Appearance examination (including base metals and welds)(5) Examine weld position and stagger between the abutti

6、ng welds(6) Check the identification steel stamp of welders and welding operators(7) Spot-check geometric dimension (including difference between the maximum and the minimum inner diameters of cylinder, angularity, straightness, misalignment and location of opening)(8) Measure wall thickness of cyli

7、nders and heads (tube plate) (if necessary)(9) Examine the number and manufacturing method of welding test plate(10) Check property test reports of welding product test plate and verify the test results(11) Check NDE report and spot-check the x-ray films. The number of the x-ray films being checked

8、should not be less than 30 per cent of the total number of films (films at cross joint, T-joint and at doubtful position and welding repair should be included.(12) Check heat treatment records and report(13) Check hydrostatic (pressure) test (including testing pressure, temperatures of test medium a

9、nd of environment, pressure raising rate, pressure dwelling time and validation of pressure gauge calibration)(14) Check the dimensions and appearance of openings for tube, the rectification of tube joints and machining quality.3. Supervisory inspection of manufacturing quality for header(1) Check m

10、aterial certificate and material re-testing report(2) Check the selection of substitute materials and material substitution formalities(3) Examine the transfer of material identification(4) Examine surface quality (including weld)(5) Wall-thickness measurement (if necessary)(6) Check the identificat

11、ion steel stamp of welders(7) Check spectrum analysis report of alloy steel tube, weld and of components and parts(8) Verifying the number and manufacturing method of welding test plate(9) Check the mechanical property test report of the product welding test plate and verify the test result(10) Chec

12、k NDE report and spot check x-ray films. The number of the x-ray films being checked should not be less than 30 per cent of the total number of films (11) Check heat treatment technology and report(12) Check hydrostatic (pressure) test (including testing pressure, temperatures of testing medium and

13、of environment, pressure raising rate, dwelling time and the validation of calibration for pressure gauges)(13) Examine the opening dimension and surface quality of tube hole, rectification of tube-joints and machining quality4. Supervisory inspection of manufacturing quality for tubes(1) Check mate

14、rial certificate and material re-testing report(2) Check the selection of substitute materials and material substitution formalities(3) Check the transfer of material identification(4) Appearance examination (including weld)(5) Spot-check geometry (including bending quality of tubes and difference b

15、etween the maximum and the minimum inner diameters)(6) Review the spectrum analysis report for alloy steel tube, welds, components and parts(7) Verifying the number and manufacturing method tube test samples made by either cutting from tubes or attaching with tubes(8) Check the mechanical property t

16、est report of the product welding test plate and verify the test result (9) Check NDE report and spot check x-ray films. The number of the x-ray films being checked should not be less than 30 per cent of the total number of films(10) Conduct sounding of tube by balls(11) Check hydrostatic (pressure)

17、 test (including testing pressure, temperatures of test medium and of environment, pressure raising rate, dwelling time and validation of calibration for pressure gauges)5. Safety appurtenanceThe number, specifications, types and certificates of compliance of safety appurtenance should meet the rele

18、vant requirements.6. Thermal adjusting test for safety performance of compact oil-fired or gas-fired boilers in manufacturer(1) Check if the types and specifications of safety valves, pressure gauges and water level indicators meet the requirements.(2) Check if the water level control devices are se

19、nsitive(3) Check if the over-pressure protection devices are sensitive(4) Check if the ignition program controllers and fire extinguish protection devices are sensitive(5) Check if the burner matches the boiler7. Examination of delivery technical document of boilers(1) Check the delivery technical d

20、ocuments (2) Check the contents on nameplate and stamp the supervisory inspection symbol on it8. Supervisory inspection dataOnce the product has passed the supervisory inspection, the supervisory inspector should summarize the data and verifying papers in time according to the Supervisory Inspection

21、 Items for Safety Performance of Boiler Products and issue the Supervisory Inspection Certificate.9. The supervisory inspector should check the following documents of the supervised companies(1) Quality manual(2) The list of appointment and dismissal of quality system personnel(3) The list of qualif

22、ied welders and welding operators engaged in boiler welding (including qualified items, term of validity in their certificates and identification steel stamp)(4) The list of personnel engaged in NDE (including qualified items, level and term of validity in their certificates)(5) The list of inspecto

23、rs engaged in boiler quality inspection(6) Boiler design data, technological document and inspection and testing report and record and a summarized table of welding procedure qualification(7) Supervised manufacturer production plan for boilers(8) Sub-contracts for boiler productionB. Pressure Vessel

24、 I. Applicable scopeThis outline is applied to the supervisory inspection on safety performance of pressure vessel except for gas cylinders.II. Contents of supervisory inspection 1. Supervisory inspecting the items related to the safety performance of the product during pressure vessel manufacturing

25、.2. Supervisory examining the implementation of the quality system of the supervised manufacturerIII. Items and methods of supervisory inspection1. Drawing and data(1) Examine the certification of pressure vessel designer, conform the effectiveness of its qualification(2) Review the effectiveness of

26、 standards on manufacture and inspection for pressure vessel(3) Review the approval formalities for design change (including material substitution).2. Materials(1) Check material certificate and material re-test report(2) Check the transplantation of material identification (3) Check the selection a

27、nd formalities of substitute materials for main pressure parts3. Welding(1) Check the welding procedure qualification and their records, verify that the welding technology used in product production is in accordance with the relevant standards and codes.(2) Confirm the number and manufacturing metho

28、d of the welding test plate.(3) Check the property test report of the product welding test plates and confirm the test results.(4) Check identification steel stamps of welders and welding operators.(5) Check formalities and procedures for welding repair.4. Visual and dimensional examination(1) Exami

29、ne the appearance of welded joints.(2) Check the mechanical damage on the surface of base metal(3) Check the difference between maximum and minimum diameters of shell. Check the straightness of the cylinder of vertical vessel with height more than 30 meters, Check the arrangement of welds and the de

30、viation of figure in head and record their actual dimensions. Check the main dimensions of the forming petal for spherical vessels. 5. Non-destructive examination(1) Check x-ray film arrangement map and NDE report. Verify the proportion and position of NDE. For the spot-NDE pressure vessel, check th

31、e extension RT for the repaired welds. As for the UT or surface flaw detection, the supervisory inspector should conduct random on-site supervisory inspection in addition checking the report.(2) Check the x-ray films. The number of the x-ray films being checked should not be less than 30 per cent of

32、 the whole and should not less than 10 films (including the x-ray films at T-joint, doubtful area and at the repaired area).6. Heat treatmentCheck and confirm the correspondence between heat treatment curve and actual heat treatment parameter and procedure.7. Pressure testBefore pressure test, confirm that all required items have passed the supervisory inspection and the supervised manufacturer has kept the testimony of the whole-completed work. During pressure test, the supe