焊接检验程序.docx

1、焊接检验程序焊接检验程序 Inspection and Test Procedure for Construction of RPLC Project RPLC 项目检查和测试程序 DOC.No.:F074-PI-0310-0001 Revision Status:C 18-07-13 Issue for Approval B 28-05-13 Issue for Approval A 17-04-13 Issue for Approval Rev.Date Description Prepared By Checked By Approved By HYUNDAI-WISON Client

2、Qin Yong Shi Xiangquan Zhang Shouyue Table of Contents 1 INTRODUCTION 简介 3 1.1 Purpose 3 1.2 Scope 3 1.3 Definitions and Abbreviations 3 2 PROCESS 5 3 GENERAL NOTICE 5 4 OVERVIEW 7 5 STEEL STRUCTURE 9 6 PAINTING,BLASTING,GALVENIZING 14 7 PIPING 17 8 EQUIPMENT 27 9 ELECTRICAL 29 10 INSTRUMENT 29 11 W

3、EIGHTING 30 12 LOAD OUT 30 13 DELIVERY 31 1 INTRODUCTION 简介简介 This document presents 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

4、 Quality Assurance Manager in accordance with the Project Specifications.本程序是项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 qu

5、ality of each product item can meet the requirement of contract,specifications 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 PDV

6、SA 的批准。1.2 Scope 前景展望前景展望 This ITP covers all BUILDER Fabrication yard inspection 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

7、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 定义和缩写代码定义和缩写代码 1.3.1 Definitions 定义定义 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 COMPANY Petroles De Venezuela,S.A.(PDVSA)CONTRACTOR A consortium formed by HYUNDAI ENGINEERIN

8、G&CONSTRUCTION CO.,LTD.,HYUNDAI ENGINEERING CO.,LTD.,and WISON ENGINEERING LTD.VENDOR Wison(Nantong)Heavy Industry(WHI)also referred to as“Wison”CLIENT COMPANYCONTRACTOR Hold Builder 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 W

9、itness Builder can proceed with the inspection/test when Contractors representatives is not present at the notified time.可以在通知时间自行检查 Surveillance Builder is not requested to notify Contractor/COMPANY.The Contractor/COMPANY inspector will monitor work in progress,test and inspections during his visit

10、 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 Review Builder shall 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 缩写代码缩写代码 The following abbreviations apply to this ITP document:下面的缩写代码适用

11、于本 ITP程序文档 API American Petroleum Institute 美国石油组织 ASME American Society of Mechanical Engineers 美国机械工程师学会 ASNT American Society of Non-Destructive Testing美国无损检测学会 AISC American Institute of Steel Construction 美国钢结构施工协会 ASTM American Society for Testing and Materials 美国材料检测学会 AWS American Welding So

12、ciety美国焊接学会 DC Digital Control 数位控制 DFT Dry Film Thickness 干膜厚度 DWG Drawing图纸 E&I Electrical&Instrumentation 电气仪表 RPLC Refinery Puerto La Cruz ID Identity ISO International Organization for Standardization 国际组织标准 ITP Inspection and Test Plan 检查测试计划 MPI Magnetic Particle Inspection 磁粉检查 NCR Non Confo

13、rmance Record 现场质量询问单 NDT Non Destructive Testing 无损检测 PEP Project Execution Plan 项目执行计划 PMI Positive Material Identification 光谱分析 PQR Procedure Qualification Record 工艺评定记录 PT Penetration Testing渗透 PWHT Post Weld Heat Treatment 焊接热处理 QA Quality Assurance 质量保证 QC Quality Control 质量控制 RT Radiographic

14、Testing射线探伤 UT Ultrasonic Testing超声探测 WHI Wison Heavy Industry惠生重工 WOM Wison Offshore&Marine 惠生海洋 WPS Welding Procedure Specification 焊接工艺评定 2 pROCESS 过程过程 The following 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/

15、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 一般一般 3.1 All inspection and testing items are to be performed 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

16、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 following 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 CONTRACT

17、ORs 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 to 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 no

18、tify 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“inspection record”with result and comments.The yard shall proceed next step or repair according to the result of survey.In order

19、 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

20、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 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

21、:H:Hold W:Witness S:Surveillance R:Review 4.0 Overview概述 4.1 Welding Procedure Specification焊接工艺评定 PQR WPS Welding Control Procedure F074-PI-0310-0002 AWS D1.1/1.8 ASME section IX Client SPEC.30510-02 Rev.2 HHRYY:YES 4.2 Welder Qualification焊工资质 Welder qualification test Review/approval of welders W

22、elder Management Procedure F074-PI-0310-0003 AWS D1.1/1.8 ASME section IX Clie 30510-03 Rev.1 HWS qualification nt SPEC.4.3 Material Control材料控制 Material receiving inspection Material inspection GB materials retest inspection by 3rd party Material traceability for members Layout for material storage

23、 Inspection of Incoming Materials Procedure F074-PI-0310-0004 Positive Material Identification Procedure F074-PI-0310-0005 Material Identification and Traceability Procedure F074-PI-0310-0035 Client SPEC.30503-41 Rev.1 30503-47 Rev.0 30516-02 Rev.3 30516-03 Rev.4 30516-04 Rev.3 30516-01 Rev.3 30516-

24、06 Rev.3 30508-01 Rev.2 HWS YY:YES 4.3 NDT personnel 无损检测人员 Review/approval of NDT operators qualification NDT personnel qualification Procedure F074-PI-0310-0006 Client SPEC.30528-02 Rev.0 HRR 4.5 Final submission 终交 Shop drawings/NDT drawings Quality plan and ITP Relevant procedures WPS and PQR Re

25、gister of qualified welders and NDT operators Project As-built Documents Control Procedure F074-PI-0310-0007 Client SPEC.N/A HRR As-built Inspection and test reports with summery list As-built drawings Material certificates 5.0 Steel Structure钢结构 5.1 Material receiving材料接收 Material ID/marking Quanti

26、ty Visual(surface,cut edge)Mill certificates Material grade Size Inspection of Incoming Materials Procedure F074-PI-0310-0004 Positive Material Identification Client SPEC.GB/T 700-2006 GB/T 1591-2008 30503-65 Rev.0 H W YY:YES Heat No.,Batch No.Mill sheet Procedure F074-PI-0310-0005 5.2 Material Re-t

27、esting inspection材料二次测试检验 Re-testing(high-strength steel)GB materials retest inspection by 3rd party Project procurement quality plan F074-PI-0305-0002 Client SPEC.30516-02 Rev.3 H W YY:YES 5.3 Cutting,beveling,transfer of identification,marking and material traceability Machining Cutting Beveling T

28、ransfer of identification Material traceability Positive Material Identification Procedure F074-PI-0310-0005 Client SPEC.30516-01 Rev.3 H S 5.4 Fit-up Prepara Structu Appr 30503HW inspection tion of edge Piece No.WPS No.Tack weld Alignment and straightness Assembly dimension Weld buttering re Fit-up

29、&visual Inspection Procedure F074-PI-0310-0009 Inspection Criteria Table F074-PI-0310-0055 oved WPS Client SPEC.-36 Rev.2 30503-39 Rev.1 5.5 Welding Control WPS approved Welding consumable control Welding equipment Preheat&post Welding Control Procedure F074-PI-0310-0002 Welding Consumables Control

30、Client SPEC.Approved PQR/WPS N/A HS heat,if necessary Run-on&run-off plates used Cleaning of welded surface Workmanship Weld profile/Tack weld Weld Repair:Removal of defect,Procedure F074-PI-0310-0010 5.6 Weld Visual Inspection Joint No./Welder No.Date of welded Crack/Undercut Welding Control Proced

31、ure F074-PI-0310-0002 Client SPEC.30503-44 Rev.2 HWS YY:YES Porosity/Arc strike/Spatter Reinforcement Lack of root surface Concave root 5.7 NDT Ultrasonic Testing is applicable to all weld types;Ultrasonic examination extent UT performance Ultrasonic examination procedure F074-PI-0310-0011 Client SP

32、EC.ASME Section V 30506-01 Rev.2 HWS YY:YES 5.8 NDT Radiographic Testing is applicable to butter welds only;Radiography procedure F074-PI-0310 Client SPEC.ASME Section V 30507-01 Rev.2 HRS YY:YES Radiography inspection extent RT performance Identification of film Radiographic film evaluation-0012 5.

33、9 NDT Magnetic particle and Liquid penetration inspection is applicable to the weld surfaces of each type of joints;Magnetic particle inspection procedure F074-PI-0310-0013 Liquid penetration procedure F074-PI-0310 Client SPEC.ASME Section V 30506-02 Rev.2 30505-01 Rev.1 HWS YY:YES-0014 5.10 Weld repair Approval of repair welding procedure Removal of defective welds Repair record,(if any NDT requi