-设备制造质量检验规程 Water Turbines-.docx

"设备制造质量检验规程WaterTurbines"1、SGSRefNo.:20Rev.:0Page:lof8INSPECTIONGIDELINESWAERTURBINEDate:19/03/041NSPECTloNGIDELINESWATERTURBINEOForApprovall9032022J.C.BrottonB.TremainB.TremainJune2022Rev.DescriptionDatePreparedCheckedApprovedDateSGSRefNo.:20Rev.:0Page:2of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/04CON2、TENTS1PURPOSE2SCOPE3PROCEDURE4DOCUMENTS5INSPECTIONPROCESS6SHIPPING7WATERTURBINEDATAD0SSIER8INSPECTI0NCHECK1.ISTSGSRefNo.:20Rev.:0Page:3of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/041.0PURPOSEThisinstructioncoverstheinspection,testandverificationactivitiesrequiredtovalidatet3、hesupply,manufactureandtestofaWaterTurbineforgeneraluse.2.0SCOPEThisinstructioncoversallnecessarystagesintheproductionofaWaterTurbinefromtheexaminationofcertificationfromprocurementsourcestothefinalinspection,preservationandpackingtodespatchtosite.Althoughthe4>methodologyincompilingthisinstructionistosystematicallyprogressthroughIheconstructionofatypicalWaterTurbine.ExperiencedJnspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticesortoutilisetheinstructionforaone-off,oralternativedesignofTur5、bine.Thedesignhavingbeenapprovedbytheclient.AnySuchvariationsshouldbenotedontheinspectorsreport.3.0PROCEDURES.1GENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonanycontractororder.ltisintendedtoactasaguidetotheinspectorinthecourseofthe6、inspectionprogramme.AnypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofInspectionrequiredwillbeasspecifiedonthechecklist.AIItestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecifications,purchasersorcompanystandards7、,andwithinthepracticesandrulesofthecountr½stateorprovinceandanygovernmentdecrees,laws,ordinanceorregulationasmayapply.lfanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreOnerousrequirementwillapplyunlessthepurchaserorclientdirectsOtherwis8、einwriting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications.Designcode(tobestatedoninspectionreport)PurchaseorderspecificationPurchasersstandardsApproveddrawingsSGScompanyStandardsAppIicabIecodesandstandards(sampleonly)JISB81034.0DOCUMENTSTOBEREC日VED/AVAILABLEA9、TINSPECTIONPurchaseOrderorContractinspectionandTestPIanDatasheetSub-assemblyClrawingsMateriaItestCertificatesWeIdproceduresandProcedureQualificationRecordsListofqualifiedweldersorweldingOperatorsSGSRefNo.:20Rev.:0Page:4of8INSPECTI0NGUIDELINESWATERTURBINEDate:19/03/04Welder10>squalificationsCalibrationofmeasuringandtestequipmentNDEprocedures,(appropriatetomaterialofconstruction)ListofqualifiedNDEoperators/inspectorsNDE/inspectorsqualificationsHydrostatictestingprocedureperformancetestprocedurepreparationandpaintingprocedurePreservationzpackingand11shippingproceduresupplylist(packinglist)5.0INSPECTIONPR0CESS5.1MATERIALS.1.1REVIEWOFCERTlFICATIONOriginaIorauthenticatedcopiesofcertificatesshouldbeavailableatthemanufacturerspremises.Theseshouldbeexaminedforcompliancewithspecificationsandwhereappropriate,drawings:Ther12、eviewwillincludechecksOni-ManufacturersnameandlocationCertificateNoMaterialSpecificationHeatorcastNoMakersNoorPlateNoChemicalcompositionMechanicalpropertiesHeattreatedconditionNDEappliedandresultsSurfacefinish5.1.2VISUALANDDIMENSIONALVERIFICATIONMateriaIidentifi13、cationoncertificatesagainstproductmarkings.Materialsuppliedagainstdrawing,materiallistandspecificationasappropriate.Visualanddimensionalcompliancewithspecification.5.1.3ADDITIONAL/SPECIALREQUIREMENTSMayapplyonspecialcomponents.Checktoensurespecificationcontractrequiremen14、tshavebeenmet.WitnessNDEexaminationsasnecessary.5.1.4REPORTINGReportingonthematerialchecksshouldinclude:ConformationofsatisfactorydocumentreviewRecordofendorsementofcertificationreviewed/witnessedRecordofallnon-conformitiesRecordofanytestswitnessedandtheresultSGS15、RefNo.:20Rev.:0Page:5of8INSPECTI0NGIDELINESWATERTURBINEDate:19/03/045.2WATERTURBINEMANUFACTUREAfterclearanceoftheabovepointstothesatisfactionoftheinspector,thefabricatorwillproceedwiththemanufactureofthesubassembliesandcomponentsfortheWaterTurbine.5.2.!FABRICATION16INSPECTIONFollowingthecompletionofweldingandmachiningoperationstheTurbinepartswillbeinspectedasrequiredbythespecificationorcontract.Theinspectionwillconsistof:VisualinspectionfordamageDimensionalchecktodrawingrequirementInspectionofparts,forcleanlinessVisualexami17、nationofweldedonconnectionsReviewofwelderqualificationsReviewofweldprocedurerecordConfirmationofsatisfactoryNDEProperdocumentationofthematerialsusedExamination/inspectionofintegralpartssuchasreductiongears5.2.2HYDROSTATICTESTSTheturbinecasingandotherpressurecont18、ainingpartswillbehydrostaticallytested.Theinspectormustverifythatthecorrecttestpressurehasbeenappliedtotherelevantpartsdependingonspecificationrequirements.5.2.3CLEARANCECHECKSAftercompletionoffabricationtherequiredclearanceswillbecheckedinaccordancewiththespecif19、icationrequirementinparticulartheareastobeexaminedare:RadialclearancebetweenrotorandcasingAxialclearancebetweentherotorbladesandstationaryparts5.2.4MECHANICALRUNNINGTESTManyturbinesaresubjectedtoamechanicalrunningtest.WhererequiredbythecontractOrpurchaseordert20、hefollowingitemswillbeCheckediCriticaIspeedBearingtemperaturesVibrationNoisetest5.2.5FINALVISUALEXAMINATIONAftercompletionofalltestingavisualexaminationincludingapartialstripdownoftheunitisusuallyrequiredbytheSpecificationTheparticularareasofinterestare:Surface21 、roughnessVaneprofilesInternalcleanlinessLocation/orientationofterminalflangesSGSRefNo.:20Rev.:0Page:6of8INSPECTI0NGUIDELINESWATERTURBINEDate:19/03/045.3NAMEPLATEContentstobecheckedinaccordancewiththeapproveddrawingsandspecificationsandstamped/markedinaccordancetoclien22 、tsrequirements.5.4PAINTINGCOATINGINSPECTIONSurfacepreparationforpaintingwillbecheckedforthefollowingattributesaccordingtothespecification:CleaningmethodblastingzscrapingandwirebrushingPreparationgradeFreedomfromweldspatter,blowholesandotherdefects.Humidityandsteelte23、mperaturestobecheckedpriortopaintingPaintmanufacture,typeandcolourtobecheckedagainstclientsspecificationDryfilmpaintthicknesstobecheckedaccordingtospecification.Surfaceconditiontobefreefrompin-holes,runs,damageorotherdiscontinuity.5.5SPAREPARTS,LOOSEItemsandacc24ESSORIESSpareparts,looseitemsandaccessorieswillbecheckedvisuallyandfordimensionsmaterials,workmanshipandquantityaccordingtopurchaseorderspecificationtestmarksandtagswillbecheckedforcorrectidentification.5.6REPORTANDRELEASE5.6.1REPORTINGAfinalreportsummarisingtheact25Nivitiescarriedoutwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthetimelimitslaiddowninthecontract.Thereportwillbeinaformatapprovedbytheclientandmustclearlyindicatethefinalacceptanceorrejectionofthewaterturbine.5.6.2RELEASENOTEWherer26、equiredbythecontractareleasedocumentwillbeissuedtothemanufacturerwhenthewaterturbinehasbeenfinallyaccepted.6.0SHIPPING6.1PREPARATIONANDPACKINGThefollowingpointsmustbechecked:AIIexteriormachinedsurfacesmustbecoatedwithrustpreventativeAllinternalsurfaceswhichare27>susceptibletocorrosionmustbecoatedwithrustpreventativeAllflangedopeningsshouldbefittedwithmetalprotectorsinaccordancewiththespecificationAllthreadedconnectionsmustbeprovidedwithsteelplugsCheckmanualsandinstructionsareincludedasthespecificationrequirementsPack28>ingstyleandsuitabilityforoverseasshipmentShippingmarksarecorrectPre-assembledsystemsaremarkedasrequiredbytheSpecificationSGSRefNo.:20Rev.:0Page:7of8INSPECTI0NGUIDELINESWATERTURBlNEDate:19/03/047.0WATERTURBINESDATADOSSIERThefollowingfinaldocumentswillbereviewedande29、ndorsedasnecessary.ManufacturersdatareportsMaterialCertificationDimensionaIrecordNDEreportsHydrostatictestreportsRotorbalancereportclearancecheckreportRun-testreportsPerformancetestFinalinspectionreportMarkingsPackinglistSparePartsSGSRefNo.:20Rev.:0Page:8ofSinspectionguideli30、NeswaterTURBINEDate:19/03/048.01NSPECTloNCHECKLISTINSPECTIONCHECKList(I)VISUALinspection/witnessingbybuyerREPRESENTATIVE(2)CERTIFICATESRECORDSTOBECHECKEDBYBUYERREPRESENTATIVE(3)CERTIFICATESDATATOBEPROVIDEDBYVENDORSPPLIERMANUFACTRERPre-FabricationProductionRequirementsSpec31、ificationDetails/NotesPurchaseOrderRequirementsInspection&TestPIan(ITP)WeIdProceduresSpecification(WPS)SProcedureQualificationRecords(PClR)WeIderQualificationRecordsNDTPersonnelandProceduresPumpPerformanceProceduresln-ProcessInspection&TestingRequirementsMateriaITestCertificates&ld32、entificationTurbineCasingInspectionSHydrauIicTestsRotorInspectionSBaIancingMechanicaIRunningTestFinaIVisualExaminationNDERecords(ifapplicable)NameplateIdentityReviewCalibrationCertificatesPaintingCoatingInspectionSparesWeIdFitUpsandConditions(ifapplicable)FinalInspection&TestingRequirementsVisual&DimensionalCheckMarkingShippingReviewofDataDocumentationPackageAdditionalZSuppIementaryRequirementsPreparationSPacking