1、SGS Ref No.:03Rev.:0Page:1 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/04INSPECTION GUIDELINESSHELL BOILER OFWELDED CONSTRUCTION0 For Approval 04/03/2004 J.C.Brotton B.Tremain B.Tremain June 2004Rev.Description Date Prepared Checked Approved DateSGS Ref No.:03Rev.:0Page:2
2、of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/04CONTENTS1 PURPOSE2 SCOPE3 PROCEDURE4 DOCUMENTS5 INSPECTION PROCESS6 SHIPPING7 SHELL BOILER DATA DOSSIER8 CERTIFICATE OF CONFORMITY9 INSPECTION CHECK LISTSGS Ref No.:03Rev.:0Page:3 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED
3、 CONSTRUCTIONDate:04/03/041.0 PURPOSEThis instruction covers the inspection,test and verification activities required to validate thesupply,manufacture,and test of all Shell Boilers.2.0 SCOPEThis instruction covers all necessary stages in the production of the Shell Boiler from theexamination of cer
4、tification from procurement sources to the final inspection,preservation andpacking to despatch for site.Although the methodology in compiling this instruction is to systematically progress through theconstruction of a typical Shell Boiler.Experienced inspectors may interpret the intent of theinstru
5、ction to accommodate local or novel practices or to utilise the instruction for a one-off,oralternative design of boiler,the design having been approved by the client.Any such variationsshould be noted on the inspectors report.Most boilers are constructed under one of the wellknown national codes wh
6、ich require an inspecting authority to survey production.Thisinstruction is based in the requirements of such a code.It assumes that the design parametershave been reviewed and approved.3.0 PROCEDURE3.1 GENERALThis instruction together with its associated check sheet may be used on any contract or o
7、rder.It is intended to act as a guide to the inspector in the course of the inspection programme.Anypart of the document may be invoked and the sections to be used and the level of inspection willbe specified on the check list.All tests and inspections will be carried out against the approved drawin
8、gs,purchase orderspecifications,purchasers or company standards,and within the practices and rules of thecountry,state or province and any government decrees,laws,ordinance or regulation as mayapply.If any conflict or contradictions should be apparent in any of the above then the more onerousrequire
9、ment shall apply unless the purchaser or client directs otherwise in writing.3.2 REFERENCE DOCUMENTSApplicable codes and specifications.Design code(to be stated on inspection report)Purchase order specification Purchasers standards Approved drawings SGS company standardsApplicable codes and standard
10、s(sample only)EN 12953:2003 ASME I AS 1229-1990SGS Ref No.:03Rev.:0Page:4 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/044.0 DOCUMENTS TO BE RECEIVED/AVAILABLE AT INSPECTIONPurchase order or contractBoiler Inspection and Test Plan ITPBoiler data sheetApproved drawings,(arra
11、ngements)Sub-assembly drawingsMaterial test certificatesWeld procedures and Procedure Qualification RecordsProduction weld test requirementsList of qualified welders or welding operatorsWelders qualificationsRepair proceduresNDE procedures,(appropriate to material of construction)List of qualified N
12、DE operators/inspectorsNDE/inspectors qualificationsHeat treatment procedureCalibration records for testing measuring equipmentHydrostatic testing procedure,water quality documentPreparation and painting procedurePreservation,packing and shipping procedureSpares/operating manualsSupply list(packing
13、list)5.0 INSPECTION PROCESS5.1 MATERIAL5.1.1 REVIEW OF CERTIFICATIONOriginal or authenticated copies of mill certificates will be available at manufacturers premises.These should be examined for compliance with specifications and where appropriate,drawings.The review will include:Makers name and loc
14、ation Material Specification Certificate No.,Grade,size and wall thickness Heat or cast No.Chemical composition Mechanical properties Heat treated condition NDE applied and results Surface finish Structural observations,notable defects5.1.2 VISUAL AND DIMENSIONAL VERIFICATIONMaterial identification
15、on certificates against product markings.Material supplied against drawing,material list and specification as appropriate.Transfer identification to cut off components,(Cast No transfer),as specified.Visual and dimensional compliance with specification.5.1.3 ADDITIONALSPECIAL REQUIREMENTSMay apply o
16、n special components,check to ensure that contract requirements have been met.Witness any NDE examination as necessary.SGS Ref No.:03Rev.:0Page:5 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/04SGS Ref No.:03Rev.:0Page:6 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTR
17、UCTIONDate:04/03/045.1.4 REPORTINGReporting on material checks must include:Confirmation of satisfactory document review Record of the endorsement of certificate reviewed/witnessed Record of all non-conformities Record of tests witnessed and the result5.2 FABRICATION OF SHELL BOILERSAfter clearance
18、of above points to satisfaction of the inspector,then the fabricator will proceedwith the manufacture of sub-assemblies and components of the Shell Boiler.Inspectors will review the following points on a basis to be outlined in the applicable NationalStandard,purchasers documentation,quality plan,te
19、st and inspection plan,or other document,as notified to the inspector.5.2.1 PREPARATION FOR WELDINGCarry out visual and dimensional check to ensure compliance with WPS and specification/Code.Where specified weld bevels will be examined by required code method after grinding/machining.Edges and weld
20、bevels will be clean,dry and free from surface defects.Laminations,cracks,voids,notches,etc.These will be cause for rejection unlesssuitable/Satisfactory remedial action can be taken.Weld repairs must be carried in accordancewith The Code requirements and approved by the client before welding procee
21、ds.Serious orExcessive defects must be reported.5.2.2 WELD INSPECTION 5.2.2.1 EDGE PREPARATION Visual and dimensional check will be formed in accordance with WPS and specifications MT or PT should be carried out in the cut edges as required.Edges must be free fromlaminations,cracks,notches etc5.2.2.
22、2 FIT UP INSPECTION.Shapes,dimension and alignments will be checked in accordance with approved WPS,drawingand specifications/code5.2.2.3 VISUAL CHECK AND NON-DESTRUCTIVE EXAMINATION The prepared groove and adjacent area will be clean and free from foreign materials,oil,paint,water and rust.The prep
23、ared edge will be re-examined to ensure no defects have been exposed during final preparation.Tack welds will be produced using the applicable WPS conditions and will be visual free from defects.Non destructive examination will be performed in accordance with the code requirements.5.2.2.4 MONITORING
24、 OF WELD CONDITIONS Preheat heat temperature and method,Interpass temperatures weld material control,welderand process qualifications will be checked for conformity to code requirements and monitoredSGS Ref No.:03Rev.:0Page:7 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/045
25、.2.2.5 BACK GOUGING INSPECTIONThe shape and dimension of the back gouged grooves will be checked for conformity to theWPS requirement.The visual appearance must be clean and free from defects.NDE examination will be in accordance with code/clients requirements5.2.2.6 POST WELD INSPECTIONAfter comple
26、tion of all welding and grinding operations a visual examination will confirm thereare no harmful defects such as cracks,lack of fusion,surface porosity or exposed slaginclusions,incomplete penetration,incorrect profile of the weld,lack of leg length and overlap.Temporary attachments will be removed
27、,ground smooth,and the areas checked for defects byMP or PT.5.2.2.7 NON DESTRUCTIVE EXAMINATIONNDE will be performed by qualified personnel to approved techniques.The techniques availableare dependent on vessels classification and the materials used.Check that the correct method has been used and ve
28、rify the approved status of bothTechniques and the personnel.5.2.2.8 WELD REPAIRSWeld repairs will be completed using an approved WPS method and retested accordingly.All repairs will be approved before any hydraulic testing is carried out.5.2.2.9 DIMENSIONAL MEASUREMENTS AND VISUALL EXAMINATIONA dim
29、ensional check covering all major dimensions and the position/orientation ofattachments will be carried out in accordance with the code and drawing requirements.In addition a full visual examination of both inside where practicable and outside surfacesof the vessel will be completed.Particular atten
30、tion should be paid to the cleanliness of theinterior of the vessel,the condition/appearance of welds and associated areas and the condition of sealing faces.5.2.3.PNEUMATIC TEST Nozzle reinforcing pads,supports saddles or other attachments shall be examined when specified by an approved low pressur
31、e pneumatic test procedure using soapy water as theindicating medium5.2.4 HYDRAULIC TESTING Check all previous items have been accepted by authorised bodies.Code requirements which specify testing will be witnessed The following items will be verified.Calibration status and correct working ranges of
32、 gauges.A minimum of 2 pressure gauges will be attached to item under test.Adequate provision for venting of high points and drains will be provided Test pressure shall be applied as directed by procedure or code until test limiting pressure isreached.During hold period,a methodical check for leaks
33、will be conducted.Test pressure,metal and water temperature will be recorded.SGS Ref No.:03Rev.:0Page:8 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/04 Water quality will be specified.5.2.5 POST HYDRAULIC TESTINGAfter depressurisation,shell boiler components will be drained
34、 and dried to meet specified requirements.Stamping of Inspection Authority stamps,will be carried out in approved area,as required by Client/code.Stamps used shall be low stress type.Application of desiccant/preservative will be directed in clients specification and checked by the inspector.5.2.6 FI
35、NAL ASSEMBLY INSPECTION After hydraulic testing,the boiler will be thoroughly drained and dried out by approved Methods.All internal fittings,attachments,coatings or other requirements will be completed.Specified post hydraulic test NDE will be completed and boiler closed.The boiler will be checked
36、for completeness and dimensionally examined to ensure that allattachments/supports are in the correct orientation.5.3 MARKINGIdentification marks will be checked and information stamped using low stress type stamps onpressure parts.5.4 NAME PLATEThe name plate will be checked to ensure it contains a
37、ll the information required by thereferencing specification/code.5.5 PAINTINGSurface preparation and painting will be checked for the following points:Correct cleaning method usedPreparation to the correct gradeSurfaces to be free from weld spatter,blow holes and other defectsa Humidity and steel te
38、mperature to be checked prior to painting b Paint manufacture,type and colour to be checked to clients specification c Dry film thickness to be checked according to specification d Surface condition to be free from pin-holes,runs,damage and other discontinuitySGS Ref No.:03Rev.:0Page:9 of 11INSPECTI
39、ON GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/045.6 SPARE PARTS,LOOSE ITEMS AND ACCESSORIESSpare parts,loose items and accessories will be checked visually and for dimensions,materialsworkmanship and quantity according to the purchase order or contract requirement.list.Marking and or Tag
40、 shall be checked for identification5.7 REPORT AND RELEASE5.7.1 REPORTINGA final report summarising the activities carried out will be issued in accordance with the contractrequirements and circulated with in the time limits laid down.The report will be in a format approved by the client and must cl
41、early indicate the finalacceptance or rejection of shell boilers.5.7.2 RELEASE NOTEWhen required by the contract a release document will be issued and issued to theManufacturer when the shell boilers have been finally accepted.6.0 SHIPPING6.1 PREPARATION AND PACKINGThe following points shall be chec
42、ked.Cleanliness and dryness of boiler components Rust prevention for all machined surfaces Protection for cover for all openings and protruding parts Packing style to be in accordance with contract requirements Shipping marks correctly and properly applied7.0 SHELL BOILER DATA DOSSIER7.1 SHELL BOILE
43、R FABRICATION DOSSIER The following final document will be reviewed and endorsed as necessary Certificate of Conformity Record of agreed deviations As Built Drawings Material List and Certificates Weld Procedures and Records NDE Procedures and Reports Hydraulic Test Certificates Rubbing of Nameplate
44、 stamping details The above item may be added to according to the requirements of the country/state of construction.8.0 CERTIFICATE OF CONFORMITY A certificate of conformity will be issued and countersigned by the Inspection Authority stating that boiler has been designed,constructed and tested in a
45、ccordance with the SGS Ref No.:03Rev.:0Page:10 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/04 relevant national standard.SGS Ref No.:03Rev.:0Page:11 of 11INSPECTION GUIDELINESSHELL BOILERSOFWELDED CONSTRUCTIONDate:04/03/049.0 INSPECTION CHECK LISTINSPECTION CHECK LIST(1)VI
46、SUAL INSPECTION/WITNESSING BY BUYER REPRESENTATIVE(2)CERTIFICATES/RECORDS TO BE CHECKED BY BUYER REPRESENTATIVE(3)CERTIFICATES/DATA TO BE PROVIDED BY VENDOR/SUPPLIER/MANUFACTURERPre-Fabrication/Production Requirements Specification Details/NotesInspection&Test Plan(ITP)Data SheetApproved Drawings(Ar
47、rangements)Sub-Assembly DrawingsWeld Procedures Specification(WPS)&Procedure Qualification Records(PQR)Welder Qualification RecordsNDT Personnel and ProceduresIn-Process Inspection&Testing RequirementsMaterial Test Certificates&IdentificationWeld Edge PreparationFit Up InspectionMonitoring Weld Cond
48、itionsWeld Back Gouging InspectionPost Weld InspectionNDE ExaminationWeld RepairsPost Weld Heat TreatmentVisual&Dimensional ExaminationPneumatic TestHydraulic TestingPost Hydraulic Testing/InspectionReview Calibration CertificatesFinal Inspection&Testing RequirementsVisual&Dimensional CheckNameplate StampingMarkingPainting/Coating InspectionSpares&AccessoriesReview of Vessel Data DossierAdditional/Supplementary RequirementsPreparation&Packing
