設備監(jiān)造的最低要求

1、CHONG QING MDI COMPLEX PROJECT重慶市MDI 體化項目CHANGSHOU ECONOMIC AND TECHNOLOGICAL DEVELOPMENT ZONE長壽經濟技術開發(fā)區(qū)MINIMUM REQUIREMENTS FOR EQUIPMENTS MANUFACTURING QUALITY SURVEILLANCE 設備監(jiān)造的最低要求Document No 文件編號：CQMCP1-0000-QTA-SPC-023C0Issued for Use發(fā)布供使用涂萬鴻08/31/2011丁景運09/01/2011曹秋平09/01/2011Graham W9/01/2011

2、發(fā)布版 次IssueRev發(fā)布或修改情況Issue or Revision Description編制人Origin by日期Date校核人Check by日期Date審核人Approve by日期Date批準人Authorize by日期Date本文件持有者This Document is Owned byOPMT QA/QC Department Manager聯合管理團隊質量部經理PAPER COPIES ARE UNCONTROLLED. THIS COPY WAS VALID AT THE TIME IT WAS PRINTED. FOR AN UP-TO-DATE COPY, PL

3、EASE VISIT CQMCP1NET硬拷貝為非受控文件，只表明其印制時為有效版本，最新版本請查閱局域網站版本號Revisi on修改內容Change Descripti on修訂位置Change Locati on目錄 TABLE OF CONTENTS1.0范圍SCOPE 32.0目的PURPOSE 33.0定義DEFINITIONS 34.0 責任RESPONSIBILITIES 錯誤!未定義書簽。5.0 參考文件REFERENCED DOCUMENTS 錯誤!未定義書簽。6.0 監(jiān)造原則及最低監(jiān)造等級錯誤!未定義書簽。SURVEILLANCE PRINCIPLE/ MINIMUM S

4、URVEILLANCE LEVELS 錯誤!未定義書 簽。6.1 監(jiān)造原則Surveillance Principle錯誤!未定義書簽。6.2 壓力容器和換熱器 Pressure Vessels and Heat Exchangers .錯誤!未定義書 簽。6.3 動設備Rotating Equipment.錯誤!未定義書簽。7.0 附錄ANNEX 錯誤!未定義書簽。ANNEX 1 設備監(jiān)造原貝U SURVEILLANCE PRINCIPLES .7Annex 2靜設備最低監(jiān)造要求Minimum surveilla nee requireme nts for static equipment8

5、Annex 3泵的最低監(jiān)造要求Minimum surveillanee requirements for pumps .-10Annex 4壓縮機的最低監(jiān)造要求Minimum surveillanee requirements for compressors .12Annex 5分供泵和壓縮機主要部件的最低監(jiān)造要求Mi nimum surveilla nee requireme ntsfor main components of sub-supplied pump and e ompressor 141.0 范圍 SCOPE本規(guī)范定義了在重慶化醫(yī)項目執(zhí)行階段應用于承壓設備供貨商工作監(jiān)督的最低要

6、求。This specification defines the minimum level of surveillanee to be applied to the work of suppliers of pressure containing equipme nt duri ng the impleme ntati on phase of the CCPHC Project.本規(guī)范將用于制造的設備，如壓力容器、換熱器、泵和壓縮機。This specification shall be applied to fabricated equipment, such as pressure ve

7、ssels, heat excha ngers, pumps, compressors.雖然本程序沒有逐一說明，但是其他設備如往復式壓縮機、汽輪機、燃氣輪機、燃燒加熱 器、鍋爐、閥門、散裝管材、嵌入式設備如混合機和過濾器等都將按照類似監(jiān)造要求進行Although not specifically covered by this specification, other items such as reciprocating compressors, steam turb in es, gas turb in es, fired-heaters, boilers, valves, pip ing

8、 bulks, in-line items such as mixers and strainers etc. shall be developed similar surveillance requireme nts.EPC/EP承包商應按照監(jiān)造活動規(guī)范進行。EPC/EP con tractor or supplier shall meet all requireme nts in this procedure.2.0 目的 PURPOSE本程序目的是建立承壓設備供應商設備監(jiān)造的一個通用方法。The purpose of this specificati on is to establish

9、 a com mon approach to surveilla nce of suppliers of pressure containing equipme nt.3.0 定義 DEFINITIONS關鍵性等級Criticality Rat ing在設計、制造和故障后果方面評估一個設備的重要性A method of assess ing the importa nce of an item with respect to its desig n, manufacture and con seque nce of failure.監(jiān)造Surveilla nceOPMT和/或EPC/EP承包商

10、監(jiān)督檢驗設備供貨商的設 計、制造，檢查測試活動，確保其符合項目和規(guī)定要求Mon itori ng by OPMT and/or EPC/EP Con tractor of suppliers desigma nu facturi ng, in spect ion and test activities to en sure complia nce to Project and Statutory requireme nts.PMI用儀表檢定公稱合金組成Verification of nominal alloy composition by means of in strume ntatio n

11、.帶位號項目Tagged Item指定唯一標記號的設備或特殊管道，如壓力容器、換熱器、 泵、壓縮機、成包單元、控制泄壓閥、伸縮接頭和列在設備 清單、特殊管道清單和儀表一覽表中的其他項目Equipme nt or special pip ing item allocated a unique tag number e.g. pressure vessel, heat exchanger, pump,compressor, packaged un it, con trol and relief valves, expa nsion joint, and any other items listed

12、 in equipme nt list, special pip ing item list or in strume nt schedule.散裝材料Bulk Items購買的散裝材料，各個條目不指定唯一的標記號，如，板、 任意長度的管子、閥門、配件、法蘭、未加工的收集器和過 濾器。Materials purchased in bulk where in dividual items are not allocated a unique tag nu mber, e.g. plate, ran dom len gth pipe, valves, fitt in gs, flan ges, n

13、on-process traps and strai ners.W:見證點W: Witness Point見證點是制造和試驗的一個鑒定步驟，供應商應在操作前10個工作日通知 CCPHC/買方以便CCPHC或買方代表能夠見 證。CCPHC或買方代表的見證活動是可選的而非強制性的。 當給出一定的百分比(如10 %),檢驗活動應根據這個規(guī)定的百分比進行現場見證。如果CCPHC或買方代表不能出席， 供應商可以通過見證點繼續(xù)其后的工作，在這種情況下，供 應商應提交見證點的控制和檢驗記錄以備CCPHC或買方代表審查。Witness points are defined as critical steps

14、in manufacturing and testing, whereby suppliers shall advise CCPHC/Buyer ten (10) working days in advance of the operati on so that it may be wit nessed by CCPHC/Buyer represe ntatives. The wit ness activities of CCPHC/Buyer represe ntatives are not man datory but opti on al. When the perce ntage e.

15、g. W10% is specified, the in specti on has to be site proved based on the perce ntage specified. The suppliers may proceed with work past the wit ness point on ly if CCPHC/Buyer represe ntatives cannot atte nd.Inthe event suppliers shall provide the con trol and in spect ion record for review by in

16、spector.I :隨機抽查I: Ran dom in spect ionCCPHC/買方代表有權隨時對產品的制造進行不定期檢查或 抽查。CCPHC/Buyer represe ntatives have authority to non-scheduled in spect ion an d/or spot-check for product manu facture at any mome nt.H:停工待檢點H: Hold Poi nt停工待檢點疋制造和試驗的個鑒疋步驟，供應商有乂務在 操作前10個工作日(國內)或 45個工作日(國外)通知 CCPHC/買方以便CCPHC或買方代表能夠

17、見證(除非在其 他監(jiān)督檢驗計劃中另有規(guī)定)。如果沒有CCPHC或買方代表的見證，供應商不能通過停工待檢點繼續(xù)其后的工作，除非 事先得到CCPHC/Buyer的書面冋意書。Hold points are defined as critical steps in manufacturing and test ing whereby suppliers is obligated to advise CCPHC/Buyer ten (10) worki ng days for on shore an d/or forty-five (45) worki ng days for offshore (un

18、i ess stated otherwise in the Surveilla nce In spect ion Pla n) in adva nceof the operation so that it can be witnessed by CCPHC/Buyer represe ntatives. The suppliers cannot proceed with work past the hold point without wit ness by CCPHC/Buyer represe ntatives, except by prior writte n Agreeme nt fr

19、om CCPHC/Buyer.R:文件審查點R: Docume nt ReviewPoi nt供貨廠商可以在進行上述活動前向檢驗員提交相關文件以 征求意見，也可以根據實際情況，向檢驗員提交或提供控制 與檢測的實施結果以備審查。The supplier can submit the releva nt docume nt to in spector for comme nts before the above activities are performed and also they can, based on the facts, delivery or provide the result

20、 of con trol and in spect ion for review.4.0 責任 RESPONSIBILITIESOPMT和/或EPC/EP 承包商負責制定設備監(jiān)造的技術標準和要求，并確保這些要求符 合重慶化醫(yī)項目要求。OPMT an d/or EPC/EP Con tractor is resp on sible for sett ing up surveilla nee specificati on and requireme nts of quality supervisi on, and for en suri ng that such requireme nts are

21、 in accorda nee with Project requireme nts.執(zhí)行檢驗測試的責任由承接采購訂單和分包合同的供貨商或者分承包商承擔。Equipme nt supplier/sub-supplier is resp on sible to en sure all manu facturi ng process meeti ng quality surveilla nee specificati on and requireme nts in this procedure.OPMT和/或EPC/EP 承包商在審查供應商/分包商質量計劃中，應考慮最低監(jiān)造要求 和停工待檢點、檢驗

22、測試點，強調這里規(guī)定的要求是最低要求，不考慮供應商執(zhí)行情況或 者成本或計劃對項目的影響。OPMT an d/or EPC/EP Con tractor shall, in review of Supplier/Subco ntractor Quality Pla ns, con sider the mi nimum surveilla nee requireme nts and in dicate required Hold, Wit ness, In spect ion and Review poin ts. It is emphasised that the requireme nts s

23、pecified here in are minimum requireme nts and take no acco unt of supplier performa nee or of cost or schedule impact to the Project.OPMT和/或EPC/EP 承包商將為其他本規(guī)范沒有詳細涉及的承壓項目制定監(jiān)造要求供 OPMT審查，這些項目如往復式壓縮機、汽輪機、燃氣輪機、燃燒加熱器、鍋爐、閥門、 散裝管材，嵌入式設備如混合機和過濾器等。這些監(jiān)造要求應該考慮項目規(guī)范要求的所有 檢查，設置等級應與本規(guī)范包括的等級相等。OPMT an d/or EPC/EP Co

24、n tractor shall develop surveilla nee requireme nts for other pressurised items not specifically covered by this specification such as reciprocating compressors, steam turb in es, gas turb in es, fired-heaters, boilers, valves, pip ing bulks, in-line items such as mixers and strainers etc. for revie

25、w by IPMT. Such surveillanee requireme nts shall take acco unt of all in spect ions required by the Project Specificati on and shall be set at levels equivale nt to those covered by this specificati on.因為OPMT要求所有設備提出停工待檢點、見證點和審查點，因此OPMT將審查EPC/EP承包商提出的監(jiān)造等級。OPMT shall review the surveilla nee levels p

26、roposed by the EPC/EP Con tractor for all equipme nt shall advise any Hold, Wit ness and Review points required by IPMT.5.0 參考文件 REFERENCED DOCUMENTSCQMCP1-0000-QTA-PRO-001CQMCP1-0000-QTA-PRO-XXX項目質量管理計劃Project Quality Management Plan 關鍵性等級程序Criticality Rating Procedure6.0 監(jiān)造原則及最低監(jiān)造等級SURVEILLANCE PR

27、INCIPLE/ MINIMUM SURVEILLANCE LEVELS6.1 監(jiān)造原則 SURVEILLANCE PRINCIPLE 監(jiān)造原則見表 1.The surveillance principle shall be as described in Table 16.2 壓力容器和換熱器 PRESSURE VESSELS AND HEAT EXCHANGERS OPMT 和或 EPC/EP 將為各設備設立關鍵性等級。OPMT and/or EPC/EP Contractor shall establish the Criticality Ratings for each item. 就

28、壓力容器和換熱器，供應商的質量活動監(jiān)督程度應在容器關鍵性等級的基礎上。最低監(jiān) 督程度如表 2 描述。qualityFor pressure vessels and heat exchangers the extent of surveillance of suppliers activities shall be based on Criticality Ratings of vessels. The minimum extent of surveillance shall be as described in Table 2.6.3 動設備 ROTATING EQUIPMENT OPMT 和

29、或 EPC/EP 將為各設備設立關鍵性等級。OPMT and/or EPC/EP Contractor shall establish the Criticality Ratings for each item. 泵的最低監(jiān)造程度表 3，壓縮機的最低監(jiān)造要求見表 4。The minimum extent of surveillance shall be as described in Table 3 for pumps and Table 4 for compressors.此外，承壓殼體最低監(jiān)造要求見表 5。In addition to the above, the minimum surv

30、eillance levels for pressure containing casings shall be as defined in Table 5.7.0 附錄附表1設備監(jiān)造原則關鍵等級CR國內設備On shore國外設備OffshoreEP/EPCOPMT (1)EP/EPCOPMTSAA/BBB1AA/BBB2BB/CCC3BB/DCC4BB/DDDA:原則上要求駐廠監(jiān)造，派遣專業(yè)人員長期駐扎在制造廠進行隨時隨地的監(jiān)督檢驗。A: Reside nt in spect ion .In spector is assig ned to the facility on a“ full t

31、imemon itor all phases of fabricati on an d/or manu facture.B :關鍵點見證，僅對ITP中的關鍵點進行生產車間的見證。B: Requires coverage of the wit ness an d/or hold poi nts detailed in ITP at the ven dor workshop.C :最終檢驗，僅在裝船前進行外觀及尺寸、最終文件、標記、保護等檢查。C : Final inspection. Just visual inspection, dimension inspection, final docu

32、ment, marking and protect etc.D :開箱檢驗，僅在安裝現場進行開箱檢驗。D : Receiving Inspection, means open box inspection only.備注：1. 關鍵設備(關鍵等級為S、1)檢驗內容的變更必須在合同/合同變更單中明確。Change the in spect ion level of key equipme nt (Criticality Rati ng S, 1) should be confirmed in PO/ CO.2. EP/EPC承包商必須嚴格遵守本規(guī)定。The EP/EPC con tractor

33、shall follow the regulati on.TABLE 1 Surveilla nee prin ciplesbasis, to附表2壓力容器及換熱器最低監(jiān)造要求TABLE 2 Mi nimum Surveilla nee Requireme nts for Pressure Vessels and Heat Excha ngers檢查/監(jiān)造項目INSPECTION/ SURVEILLANCEITEMS監(jiān)造活動SURVEILLANCE ACTIVITYCR SCR1CR2CR3CR4制造前準備PRIOR TOMANUFACTURE圖紙審查及批準Review and approve

34、 draw ingsHHWRR計算書審查及批準Review and approve calculati onsHHWRR質量計劃批準Approve Quality Pla nHHWR-預檢驗會PRE-INSPECTION MEETING預檢驗會 Pre-Inspection MeetingHHW-材料MATERIALS材料合格證 Material CertificatesRRRRR材料鑒定/標記移植Material ide ntificati on / tran sfer of markingIIII機械性能 Supplementary mecha ni cal propertiesRRRRR

35、子訂單 Sub-ordersRRRR資質QUALIFICATIONS焊工資格證WeldersHHRR-無損檢測資格證NDT operatorsRRRR-程序文件PROCEDURES焊接規(guī)范WPS sRRRRR焊接工藝評定 PQRsH/RW/RRRR無損檢測程序/PMI程序NDT/PMIRRRRR加工工藝流程ManufacturingRRRRR熱處理程序Heat TreatmentHHRRR壓力試驗程序Press Testi ng procedureRRRR-涂裝程序 Pain ti ng procedureRRRR-酸洗鈍化 Pickli ng/ Passivati onRRRR-保存、包裝和

36、運輸程序Preservati on. Pack ing andTran sportati onRRRRR返修程序 Repair procedureRRRR-無損檢測NON-DESTRUCTIVE TESTING滲透/磁粉檢測PT/MTRRRR-超聲波檢測UTRRRR-射線檢測 RT & radiograph reviewRRRR-鐵素體測定/硬度檢查Ferrite/hard ness checksRRRR-材料精確性鑒定 PMI Test ingIIIRR產品試板性能試驗PRODUCTIONTEST COUPONS產品試板 Production TestCouponsWRRRR制造FABRIC

37、ATION不合格項糾錯Corrective actio ns for non-con formitiesWWIRR組對/點焊/焊接準備 fit-up/tack weld /Weld prepHHII-焊接參數 Welding parametersIIII-焊接返修 Weld repairsHHIRR成型 FormingIRRRR焊后熱處理PWHTHHWRR尺寸 /外觀 Dimensional/VisualRRRRR壓力試驗Pressure testHHHWR運輸準備PREPARATIONFOR SHIPMENT表面處理/油漆Shotblast in g/pa in ti ngIIIRR酸洗鈍化

38、檢查Pickli ng/Passivati onIIIRR干燥 /保存 Drying/preservationWII-包裝 / 標記 Pack in g/mark ingWWW-裝船文件EQUIPMENTDATA BOOK裝船文件 Equipment data bookHHRRR現場安裝SITEINSTALLATION內件安裝INTERNALSIn stallati onHHI-附表3泵的監(jiān)造最低要求TABLE 3 Minimum Surveilla nee Requireme nts for Pumps檢查/監(jiān)造項目INSPECTION/SURVEILLANCE STAGE監(jiān)造活動SURVE

39、ILLANCE ACTIVITYCRSCR 1CR 2CR 3CR 4制造前準備PRIOR TOMANUFACTURE質量計劃批準Approve Quality Pla nHHHR-圖紙審查和批準Review and approve draw ingsHHRR-批準程序PROCEDUREAPPROVAL材料、標記、材料精確鑒定Material ID, Marki ng, PMIHHHRR無損檢測NDTRRRRR熱處理 Heat TreatmentRRRRR焊接規(guī)范/焊接工藝評定WPS s/PQRsHHRRR涂裝程序 Pain ti ng procedureRRRR-酸洗鈍化 Pickli ng

40、/ Passivati onRRRR-檢驗測試程序In spect ion and test proceduresHHRRR保存、包裝和運輸Preservati on, Pack ing and Tran sportati onRRRRR資質QUALIFICATIONS焊工資質WeldersRRRR-無損檢驗資格證NDT operatorsRRRR-分供貨商SUBSUPPLIERS質量計劃批準Approve Quality Plan sHHHR-承壓外殼 Pressure Casings見表 5 See Table 5主要分供貨商按照上述程序批 準 Procedure approval as

41、per above for major sub suppliersRRRRR預檢驗會PRE-INSPECTION MEETING預檢驗會 Pre-Inspection Meet ingHHWW-制造期間Duri ngManu facturi ng質量審核 Quality AuditsIIII-監(jiān)測供貨商質量控制Mon itor Supplier QCIIIII監(jiān)測分供貨商質量控制Mon itor Sub-supplier QCIIII-材料標識核實Material IDChecksWWIIR材料合格證檢查Material Certificati on checksRRRRR材料精確性鑒定 PM

42、I Test ingHHWWR材料可追溯性MaterialIIII-traceability無損檢測監(jiān)控 Monitor NDTWWIIR熱處理 Heat treatmentWWIIR見證壓力測試 witness pressure testH/WH/WWWW見證動平衡試驗wit ness dyn amic bala ncingHHWWR測量紀錄泵葉輪間距 Measureand record Pump ImpellerCleara ncesHHWWR噪音和震動試驗Noise and vibration testsHHWWR見證NPSH測試Wit ness NPSH testsHHWWR最終外觀檢

43、查Final VisualIn spect ionWWWWW見證性能測試Wit ness performa nee testHHHHR檢查主要尺寸Check Main dime nsionsWWWWW檢查機械密圭寸Check Mechanical SealsIIIII除銹和油漆Blasting andPain ti ngIIII-酸洗鈍化檢查Pickli ng/Passivati onIIIRR處理、清潔、保存、包裝和標 識 Handling, cleanliness, preservati on, packagi ng and ide ntificati on.IIIII裝船文件EQUIPM

44、ENTDATA BOOK裝船文件 Equipment data bookHHH/RH/RH/R附表4壓縮機和特殊蒸汽輪機的最低監(jiān)造要求TABLE 4Mi nimum Surveilla nee Requireme nts for Compressors and SpecialPurpose Steam Turb ines檢驗和監(jiān)造項目INSPECTION/ SURVEILLANCE ITEMS監(jiān)造活動SURVEILLANCE ACTIVITYCRSCR 1CR 2CR 3CR 4制造前準備PRIOR TOMANUFACTURE質量計劃批準Approve Quality Pla nHHHR-圖紙

45、審查和批準Review and approve draw ingsHHRR-批準程序PROCEDUREAPPROVAL材料標識、標記、PMI Material ID, Marki ng, PMIHHHRR無損檢驗資格證NDTRRRRR熱處理 Heat TreatmentR :RRP RR焊接規(guī)范/焊接工藝評定WPS s/PQRsHHRRR檢驗和測試程序In spect ion and test proceduresHHRRR涂裝程序 Painting procedureRRRR-保存、包裝和運輸Preservati on, Pack ing and Tran sportati onRRRRR資

46、質QUALIFICATIONS焊工資質WeldersR :RRP R-無損檢驗資格證NDT operatorsRRRR-分供應商SUB-SUPPLIERS質量計劃批準Approve Quality Plan sHHRRR承壓外殼 Pressure Casings見表 5 See Table 5預檢驗會PRE-INSPECTION MEETING預檢驗會 Pre-Inspection Meet ingHHWW-制造期間DURING FABRICATION監(jiān)測供貨商質量控制Mon itor Supplier QCIIIII監(jiān)測分供貨商質量控制Mon itor Sub-supplier QCIIII-材料標識核查Material ID ChecksWWIIR材料合格證核查Material Certificati on checksRRRRR材料精確性鑒定 PMI Test ingH :HWr wR材料的可追溯性Material traceabilityIIII-監(jiān)測 NDT Monitor NDTWWIIR熱處理 Heat treatmentWWIIR見證壓力測試 witness pressure testHHWWW主要尺寸 Main dimensionsWWWR-元成法二 Flange finishWWWP RR外殼壁厚Casing Wall thick nessWWW