RPLC項目檢查和測試程序

1、 inspection and test procedurefor construction of rplc projectrplc 項目檢查和測試程序 doc. no.: f074-pi-0310-0001revision status:c18-07-13issue for approvalb28-05-13issue for approvala17-04-13issue for approvalrev.datedescriptionprepared bychecked byapproved byhyundai-wisonclientqin yongshi xiangquanzhang sh

2、ouyuetable of contents1introduction 簡介簡介.31.1 purpose.31.2 scope .31.3 definitions and abbreviations.32process .53general notice .54overview.75steel structure.96painting, blasting, galvenizing .147piping .178equipment.279electrical.2910 instrument.2911 weighting.3012 load out.3013 delivery .311intro

3、duction 簡介簡介this document presents the wison (nantong) heavy industry (builder) project fabrication inspection and test plan (itp) for the module of rplc deep conversion project.本程序介紹的是惠生重工 rplc 項目的關(guān)于生產(chǎn)檢查和試驗計劃。the itp is prepared and managed by the project quality assurance manager in accordance wit

4、h the project specifications.本程序是項目質(zhì)量保證經(jīng)理根據(jù)項目的特殊說明而啊指定的。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 quality of each product item can meet the

5、requirement of contract, specifications and drawings. this inspection test plan (itp) shall be issued for hiwin (contractor) and/or pdvsa (company) approval as required.本程序是在項目施工期間，為了描述檢查和測試項目以及定義“節(jié)點控制”或者“見證點” 、 “檢查點” 、 “監(jiān)測點”來確保產(chǎn)品質(zhì)量滿足合同需要，滿足圖紙的說明。此 itp 程序文件必須經(jīng)過 hwin 和 pdvsa 的批準。1.2 scope 前景展望前景展望thi

6、s 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 項目部管廊模塊所有預制廠房的檢查和測試項目。此 itp 必須確保遵守生產(chǎn)

7、圖紙，說明以及合同相關(guān)標準的需要。1.3 definitions and abbreviations 定義和縮寫代碼定義和縮寫代碼1.3.1definitions 定義 the following definitions apply to this project inspection and test plan:下面的定義適用于此項目的檢查和測試計劃companypetroles de venezuela, s.a. (pdvsa)contractora consortium formed by hyundai engineering & construction co., ltd.

8、, hyundai engineering co., ltd., and wison engineering ltd.vendorwison (nantong) heavy industry (whi) also referred to as “wison”clientcompanycontractorholdbuilder is not allowed to proceed with the inspection/test unless a written release is issued by the contractor.必須有總包批準方可檢查witnessbuilder can pr

9、oceed with the inspection/test when contractors representatives is not present at the notified time.可以在通知時間自行檢查 surveillancebuilder is not requested to notify contractor / company. the contractor / company inspector will monitor work in progress, test and inspections during his visit or periodical i

10、nspection. 不需要通知總包和甲方，總包和甲方的檢查員將會周期性的監(jiān)督工作的進程測驗和檢查reviewbuilder shall provide contractor and or company with certificates, reports and records as applicable for review.分包需要提供可用的證書，報告和記錄給甲方和總包1.3.2abbreviations 縮寫代碼 the following abbreviations apply to this itp document:下面的縮寫代碼適用于本 itp程序文檔apiamerican

11、petroleum institute 美國石油組織asmeamerican society of mechanical engineers 美國機械工程師學會asntamerican society of non-destructive testing 美國無損檢測學會aiscamerican institute of steel construction 美國鋼結(jié)構(gòu)施工協(xié)會astmamerican society for testing and materials 美國材料檢測學會awsamerican welding society 美國焊接學會dcdigital control 數(shù)位控

12、制dftdry film thickness 干膜厚度dwgdrawing 圖紙e&ielectrical & instrumentation 電氣儀表rplcrefinery puerto la cruzididentityisointernational organization for standardization 國際組織標準itpinspection and test plan 檢查測試計劃mpimagnetic particle inspection 磁粉檢查ncrnon conformance record 現(xiàn)場質(zhì)量詢問單ndtnon destructive t

13、esting 無損檢測pepproject execution plan 項目執(zhí)行計劃pmipositive material identification 光譜分析pqrprocedure qualification record 工藝評定記錄ptpenetration testing 滲透pwhtpost weld heat treatment 焊接熱處理qaquality assurance 質(zhì)量保證qcquality control 質(zhì)量控制rtradiographic testing 射線探傷utultrasonic testing 超聲探測whiwison heavy indust

14、ry 惠生重工womwison offshore & marine 惠生海洋wpswelding procedure specification 焊接工藝評定2process 過程過程the following fabrication itp work sheets identify the following processes:下面的 itp 制作工作表印證了下面的程序；overview 概況steel structure 鋼結(jié)構(gòu)painting/blasting/galvanizing 涂漆、噴砂和鍍鋅piping 管道equipment 設(shè)備electrical 電氣instr

15、ument 儀表insulation 保溫load out 外運 delivery 運送3general 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。所有的檢查和檢驗項目必須與工程的相關(guān)說明，相關(guān)特殊的規(guī)章制度保持一致。3.2 according to the construction schedule, qa/qc s

16、hall notify the contractors and/or companys representative to attend the inspection and/or testing as the following procedure:根據(jù)施工日程表，質(zhì)量檢查和控制人員必須通知總包和業(yè)主的代表去參加檢查和檢驗根據(jù)以下程序；a. ”daily inspection application form” shall be submitted to contractors and/or companys representative before 17:00 by email one

17、day before yard carried out inspection or test. inspections scheduled on weekend or during national holiday have to be submitted two days before. 日常的檢查申請表必須在檢查的前一天下午 5 點之前通過郵件發(fā)送給總包或業(yè)主代表；檢查計劃在周末和假期的需要提前兩天申報； b. if schedule changed, qa/qc shall notify the contractors and/or companys representative as

18、early as possible. 如果檢查日期變更，qa/qc 人員需盡早通知業(yè)主和總包代表；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 to enhance effectively working progress, re-inspe

19、ction will be based on the comments of first inspection.業(yè)主和總包代表需要檢查簽字做好記錄以及備注。根據(jù)檢查結(jié)果，對產(chǎn)品進行下一步的推動工作或修改。為了加強工作效率，二次檢驗將會根據(jù)第一次檢查的備注來實施。3.4 the contractors and/or companys representative shall attend inspection and testing as”h”, and “w”, in plan. 業(yè)主和總包方將會根據(jù)檢查計劃表里的“h”和“w”來參加價差測試3.5 builder shall provide

20、all the notification to contractors and/or companys representative as”h” and “w” in plan.過程中，生產(chǎn)方必須給出業(yè)主和總包方“h”和“w”3.6 the contractors and/or companys representative inspection shall be carried out after internal inspection of whi.業(yè)主和總包方將會在惠生自檢之后進行檢查測驗； remark: h: hold w: witness s:surveillance r: rev

21、iew 4.0 overview 概述概述4.1welding procedure specification焊接工藝評定pqrwpswelding control proceduref074-pi-0310-0002aws d1.1/1.8asme section ixclient spec.30510-02 rev.2hhryy:yes4.2welder qualification焊工資質(zhì)welder qualification testreview/ approval of welders qualificationwelder management proceduref074-pi-0

22、310-0003aws d1.1/1.8asme section ixclient spec.30510-03rev.1hws4.3 material control 材料控制material receiving inspectionmaterial inspectiongb materials retest inspection by 3rd partymaterial traceability for memberslayout for material storageinspection of incoming materials proceduref074-pi-0310-0004po

23、sitive material identification procedure f074-pi-0310-0005material identification and traceability proceduref074-pi-0310-0035client spec.30503-41 rev.130503-47 rev.030516-02 rev.330516-03 rev.430516-04 rev.330516-01 rev.330516-06 rev.330508-01 rev.2hwsyy:yes4.3ndt personnel 無損檢測人員review / approval o

24、f ndt operators qualificationndt personnel qualification proceduref074-pi-0310-0006client spec.30528-02rev.0hrr4.5final submission 終交shop drawings / ndt drawingsquality plan and itprelevant procedures wps and pqrregister of qualified welders and ndt operatorsas-built inspection and test reports with

25、 summery listas-built drawings material certificatesproject as-built documents control proceduref074-pi-0310-0007client spec.n/ahrr5.0 steel structure 鋼結(jié)構(gòu)鋼結(jié)構(gòu)5.1material receiving 材料接收material id/ markingquantityvisual (surface , cut edge )mill certificatesmaterial gradesizeheat no., batch no.mill sh

26、eetinspection of incoming materials proceduref074-pi-0310-0004 positive material identification proceduref074-pi-0310-0005client spec.gb/t 700-2006gb/t 1591-2008 30503-65 rev.0hwsyy:yes5.2material re-testing inspection 材料二次測試檢驗re-testing (high-strength steel)gb materials retest inspection by 3rd par

27、typroject procurement quality planf074-pi-0305-0002client spec.30516-02rev.3hwsyy:yes5.3cutting , beveling , transfer of identification , marking and material traceabilitymachiningcuttingbevelingtransfer of identificationmaterial traceabilitypositive material identification proceduref074-pi-0310-000

28、5client spec.30516-01rev.3hss5.4fit-up inspectionpreparation of edgepiece no. wps no.tack weldalignment and straightnessassembly dimensionweld butteringstructure fit-up & visual inspection proceduref074-pi-0310-0009inspection criteria table f074-pi-0310-0055approved wpsclient spec.30503-36 rev.2

29、30503-39 rev.1hws5.5welding controlwps approvedwelding consumable controlwelding equipmentpreheat & post heat , if necessaryrun-on & run-off plates usedcleaning of welded surfaceworkmanshipweld profile/ tack weldweld repair: removal of defect, welding control proceduref074-pi-0310-0002weldin

30、g consumables control proceduref074-pi-0310-0010client spec.approved pqr/wpsn/ahss5.6weld visual inspectionjoint no./ welder no.date of weldedcrack/ undercutporosity/ arc strike/ spatterreinforcementlack of root surfaceconcave root welding control proceduref074-pi-0310-0002client spec.30503-44 rev.2

31、hwsyy:yes5.7ndtultrasonic testing is applicable to all weld types;ultrasonic examination extentut performanceultrasonic examination proceduref074-pi-0310-0011client spec.asme section v 30506-01rev.2hwsyy:yes5.8ndtradiographic testing is applicable to butter welds only;radiography inspection extentrt

32、 performanceidentification of filmradiographic film evaluationradiography proceduref074-pi-0310-0012client spec.asme section v 30507-01rev.2hrsyy:yes5.9ndtmagnetic particle and liquid penetration inspection is applicable to the weld surfaces of each type of joints;magnetic particle inspection proced

33、uref074-pi-0310-0013liquid penetration proceduref074-pi-0310-0014client spec.asme section v 30506-02rev.230505-01rev.1hwsyy:yes5.10weld repairapproval of repair welding procedureremoval of defective weldsrepair record , (if any ndt required after repair)welding repair proceduref074-pi-0310-0015clien

34、t spec.asme section vasme section ix approved pqr/wps30506-02 rev.230507-01 rev.230506-01 rev.2hwsyy:yes5.11dimensional controlrolled tubularnodes panelsassembled blockscompleted jacketpiles and legsflatnesserection dimensional structure and pipeline dimensional control proceduref074-pi-0310-0016hea

35、t straightening proceduref074-pi-0310-0017client spec.inspection criteriatable f074-pi-0310-005530503-39 rev.1hwsyy:yes5.12release checkbefore blasting: overall visual / dimensionndt/ any tests requireddelivery checkoverall visual/ dimensionpaintingncr clearancerelease check proceduref074-pi-0310-00

36、18control of non-conforming proceduref074-pi-0310-0019client spec.n/ahwsyy:yes5.13pwht( if applicable )equipmentperformancerecords & curve chartpost weld heat treatment proceduref074-pi-0310-0020client spec.asme b31.3 30503-13 rev.2hwsyy:yes6.0 painting/blasting/galvanizing6.1receiving inspectio

37、n of coating materialpaint batch no. paint manufacturers specificationspaint certificatesabrasive materialpacking conditioninspection of incoming materials proceduref074-pi-0310-0004client spec.30503-47 rev.0hwsyy:yes6.2surface preparationcleanliness : sspc-sp5 -sp6 sspc-sp7 -sp10 sspc-sp11blasting

38、method: dry blastingblasting condition surface preparation and painting inspection proceduref074-pi-0310-0021client spec.iso8501sspc-sp5/sp6 -sp7/sp10 -sp1130517-02 rev.2hwsyy:yes6.3painting inspection andcoating thickness(d.f.t)applicable area coat systemfilm thickness (d.f.t)defect repairsurface p

39、reparation and painting inspection proceduref074-pi-0310-0021color coding proceduref074-pi-0310-0022client spec.sspc-pa 230517-02 rev.2hwsyy:yes6.4inspection of adhesionadhesion test shall be checked at 3 pointssurface preparation and painting inspection proceduref074-pi-0310-0021client spec.astm d

40、3359sspc30517-02rev.2hwsyy:yes6.5inspection of holidayholiday check with a holiday detectorrepair defects and re-inspectpainting repair proceduref074-pi-0310-0023client spec.astm g 62sspcnace30517-02rev.2hwsyy:yes6.6repairdamaged portion shall be thoroughly cleaned by blasting , power tools or sandp

41、aperpainting repair proceduref074-pi-0310-0023client spec.sspcnace30517-02 rev.2after repair, re-inspectionhwsyy:yes6.7handlingprotection of coated surface during lifting and handling operationssurface preparation and painting inspection proceduref074-pi-0310-0021client spec.n/awss6.8hot-dip galvani

42、zingstructure preparing before galvanizinggalvanizingrepair the damaged surface:washing with fresh water;cleanliness: sspc-sp3;cleaning by solvent washing;brush the specified paint.galvanizing control proceduref074-pi-0310-0024client spec.aastm a 53/a 53mastm a 153/a 153mastm a 123/a123m30583-01 rev

43、.1hwsyy:yes7.0 piping7.1material receiving supplyby contractormaterial id/ markingquantityvisual (surface , cut edge ) material gradesizeheat no., batch no.material test certificatematerials and equipments of client inspection proceduref074-pi-0310-0025 client specasme b31.3 n/ahwsyy:yes7.2material

44、identificationidentify material size, marking (grade, heat no., vendor name) & transferred marking(spool no., against mill certificatespool dwg. (iso drawings.) roundnesscracks, lamination boltsgasketsflanges & fittingspositive material identification proceduref074-pi-0310-0005inspection of

45、client offered materials proceduref074-pi-0310-0025client spec.30516-03 rev.430516-04rev.330516-06 rev.3hws7.3surface preparation of pipecleanliness : sspc-sp5 -sp6 sspc-sp7 -sp10 sspc-sp11blasting method: dry blastingblasting condition surface preparation and painting inspection proceduref074-pi-03

46、10-0021client spec.iso8501sspc-sp5/sp6 -sp7/sp10 -sp1130517-02 rev.2hwsyy:yes7.4painting inspection andcoating thickness(d.f.t) of pipeapplicable area coat systemfilm thickness (d.f.t)defect repairsurface preparation and painting inspection proceduref074-pi-0310-0021color coding proceduref074-pi-031

47、0-0022client spec.sspc-pa 230517-02 rev.2hwsyy:yespipe piece identification (spool no.)joint number identificationhws7.5fit-upjoint configuration (root face/opening, groove angle, offset ) tapered angletack weldsalignmentpipe prefabrication, installation and inspection proceduref074-pi-0310-0026clie

48、nt spec.approved wpsasme 31.3inspection criteriatable f074-pi-0310-005530503-12rev.2hws7.6welding inspectionverification of equipment calibrationcompliance to wps & pqrverification of welders/ welding operators qualificationwelder number identificationwelding consumable control preheating/inter-

49、pass temperaturecleaning of welded surfaceswelding consumables control proceduref074-pi-0310-0010welding control proceduref074-pi-0310-0002client spec.approved wpsasme 31.3n/awss7.7visualinspectionjoint number/spool numberweld defectcrack ,undercut, porosityarc strike, spatterreinforcementlack of ro

50、ot surfaceconcave root penetration straightnesswelding control proceduref074-pi-0310-0002client spec.approved wpsasme b31.330503-14rev.2hwsyy:yes7.8ndtultrasonic testing is applicable to all weld types;ultrasonic examination extentut performanceultrasonic examination proceduref074-pi-0310-0011client

51、 spec.asme sec. v30506-01rev.2hwsyy:yes7.9ndtradiographic testing is applicable to butter welds only;radiography inspection extentrt performancefilm identificationradiography proceduref074-pi-0310-0012client spec.drawing requireasme sec. v30507-01rev.2hrsyy:yesradiographic film evaluation7.10ndtmagn

52、etic particle and liquid penetration inspection is applicable to the weld surfaces of each type of joints;magnetic particle inspection proceduref074-pi-0310-0013liquid penetration proceduref074-pi-0310-0014client spec.drawing requirendt planasme sec. v30506-02rev.230505-01rev.1hwsyy:yes7.11weld repa

53、irapproval of repair welding procedureremoval of defective weldsrepair record , (if any ndt required after repair)welding repair proceduref074-pi-0310-0015client spec.approved pqr/wps30506-02 rev.230507-01 rev.230506-01 rev.2hwsyy:yes7.12spool final inspectionreview of the following inspection resul

54、ts: m/i, fit-up, visual, ndt, pwht, hardnessiso drawingspool drawingspool physical conditionpipe prefabrication, installation and inspection proceduref074-pi-0310-0026client spec.asme b31.3n/ah ws7.13pwht( if applicable )joint (spool ) number identificationheat treatment time /temperatureloading/unl

55、oading temperatureholding time/temperaturecalibration of pwht equipmentspost weld heat treatment proceduref074-pi-0310-0020client spec.asme b31.330503-13 rev.2hwsyy:yes7.14hardness test ( if applicable )hardness check pointshardness valuewelding control proceduref074-pi-0310-0002client spec.asme b31

56、.330503-11 rev.2hwsyy:yes7.15installationpipe support pre-fabrication cleaning pipe inside & capping of open ends lubrication rust preventionfit-up/welding on erection jointndt pipe prefabrication, installation and inspection proceduref074-pi-0310-0026client spec.asme b31.3n/awss7.16line inspect

57、ionline (hydro-package) identificationclearance between pipesaccess for operation & interference of valves with other structures/ equipment protection of galvanic attackisolation of hazardous fluidbends/elbows/ flanges/bolting /gaskets/valves (type/orientation /stem/chain wheel/rating)/branch co

58、nnections/ pipe supportspipe prefabrication, installation and inspection proceduref074-pi-0310-0026client spec.30503-62rev.1 hwwyy:yes7.17pressure testhhwyy:yes7.18piping system hydrostatic testflushing fluidflushing velocityremoval of valve, instrumentscalibration of pressure gauge & relief val

59、vevent & draintest medium/temperature/pressure/holding timetemporary supports for hydro test valve testing after pressure testpressure testing and flushing procedure of pipework f074-pi-0310-0027client spec.asme b31.330503-19rev.130503-15rev.1hhwyy:yes7.19cleaningchemical cleaning and picklingch

60、emical cleaning and pickling procedure f074-pi-0310-0028client spec.asme b31.3n/ahws7.20reinstatementdrain/ dry of linesremoval of temporary attachmentspipe prefabrication, installation and inspection proceduref074-pi-0310-0026client spec.asme b31.3n/awws7.21final line checkbefore insulationpainting conditioncompletion of inspection of previous stagepipe prefabrication,