RPLC项目检查和测试程序.doc

inspection and test procedure page 1 of 34 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: c18-07-13issue for approval b28-05-13issue for approval a17-04-13issue for approval rev.datedescription prepared bychecked byapproved byhyundai-wisonclient qin yongshi xiangquanzhang shouyue inspection and test procedure page 2 of 34 table of contents 1introduction 简介简介3 1.1 purpose3 1.2 scope .3 1.3 definitions and abbreviations.3 2process 5 3general notice .5 4overview7 5steel structure.9 6painting, blasting, galvenizing .14 7piping .17 8equipment27 9electrical.29 10 instrument29 11 weighting.30 12 load out.30 13 delivery .31 inspection and test procedure page 3 of 34 1introduction 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 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 quality 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 pdvsa 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 1.3.1definitions 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 companypetroles de venezuela, s.a. (pdvsa) contractor a consortium formed by hyundai engineering ultrasonic examination extent ut performance ultrasonic examination procedure f074-pi-0310 -0011 client spec. asme section v 30506-01 rev.2 hwsyy:yes 5.8ndt radiographic testing is applicable to butter welds only; radiography inspection extent rt performance identification of film radiographic film evaluation radiography procedure f074-pi-0310 -0012 client spec. asme section v 30507-01 rev.2 hrsyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 13 of 34 5.9ndt 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 -0014 client spec. asme section v 30506-02 rev.2 30505-01 rev.1 hwsyy:yes 5.10weld repair approval of repair welding procedure removal of defective welds repair record , (if any ndt required after repair) welding repair procedure f074-pi-0310 -0015 client spec. asme section v asme section ix approved pqr/wps 30506-02 rev.2 30507-01 rev.2 30506-01 rev.2 hwsyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 14 of 34 5.11 dimensional control rolled tubular nodes panels assembled blocks completed jacket piles and legs flatness erection dimensional structure and pipeline dimensional control procedure f074-pi-0310 -0016 heat straightening procedure f074-pi-0310 -0017 client spec. inspection criteriatable f074- pi-0310-0055 30503-39 rev.1 hwsyy:yes 5.12 release check before blasting: overall visual / dimension ndt/ any tests required delivery check overall visual/ dimension painting ncr clearance release check procedure f074-pi-0310 -0018 control of non- conforming procedure f074-pi-0310 -0019 client spec.n/ahwsyy:yes 5.13 pwht ( if applicable ) equipment performance records cleanliness: sspc-sp3; cleaning by solvent washing; brush the specified paint. galvanizing control procedure f074-pi-0310 -0024 client spec. aastm a 53/a 53m astm a 153/a 153m astm a 123/a123m 30583-01 rev.1 hwsyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 18 of 34 7.0 piping 7.1 material receiving supply by contract or material id/ marking quantity visual (surface , cut edge ) material grade size heat no., batch no. material test certificate materials and equipments of client inspection procedure f074-pi-0310 -0025 client spec asme b31.3 n/ah wsyy:yes 7.2 material identification identify material size, marking (grade, heat no., vendor name) ultrasonic examination extent ut performance ultrasonic examination procedure f074-pi-0310 -0011 client spec. asme sec. v 30506-01 rev.2 hwsyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspection controlling procedures acceptance criteria / standards codes, procedures record form whi contr actor compa ny or/ ir fidb re marks page 22 of 34 7.9ndt radiographic testing is applicable to butter welds only; radiography inspection extent rt performance film identification radiographic film evaluation radiography procedure f074-pi-0310 -0012 client spec. drawing require asme sec. v 30507-01 rev.2 hr syy:yes 7.10ndt 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-0310-0014 client spec. drawing require ndt plan asme sec. v 30506-02 rev.2 30505-01 rev.1 hwsyy:yes 7.11weld repair approval of repair welding procedure removal of defective welds repair record , (if any ndt required after repair) welding repair procedure f074-pi-0310-0015 client spec. approved pqr/wps 30506-02 rev.2 30507-01 rev.2 30506-01 rev.2 hwsyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 23 of 34 7.12 spool final inspection review of the following inspection results: m/i, fit-up, visual, ndt, pwht, hardness iso drawing spool drawing spool physical condition pipe prefabrication, installation and inspection procedure f074-pi-0310 -0026 client spec. asme b31.3 n/ah w s 7.13 pwht ( if applicable ) joint (spool ) number identification heat treatment time /temperature loading/unloading temperature holding time/temperature calibration of pwht equipments post weld heat treatment procedure f074-pi-0310 -0020 client spec. asme b31.3 30503-13 rev.2 hwsyy:yes 7.14 hardness test ( if applicable ) hardness check points hardness value welding control procedure f074-pi-0310 -0002 client spec. asme b31.3 30503-11 rev.2 hwsyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 24 of 34 7.15installation pipe support pre- fabrication cleaning pipe inside & capping of open ends lubrication rust prevention fit-up/welding on erection joint ndt pipe prefabrication, installation and inspection procedure f074-pi-0310- 0026 client spec. asme b31.3 n/awss 7.16 line inspection line (hydro-package) identification clearance between pipes access for operation & interference of valves with other structures/ equipment protection of galvanic attack isolation of hazardous fluid bends/elbows/ flanges/bolting /gaskets/ valves (type/orientation /stem/chain wheel/rating)/ branch connections/ pipe supports pipe prefabrication, installation and inspection procedure f074-pi-0310- 0026 client spec. 30503- 62rev.1 hwwyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 25 of 34 7.17 pressure test hh wyy:yes 7.18 piping system hydrostatic test flushing fluid flushing velocity removal of valve, instruments calibration of pressure gauge & relief valve vent & drain test medium/temperature/pr essure/ holding time temporary supports for hydro test valve testing after pressure test pressure testing and flushing procedure of pipework f074-pi-0310-0027 client spec. asme b31.3 30503-19 rev.1 30503-15 rev.1 hh wyy:yes 7.19cleaning chemical cleaning and pickling chemical cleaning and pickling procedure f074-pi-0310-0028 client spec. asme b31.3 n/ahws rplc deep conversion project partyrecord no. quality control activity item to be inspection controlling procedures acceptance criteria / standards codes, procedures record form whi contr actor compa ny or/ ir fidb re marks page 26 of 34 7.20 reinstateme nt drain/ dry of lines removal of temporary attachments pipe prefabrication, installation and inspection procedure f074-pi-0310-0026 client spec. asme b31.3 n/awws 7.21 final line check before insulation painting condition completion of inspection of previous stage pipe prefabrication, installation and inspection procedure f074-pi-0310-0026 client spec. asme b31.3 n/ahww 7.22 insulation fire proofing extent of insulation insulation thickness insulation material bands & sealer insulation type(hot or cold) insulation procedure f074-pi- 0310-0040 fire proofing inspection procedure f074-pi-0310-0029 client spec. 30503- 61rev.1 hw syy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspection controlling procedures acceptance criteria / standards codes, procedures record form whi contr actor compa ny or/ ir fidb re marks page 27 of 34 7.23 surface preparation of welding joints cleanliness : sspc-sp5 -sp6 sspc-sp7 -sp10 sspc-sp11 blasting method: dry blasting blasting condition surface preparation and painting procedure f074-pi-0310 -0021 client spec. iso8501 sspc -sp5/sp6 -sp7/sp10 -sp11 30517- 02 rev.2 hwsyy:yes 7.24 painting inspection and coating thickness (d.f.t) applicable area coat system film thickness (d.f.t) defect repair surface preparation and painting procedure f074-pi-0310 -0021 color coding procedure f074-pi-0310 -0022 client spec. sspc-pa 2 30517- 02 rev.2 hwsyy:yes 7.25 painting repair damaged portion shall be thoroughly cleaned by blasting , power tools or sandpaper painting repair procedure f074-pi-0310 -0023 client spec. 30517- 02 rev.2 after repair, re-inspection hwsyy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspection controlling procedures acceptance criteria / standards codes, procedures record form whi contr actor compa ny or/ ir fidb re marks page 28 of 34 8.0 equipment 8.1 receiving inspection of the equipments supplied by contractor size of the equipment name plate identification damages loose and missing item preservation of equipment materials and equipments of client inspection procedure f074-pi-0310 -0025 client spec. 30503-29 rev.1 hw syy:yes 8.2 marking & dimension for installation location and election anchor bolt location mechanical equipment installation and inspection procedure f074-pi-0310-0030 client spec.n/ahws 8.3 base supports welding base supports pads where applicable welding control procedure f074-pi-0310-0002 approved wps aws d1.1/1.8 client spec. n/ahws 8.4 coating of base supports coating condition surface preparation and painting inspecting procedure f074-pi-0310-0021 client spec.n/ahws rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 29 of 34 8.5 lifting & setting lifting lug & sling wire locked shackle pin setting location level of equipment bolt hole condition cranes capacity mechanical equipment installation & inspection procedure f074-pi-0310-0030 client spec.n/awss 8.6 installation/we lding surface cleaning alignment root opening welding consumable welding no. mechanical equipment installation & inspection procedure f074-pi-0310-0030 client spec. approved procedures aws d1.1 n/ahws 8.7 final visual inspection width of bead weld defect arc strike weld profile mechanical equipment installation & inspection procedure f074-pi-0310-0030 client spec. aws d1.1 n/ahww rplc deep conversion project partyrecord no. quality control activity item to be inspected controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor compa ny or /ir fidb re marks page 30 of 34 8.8 machinery installation contact condition orientation elevation leveling mechanical equipment installation & inspection procedure f074-pi-0310-0030 client spec. 30503-17 rev.2 hw s 8.9 equipment protection protection covering protection control procedure f074-pi-0310-0031 client spec.n/awss 9.0 electrical 9.1 installation check of electrical support, cable tray electrical support, inspection procedure f074-pi- 0310-0032 client spec.n/ah ws yy:yes 10.0 instrument 10.1 installation check of instruments installation check of instruments instrument installation inspection procedure f074-pi-0310-0033 client spec. 30503-27 rev.1 hw syy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspection controlling procedures acceptance criteria / standards codes, procedures record form whi contra ctor comp any or /ir fidb re marks page 31 of 34 11.0 weighting 11.1preparation weighting procedure qualification weight control procedure f074-pi-0304 -0002 project spec.n/arrr 11.2 completion inspection structure completeness piping completeness equipment completeness e&i completeness others weight control procedure f074-pi-0304 -0002 project spec.n/ahws 11.3weightingweighting weighting procedure f074-pi-0304 -0003 project spec. 30503-63 rev.1 hhsyy:yes 12.0 load out 12.1lifting eyendt load out regulations client spec. 30506- 02 rev.2 hws rplc deep conversion project partyrecord no. quality control activity item to be inspection controlling procedures acceptance criteria / standards codes, procedures record form whi contr actor compa ny or/ ir fidb re marks page 32 of 34 12.2 steel wire rope & snap ring tensile test dimensional measure under tensile status visual inspection load out regulations client spec.n/ahw s 123 export parts and components export parts and components inspection export parts and components packing and coding procedure f074-pi-0304-0034 client spec.n/ahw s 12.4load out package number check fasten status hoisting sling certification load out regulations client spec. n/ahws 13.0 delivery 13.1 irc as-built documents inspection release certificate as-built dwg. inspection & test reports material certificates procedures project delivery regulations client spec. as-built documents hh ryy:yes rplc deep conversion project partyrecord no. quality control activity item to be inspection controlling procedures acceptance criteria / standards codes, procedures record form whi contr actor compa ny or/ ir fidb re marks page 33 of 34 attachment-1 30510-02 rev.2 weld procedure specification register(structure/pipework) attachment-2 30512-03 rev.1 welder qualification register attachment-3 30528-02 rev.0 project nondestructive inspector qualification register attachment-4 30503-41 rev.1 welding consumable inspection report attachment-5 30503-47 rev.0 report of painting material inspection attachment-6 30516-02 rev.3 structure material inspection record attachment-7 30516-03 rev.4 pipe material inspection report attachment-8 30516-04 rev.3 inspection report on flange, elbow, unequal-diameter joint pipe accessory attachment-9 30508-01 rev.2 ut report of testing for steel material lamination attachment-10 30503-29 rev.1 equipment unpacking inspection record attachment-1130516-01 rev.3 structure material traceability report attachment-12 30516-06 rev.3 pipe material traceability report attachment-1330503-36 rev.2 fit-up inspection record of structure attachm