8吨油炉外协ITP.doc

InspectionandTest Plan(ITP)Job Number: 06G8-1Page 21 of 21Customer: 国内Product: /Supplier: Deltak Power equipment(China)Co.LtdDucument No.: /Rev.: BBy:廖永新 06/20/06Released:姚青炜Inspection and Test Plan CodesCode Description H HOLD. NOT TO PROCEED UNTIL RELEASEDI INPROCESS INSPECTIONR DOCUMENTATION TO BE REVIEWEDW INSPECTION POINTComments1. All Inspection Points must be part of the supplier quality process (Hold Point)2.All documents shall be clearly identified with the following information: Plant; Specification Number; Purchase Order Number and Equipment Number.3. Tube Module fabrication must comply with ASME I.4. All welding must comply with ASME 9 for pressure containing components.5. All structural welding must comply with AWS Dl. 1.6. DPEC shall notice Customer at least sixteen (16) days in writing of the date and the place at which the equipment will be ready for testingApplicable Deltak SpecificationsSpecification Name Drawing No: 1.Stainless steel contamination control 080013152. Header inspection specifications 080011433. Hydrostatic testing procedure 080013044. Threaded hydro plug weld preparation 080009325. Tube handling 080008106. Tube inspection 080010257. Casing fabrication 080010828. Insulation blanket, international 08001006 9. Postweld Heat Treatment using local stress relief For carbon and alloy steels 0800102310.Tube to header weld - full penetration 0800131011.PWHT procedure for carbon and alloy steels 0800127512.Steam drum fabrication 0800108613.Header fabrication inspection 0800114314.Internal attachment inspection 08001142VENDOR REQUIREDVendor Required Deliverable RecordsSUBMITTAL DOCUMENTSxWeld Procedures & PQRsASME Manufacturers Data Reports (MDRs)xWeld MapxWelders QualificationsxWelding Specification1Copy Manufacturers Data Reports shipped with componentxElectrode Storage Procedure1Copy Manufacturers Data Reports in each Vendor Records PkgxHeat Treatment ProcedurexNonconformity Report Procedure1PaperxInspector QualificationsxRadiographic Exam ProcedureX3.2a. Mfrs Data Reports X3.2d Hydrotest ReportsxUltrasonic Exam ProcedureX3.2b. Material Test Reports* X3.2e. Code Stamp RubbingsxLiquid Penetrant Exam ProcedureX3.2c. P.W.H.T. Charts3.2f. Nameplate PhotocopiesxMagnetic Particle Exam Procedure*MTRs are required for pressure containing fittingsxQA ProgramxEquipment Calibration CertificatesXNDE Exam ReportsXRT Exam Reader SheetsxPaint ProcedureXFinal NCRsXPaint Inspection ReportxQuality Assurance ManualXCertificate of ComplianceXShipping ReleasexIn-Process NCRsXTravelerxEquipment photo PhotographsXDimensional/As Built DrawingsXFinal Inspection Report1.HP steam drum - FORGINGSItmInspection PointRef. Doc.VendorDPECCTCIPTTUTRemarks1Furnace calibration procedurePO/SPECR2Furnace layout drawingPO/SPECR3Thermocouple location diagramPO/SPECR4NDE procedure approvalPO/SPECR5 Supplier operating procedure approval, Heat treatment procedure, material traceabilityPO/SPECR6 Supplier check off list approvalPO/SPECR7Review material receiptDWGR8Check heat code stamping/identificationDWGII9Verify furnace calibration recordsPROCEDUREI10Verify furnace loadingsPROCEDUREI11Verify heat treatmentPROCEDUREIR12Check thermocouple temperature recordsPROCEDUREI13Verify thermocouple insulatedPROCEDUREH14Verify grain structure metallograph/one for each furnace heatDWGH15Verify mechanical testing per codeASTMHR16Review quality documentationQA PLANRR2.HP steam drumItmInspection PointRef. Doc.VendorDPECCTCIPTTUTAI1Prefabrication MeetingPO/SPECH2QA approvalPO/SPECR3WPS/PQR approvalPO/SPECRR4Weld map approvalPO/SPECRR5 Welder qualification and track welder qualificationsPO/SPECHR6 NDE procedure approvalPO/SPECR7Supplier operating procedure approval (For example: painting, PWHT, etc.)PO/SPECR8Supplier check off list approvalPO/SPECRR9Verify shell/head UT per ASTM 578 for plates greater than 1.5 thickness.SPECRR10Layout of a drum head prior to flame cutting/drilling nozzle holesDWGI11Verify fit-up of manway ring. Verify base metal cleanlinessDWGI12Check ring flatness and finishDWGI13Back gouge of manway ring and MTDWGIR14Fit-up/subarc welding of long seamsDWGI15Fit-up of shell courses/check out of roundness DWGI16Fit-up of drum head to shellDWGII17Review RT film of long/round seamsASMEIHR18Hardness test on long/round seamsITPI19Check layout of nozzles prior to flame cutting holesDWGI20Check fit-up of reinforcing nozzlesDWGI21Check back-gouging of reinforcing nozzles/MT root for full penetration welds only.WPSI22UT Base metal around all sit-on nozzles equal to 4 of flame cut hole and largerSPECIR23PT/MT hole plate edge for sit on nozzle only.SPECIR24MT test all nozzle weldsSPECIR25MT temporary attachments prior to PWHTSPECIR26Verify welder identification of all weldsQA ManualI27Final inspect all weldingDWGHHHH28Verify PWHT/procedure approvalSPECIRR29Check PWHT chartsASME IIRR30Hardness testRR31Hydrotest one hour minimum hold time 1.5 MAWPASME IHHHH32Verify ASME code stampingsDWGHH33Final inspect internals and/or surface blastprocedureI34Final inspect surface prepare and paintprocedureI35Final inspect packingI36Final inspect shipping preparation/ identificationDWGHHHIReview quality documentationITP/P.O.RRRR3. Module Fabrication3.1 welder qualification for tube to header weldingItmInspection PointRef. Doc.VendorDPECCTCIPTTUTRemarksPrior to production welding each welder must demonstrate the ability to successfully weld REF. DOC1.A production mock up of the same configuration as the panel welds (number of tube rows with 3 tube to header welds)SPECI2.The welds must be cross-sectioned to check for weld Penetration and defectsASME CodeI3.All welds must be acceptable before initiating production weldingSPECHRR3.2 FIN TUBES RECEIPT INSPECTIONItmInspection PointRef. Doc.VendorDPECCTCIPTTUTAI1.Check material packing list items.DWGR2.Check heat code markings on each tube, header and theromocouplesPOR3.Review/approve tube material test reports per ASME Section IISPEC.RR4.Check fin length, segments and thickness.DWGI5.Verify fin material specifications.DWGRRRR6.Check fin tube lengths with templates (one tube per bundle). (Note any variations exceeding drawings tolerances on an NCR)DWGI7PMI test on alloy tubeITPI3.3 HEADERS FABRICATIONItmInspection PointRef. Doc.VendorDPECCTCIPTTUTAI1.Review material identification and stampingDWGIR2.Check tube hole layout/hole diameterDWGI3.Check header cleanlinessDWGI4.Visually inspect all accessible full penetration weldsDWGI5.Verify baffle plate installationDWGH6.MT or PT on header grade and endplate edge after weldingITPI7Check end plate fit up/weldDWG8.Check weld fitting fit up/weldDWGI9.PMI test on alloy header and weldingITPI10.Check final dimensionsDWGI11.UT header endplates welding per codeASME1H12.Radiograph butt welds per codeASME1IR13UT full penetration header lug welds (10% random)ITPIR14MT full penetration header lug and nozzle welds (100%)ITPIR3.4 CASING FABRICATIONItmInspection PointRef. Doc.VendorDPECCTCIPTTUTRemarks1Receipt inspection of all Deltak supplied materialsPO/SPECR2Check material documentation per drawing specificationsDWG/MTRR3Confirm that proper WPS is utilized & welder qualificationDWG/WELD MAP/AWSD1.1R4Check I Beam/Fitups/Weld penetration/ Final welds. PT 10% of composite welds.DWGI5Check fit up of full penetration weldsDWGI6Confirm that welding is performed in accordance with requirements, including proper back gouging.DWG/WELD MAP/AWSD1.1H7UT Test 100% of all full penetration weldingSTRUCTURAL WELD STD.H8Check all welds after sandblast and before painting, verify sandblast profileDWG WELD MAPAWSD1.1H9Check paint thickness, verify weldable prime applicationDWG PROCEDURE SPECI10Verify stud welding tests, check stud and weld size per code, insulation pin weldsDWG AWSD1.1H11Check stud welding locations size and materialDWG SPEC AWS Dl.lH12Verify insulation thickness and density (verify 5% by weight testing) and MTRDWG 06100159W13Confirm proper insulation installation and weather protection plastic installationDWG 06100159H14Check liner Fabrication, dimensions, materials, verify flame cut hole roundness, toleranceDWG 06100159H15Confirm proper liner installation, verify liner plates are compressed/Check washer fillet weld sizeDWG 06100159H3.5 MODULE FABRICATIONItmInspection PointRef. Doc.VendorDPECCTCIPTTUTAI1Prefabrication MeetingPO/SPECH2QAM approvalPO/SPECR3WPS/PQR approvalPO/SPECRR4Weld map approvalPO/SPECRR5Welder qualificationPO/SPECRR6NDE procedure approvalPO/SPECR7Supplier operating procedure approval (For example: painting, PWHT, etc.)PO/SPECR8Supplier check off list approvalPO/SPECRR9Verify tube blockage/handling per 08001025 and 08000810.DWGI10Check tube bevelsDWGH11Verify hole diameter, overall dimensions, and steel stamping of headers.DWGI12Verify upper and lower headers are paired for each panel.DWGI13Check positioning of headers in fixture for dimensions and rotation.DWGI14Check fit-up of tube to header welds.WPSI15Verify welders qualifications and electrode.ASMEIIR16Verify welds are purged as necessary. (Alloy welds only)WPSI17Check 10% of tube to header welds (GTAW) (size/ penetration/ preheating). Complete weld only after QA verification.SPEC.H18Check tube support dimension tolerance and location.DWGI19Verify tube support welds are performed by qualified welders.DWGI20Final inspect all tube to header welds prior to removing from fixture.ASMEHWW21PT 10% of tube to header fillet welds.SPECWR22Verify welder identificationQA ManualIR23Verify heat treat thermocouple locationPROC.RI24Verify heat treat chart calibration recordsPROC.R25Verify heat treat heating holding, and cooling timesPROC.HR26100% RT on header butt welding after PWHTIR27Witness panel hydrotest - one hour minimum 1.5 MAWP. QA presence required at ALL times when test pressure exceeds MAWP.08001304HHHH28Verify test times and pressure - sign hydrotest sheet.SPECWR29Install Jumper piping (RT -100 % of welds)SPECWR30Install roof casing panels/expansion jointsDWGW31Final inspect casing weldingDWGH32Verify final dimensionsAssy DwgHHH33Final inspect cedureH34Final inspect shipping preparation/identification flow arrow directionAssy DwgHHH35Verify all NCRS are closedQA ManualRR4.Interconnecting PipingItmInspection PointRef. Doc.VendorDPECCTCIPTTUTAI1QAM approvalPO/SPECR2WPS/PQR approvalPO/SPECRR3Weld map approvalPO/SPECRR4Welder qualificationPO/SPECRR5NDE procedure approvalPO/SPECRR6Supplier operating procedure approval (For example: painting, PWHT, etc.)PO/SPECR7Supplier Traveler approvalPO/SPECRR8Review operational routing sign-off s/AIDWGR9Review material receipt inspectionDWGRRRR10Verify production identification and traceabilityDWGWI11Check fit-upDWGW12Check welder/tacker qualificationsASMEWR13Check drawing welding procedure instructions preheatWPSW14Review RT film - Note defect typesASMERR15Verify preheating/cool down requirementsWPSW16Verify x-rays are taken for each welderASMEW17Verify 2 for 1 additional RT of defective weldsContractWR18Penetrant test nozzle welds when required per ASME B31.1ASMERR19Final inspect all weldsDWGHHH20Verify heat treat thermocouple locationProcedureW21Verify heat treat recorder calibrationProcedureR22Sign-off/approve PWHT charts per pecificationASME/SPECRR23Verify supplier travelers completed prior to release for shipment/NCRs closedQA PlanWR24Final inspect shipping reparation identificationContractWHH25Review QA DocumentationContractRRRR5.Walkways/PlatformsItmInspection PointRef. Doc.VendorDPECCTCIPTTUTRemarks1QAM approvalPO/SPECR2WPS/PQR approvalPO/SPECR3Weld map approvalPO/SPECR4Welder qualificationPO/SPECR5NDE procedure approvalPO/SPECR6Supplier operating procedure approval (for example: painting, PWHT, etc.)PO/SPECR7Supplier I & T Plan approvalPO/SPECR8Check material documentation per drawing specificationDWGR9Check welder qualifications and weld procedureAWS Dl.lR10Check fit-up of frameDWGW11Check welding of frameDWGW12Verify dimensionsDWGW13Verify frame identificationDWGW14Verify supplier traveler/QA check points are being followedQA PLANR15Check all walkways/ladders for weld size and dimensionsDWGW16Verify weld spatter removal prior to galvanizingAWS Dl.lW17Check galvanizing per ASTM A-123SPECW18Trial fit first unitDWGH19Check banding/blockingDWGW20Check pack list and material markingsDWGW21Final inspect dimensions/shipping preparation identificationDWGHHH6.Outlet stacksItmInspection PointRef. Doc.VendorDPECCTCIPTTUTRemarks1Check materials compliance to drawing specification.SPEC.R2Check HT number stamping on plates/mill test reports.SPEC.W3Check cylinder thickness and diameter per print. (1% diameter max out of round.)SPEC.W4Check WPS and operator approval.CODER5Check weld bevel for full penetration welding.DWGW6Check first weld seam (subarc).WPSW7Check first weld seam backgouge. DWGH8Check cylinder fit-ups. RT 5%.DWGW9Check base ring diameter/thickness hole size.WPSW10Verify preheat of base ring sections if greater than 1 thick.DWGW11Verify full penetration weld of base ring. DWGW12Check layout of nozzles prior to flame cutting.DWGW13Check overall dimensions per print. Note each dimension on the print for record.DWGH14Check final welding/reinforcement.DWGH15PT structural welds.SPEC.R16Check internal blast/paint as required.DWGH17Check external blast/paintDWGH18Check final ship preparation/identificationSPEC.HHH19Final dimensional inspection.POHHH20Review Quality documentationPOR7.DuctsItmInspection PointRef. Doc.VendorDPECCTCIPTTUTRemarks1Prefabrication MeetingPO/SPECR2QAM approvalPO/SPECR3WPS/PQR approv