RPLC项目检查和测试程序

1、inspection and test procedurepage 1 of 34 inspection and test procedurefor construction of rplc projectrplc 项目检查和测试程序 doc. no.: f074-pi-0310-0001revision status:c18-07-13issue for approvalb28-05-13issue for approvala17-04-13issue for approvalrev.datedescriptionprepared bychecked byapproved byhyundai

2、-wisonclientqin yongshi xiangquanzhang shouyueinspection and test procedurepage 2 of 34table of contents1introduction 简介简介.31.1 purpose.31.2 scope .31.3 definitions and abbreviations.32process .53general notice .54overview.75steel structure.96painting, blasting, galvenizing .147piping .178equipment.

3、279electrical.2910 instrument.2911 weighting.3012 load out.3013 delivery .31inspection and test procedurepage 3 of 341introduction 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

4、.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 poi

5、nt”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

6、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

7、 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

8、companypetroles de venezuela, s.a. (pdvsa)contractora consortium formed by hyundai engineering & construction co., ltd., hyundai engineering co., ltd., and wison engineering ltd.vendorwison (nantong) heavy industry (whi) also referred to as “wison”clientcompanycontractorinspection and test procedure

9、page 4 of 34holdbuilder is not allowed to proceed with the inspection/test unless a written release is issued by the contractor.必须有总包批准方可检查witnessbuilder can proceed with the inspection/test when contractors representatives is not present at the notified time.可以在通知时间自行检查 surveillancebuilder is not r

10、equested to notify contractor / company. the contractor / company inspector will monitor work in progress, test and inspections during his visit or periodical inspection. 不需要通知总包和甲方，总包和甲方的检查员将会周期性的监督工作的进程测验和检查reviewbuilder shall provide contractor and or company with certificates, reports and record

11、s as applicable for review.分包需要提供可用的证书，报告和记录给甲方和总包1.3.2abbreviations 缩写代码 the following abbreviations apply to this itp document:下面的缩写代码适用于本 itp程序文档apiamerican petroleum institute 美国石油组织asmeamerican society of mechanical engineers 美国机械工程师学会asntamerican society of non-destructive testing 美国无损检测学会aisc

12、american institute of steel construction 美国钢结构施工协会astmamerican society for testing and materials 美国材料检测学会awsamerican welding society 美国焊接学会dcdigital control 数位控制dftdry film thickness 干膜厚度dwgdrawing 图纸e&ielectrical & instrumentation 电气仪表rplcrefinery puerto la cruzididentityisointernational organizati

13、on for standardization 国际组织标准inspection and test procedurepage 5 of 34itpinspection and test plan 检查测试计划mpimagnetic particle inspection 磁粉检查ncrnon conformance record 现场质量询问单ndtnon destructive testing 无损检测pepproject execution plan 项目执行计划pmipositive material identification 光谱分析pqrprocedure qualificati

14、on record 工艺评定记录ptpenetration testing 渗透pwhtpost weld heat treatment 焊接热处理qaquality assurance 质量保证qcquality control 质量控制rtradiographic testing 射线探伤utultrasonic testing 超声探测whiwison heavy industry 惠生重工womwison offshore & marine 惠生海洋wpswelding procedure specification 焊接工艺评定2process 过程过程the following f

15、abrication itp work sheets identify the following processes:下面的 itp 制作工作表印证了下面的程序；overview 概况steel structure 钢结构painting/blasting/galvanizing 涂漆、喷砂和镀锌piping 管道equipment 设备electrical 电气inspection and test procedurepage 6 of 34instrument 仪表insulation 保温load out 外运 delivery 运送3general 一般一般3.1 all inspe

16、ction and testing items are to be performed in accordance with project specification, relevant rules and regulations specified in specification。所有的检查和检验项目必须与工程的相关说明，相关特殊的规章制度保持一致。3.2 according to the construction schedule, qa/qc shall notify the contractors and/or companys representative to attend t

17、he inspection and/or testing as the following procedure:根据施工日程表，质量检查和控制人员必须通知总包和业主的代表去参加检查和检验根据以下程序；a. ”daily inspection application form” shall be submitted to contractors and/or companys representative before 17:00 by email one day before yard carried out inspection or test. inspections scheduled

18、on weekend or during national holiday have to be submitted two days before. 日常的检查申请表必须在检查的前一天下午 5 点之前通过邮件发送给总包或业主代表；检查计划在周末和假期的需要提前两天申报； b. if schedule changed, qa/qc shall notify the contractors and/or companys representative as early as possible. 如果检查日期变更，qa/qc 人员需尽早通知业主和总包代表；3.3 the contractors a

19、nd/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-inspection will be based on the comments of first inspection.业主和总包代表需要检查签字做

20、好记录以及备注。根据检查结果，对产品进行下一步的推动工作或修改。为了加强工作效率，二次检验将会根据第一次检查的备注来实施。3.4 the contractors and/or companys representative shall attend inspection and testing as”h”, and “w”, in plan. 业主和总包方将会根据检查计划表里的“h”和“w”来参加价差测试3.5 builder shall provide all the notification to contractors and/or companys representative as”

21、h” and “w” in plan.过程中，生产方必须给出业主和总包方“h”和“w”inspection and test procedurepage 7 of 343.6 the contractors and/or companys representative inspection shall be carried out after internal inspection of whi.业主和总包方将会在惠生自检之后进行检查测验； remark: h: hold w: witness s:surveillance r: review rplc deep conversion proj

22、ectpartyrecord no. quality control activityitem to be inspectioncontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbre-markspage 8 of 344.0 overview 概述概述4.1welding procedure specification焊接工艺评定pqrwpswelding control proceduref074-pi-0310-0002

23、aws d1.1/1.8asme section ixclient spec.30510-02 rev.2hhryy:yes4.2welder qualification焊工资质welder qualification testreview/ approval of welders qualificationwelder management proceduref074-pi-0310-0003aws d1.1/1.8asme section ixclient spec.30510-03rev.1hws4.3 material control 材料控制material receiving in

24、spectionmaterial inspectiongb materials retest inspection by 3rd partymaterial traceability for memberslayout for material storageinspection of incoming materials proceduref074-pi-0310-0004positive material identification procedure f074-pi-0310-0005material identification and traceability proceduref

25、074-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:yes rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, p

26、roceduresrecord formwhicontractorcompanyor/irfidbremarkspage 9 of 344.3ndt personnel 无损检测人员review / approval of ndt operators qualificationndt personnel qualification proceduref074-pi-0310-0006client spec.30528-02rev.0hrr4.5final submission 终交shop drawings / ndt drawingsquality plan and itprelevant

27、procedures wps and pqrregister of qualified welders and ndt operatorsas-built inspection and test reports with summery listas-built drawings material certificatesproject as-built documents control proceduref074-pi-0310-0007client spec.n/ahrr rplc deep conversion projectpartyrecord no. quality contro

28、l activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 10 of 345.0 steel structure 钢结构钢结构5.1material receiving 材料接收material id/ markingquantityvisual (surface , cut edge )mill certificatesmaterial grade

29、sizeheat no., batch no.mill sheetinspection 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 材料二次测试检验re-testing (high-strength steel)gb material

30、s retest inspection by 3rd partyproject procurement quality planf074-pi-0305-0002client spec.30516-02rev.3hwsyy:yes5.3cutting , beveling , transfer of identification , marking and material traceabilitymachiningcuttingbevelingtransfer of identificationmaterial traceabilitypositive material identifica

31、tion proceduref074-pi-0310-0005client spec.30516-01rev.3hss rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 11 of 345.4fit-up inspectionp

32、reparation 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.230503-39 rev.1hws5.5welding controlwps approvedwelding

33、 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-0310-0002welding consumables control proceduref074-pi-0310-0010client spec.ap

34、proved pqr/wpsn/ahss rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 12 of 345.6weld visual inspectionjoint no./ welder no.date of welded

35、crack/ undercutporosity/ arc strike/ spatterreinforcementlack of root surfaceconcave root welding control proceduref074-pi-0310-0002client spec.30503-44 rev.2hwsyy:yes5.7ndtultrasonic testing is applicable to all weld types;ultrasonic examination extentut performanceultrasonic examination proceduref

36、074-pi-0310-0011client spec.asme section v 30506-01rev.2hwsyy:yes5.8ndtradiographic testing is applicable to butter welds only;radiography inspection extentrt performanceidentification of filmradiographic film evaluationradiography proceduref074-pi-0310-0012client spec.asme section v 30507-01rev.2hr

37、syy:yes rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 13 of 345.9ndtmagnetic particle and liquid penetration inspection is applicable t

38、o the weld surfaces of each type of joints;magnetic particle inspection proceduref074-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 , (i

39、f any ndt required after repair)welding repair proceduref074-pi-0310-0015client spec.asme section vasme section ix approved pqr/wps30506-02 rev.230507-01 rev.230506-01 rev.2hwsyy:yes rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresaccepta

40、nce criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 14 of 345.11dimensional controlrolled tubularnodes panelsassembled blockscompleted jacketpiles and legsflatnesserection dimensional structure and pipeline dimensional control proceduref074-pi-0310-0016heat

41、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-0310-0018

42、control 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:yes rplc deep conversion projectpartyrecord no. quality control

43、activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 15 of 346.0 painting/blasting/galvanizing6.1receiving inspection of coating materialpaint batch no. paint manufacturers specificationspaint certifica

44、tesabrasive 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 method: dry blastingblasting condition surface preparation and painting inspection pro

45、ceduref074-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 preparation and painting inspection proceduref074-pi-0310-0021color coding proceduref07

46、4-pi-0310-0022client spec.sspc-pa 230517-02 rev.2hwsyy:yes rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 16 of 346.4inspection of adhes

47、ionadhesion test shall be checked at 3 pointssurface preparation and painting inspection proceduref074-pi-0310-0021client spec.astm d 3359sspc30517-02rev.2hwsyy:yes6.5inspection of holidayholiday check with a holiday detectorrepair defects and re-inspectpainting repair proceduref074-pi-0310-0023clie

48、nt spec.astm g 62sspcnace30517-02rev.2hwsyy:yes6.6repairdamaged portion shall be thoroughly cleaned by blasting , power tools or sandpaperpainting repair proceduref074-pi-0310-0023client spec.sspcnace30517-02 rev.2after repair, re-inspectionhwsyy:yes6.7handlingprotection of coated surface during lif

49、ting and handling operationssurface preparation and painting inspection proceduref074-pi-0310-0021client spec.n/awss rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractor

50、companyor/irfidbremarkspage 17 of 346.8hot-dip galvanizingstructure 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

51、 53/a 53mastm a 153/a 153mastm a 123/a123m30583-01 rev.1hwsyy:yes rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 18 of 347.0 piping7.1ma

52、terial 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 identificationidentify mat

53、erial 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 client offered materials procedure

54、f074-pi-0310-0025client spec.30516-03 rev.430516-04rev.330516-06 rev.3hws rplc deep conversion projectpartyrecord no. quality control activityitem to be inspectioncontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbre markspage 19 of 347.3su

55、rface preparation of pipecleanliness : sspc-sp5 -sp6 sspc-sp7 -sp10 sspc-sp11blasting method: dry blastingblasting condition surface preparation and painting inspection proceduref074-pi-0310-0021client spec.iso8501sspc-sp5/sp6 -sp7/sp10 -sp1130517-02 rev.2hwsyy:yes7.4painting inspection andcoating t

56、hickness(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-0310-0022client spec.sspc-pa 230517-02 rev.2hwsyy:yes rplc deep conversion projectpartyrecord no. quality control a

57、ctivityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 20 of 34pipe piece identification (spool no.)joint number identificationhws7.5fit-upjoint configuration (root face/opening, groove angle, offset ) tap

58、ered angletack weldsalignmentpipe prefabrication, installation and inspection proceduref074-pi-0310-0026client spec.approved wpsasme 31.3inspection criteriatable f074-pi-0310-005530503-12rev.2hws7.6welding inspectionverification of equipment calibrationcompliance to wps & pqrverification of welders/

59、 welding operators qualificationwelder number identificationwelding consumable control preheating/inter-pass temperaturecleaning of welded surfaceswelding consumables control proceduref074-pi-0310-0010welding control proceduref074-pi-0310-0002client spec.approved wpsasme 31.3n/awss rplc deep convers

60、ion projectpartyrecord no. quality control activityitem to be inspectedcontrolling proceduresacceptance criteria / standards codes, proceduresrecord formwhicontractorcompanyor/irfidbremarkspage 21 of 347.7visualinspectionjoint number/spool numberweld defectcrack ,undercut, porosityarc strike, spatte