Outline for Safety Performance Supervisory Inspection.docx
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Outline for Safety Performance Supervisory Inspection.docx
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OutlineforSafetyPerformanceSupervisoryInspection
AppendixI
OutlineforSafetyPerformanceSupervisoryInspection
ofBoilerandPressureVesselProducts
A.BOILER
I.Applicablescope
Thisoutlineisthegeneralrequirementsforsupervisoryinspectionofthesafetyperformanceofstationarypressure-containingboilerswithwatermediumandorganicfluidHeatersandtheirparts.Thesupervisoryagencymayadjusttheitemsandcontentsbasedontheactualsituation.
II.Contentsofsupervisoryinspection
1.Supervisoryinspectingtheitemsrelatedtothesafetyperformanceoftheproductduringboilermanufacturing.
2.Supervisoryexaminingtheimplementationofthequalitysystemofthesupervisedmanufacturer
III.Itemsandmethodsofsupervisoryinspection
1.Drawinganddatareview
(1)Reviewthedesigndataoftheboilerproducts,
(2)Examinethestandardsandtechnologyforboilermanufactureandinspection;
(3)Reviewthestandardsandtechnologyfornon-destructiveexamination(NDE);
(4)Reviewtheapprovalformalitiesofdesignchange(includingmaterialsubstitution).
2.Manufacturequalityofdrum(shell),furnace,tube-plate,reversecombustionchamber,verticalflueandlowersupportring
(1)Checkmaterialcertificateandmaterialre-testreport
(2)Checktheselectionandformalitiesofsubstitutematerials
(3)Checkthetransplantationofmaterialidentification
(4)Appearanceexamination(includingbasemetalsandwelds)
(5)Examineweldpositionandstaggerbetweentheabuttingwelds
(6)Checktheidentificationsteelstampofweldersandweldingoperators
(7)Spot-checkgeometricdimension(includingdifferencebetweenthemaximumandtheminimuminnerdiametersofcylinder,angularity,straightness,misalignmentandlocationofopening)
(8)Measurewallthicknessofcylindersandheads(tubeplate)(ifnecessary)
(9)Examinethenumberandmanufacturingmethodofweldingtestplate
(10)Checkpropertytestreportsofweldingproducttestplateandverifythetestresults
(11)CheckNDEreportandspot-checkthex-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthetotalnumberoffilms(filmsatcrossjoint,T-jointandatdoubtfulpositionandweldingrepairshouldbeincluded.
(12)Checkheattreatmentrecordsandreport
(13)Checkhydrostatic(pressure)test(includingtestingpressure,temperaturesoftestmediumandofenvironment,pressureraisingrate,pressuredwellingtimeandvalidationofpressuregaugecalibration)
(14)Checkthedimensionsandappearanceofopeningsfortube,therectificationoftubejointsandmachiningquality.
3.Supervisoryinspectionofmanufacturingqualityforheader
(1)Checkmaterialcertificateandmaterialre-testingreport
(2)Checktheselectionofsubstitutematerialsandmaterialsubstitutionformalities
(3)Examinethetransferofmaterialidentification
(4)Examinesurfacequality(includingweld)
(5)Wall-thicknessmeasurement(ifnecessary)
(6)Checktheidentificationsteelstampofwelders
(7)Checkspectrumanalysisreportofalloysteeltube,weldandofcomponentsandparts
(8)Verifyingthenumberandmanufacturingmethodofweldingtestplate
(9)Checkthemechanicalpropertytestreportoftheproductweldingtestplateandverifythetestresult
(10)CheckNDEreportandspotcheckx-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthetotalnumberoffilms
(11)Checkheattreatmenttechnologyandreport
(12)Checkhydrostatic(pressure)test(includingtestingpressure,temperaturesoftestingmediumandofenvironment,pressureraisingrate,dwellingtimeandthevalidationofcalibrationforpressuregauges)
(13)Examinetheopeningdimensionandsurfacequalityoftubehole,rectificationoftube-jointsandmachiningquality
4.Supervisoryinspectionofmanufacturingqualityfortubes
(1)Checkmaterialcertificateandmaterialre-testingreport
(2)Checktheselectionofsubstitutematerialsandmaterialsubstitutionformalities
(3)Checkthetransferofmaterialidentification
(4)Appearanceexamination(includingweld)
(5)Spot-checkgeometry(includingbendingqualityoftubesanddifferencebetweenthemaximumandtheminimuminnerdiameters)
(6)Reviewthespectrumanalysisreportforalloysteeltube,welds,componentsandparts
(7)Verifyingthenumberandmanufacturingmethodtubetestsamplesmadebyeithercuttingfromtubesorattachingwithtubes
(8)Checkthemechanicalpropertytestreportoftheproductweldingtestplateandverifythetestresult
(9)CheckNDEreportandspotcheckx-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthetotalnumberoffilms
(10)Conductsoundingoftubebyballs
(11)Checkhydrostatic(pressure)test(includingtestingpressure,temperaturesoftestmediumandofenvironment,pressureraisingrate,dwellingtimeandvalidationofcalibrationforpressuregauges)
5.Safetyappurtenance
Thenumber,specifications,typesandcertificatesofcomplianceofsafetyappurtenanceshouldmeettherelevantrequirements.
6.Thermaladjustingtestforsafetyperformanceofcompactoil-firedorgas-firedboilersinmanufacturer
(1)Checkifthetypesandspecificationsofsafetyvalves,pressuregaugesandwaterlevelindicatorsmeettherequirements.
(2)Checkifthewaterlevelcontroldevicesaresensitive
(3)Checkiftheover-pressureprotectiondevicesaresensitive
(4)Checkiftheignitionprogramcontrollersandfireextinguishprotectiondevicesaresensitive
(5)Checkiftheburnermatchestheboiler
7.Examinationofdeliverytechnicaldocumentofboilers
(1)Checkthedeliverytechnicaldocuments
(2)Checkthecontentsonnameplateandstampthesupervisoryinspectionsymbolonit
8.Supervisoryinspectiondata
Oncetheproducthaspassedthesupervisoryinspection,thesupervisoryinspectorshouldsummarizethedataandverifyingpapersintimeaccordingtotheSupervisoryInspectionItemsforSafetyPerformanceofBoilerProductsandissuetheSupervisoryInspectionCertificate.
9.Thesupervisoryinspectorshouldcheckthefollowingdocumentsofthesupervisedcompanies
(1)Qualitymanual
(2)Thelistofappointmentanddismissalofqualitysystempersonnel
(3)Thelistofqualifiedweldersandweldingoperatorsengagedinboilerwelding(includingqualifieditems,termofvalidityintheircertificatesandidentificationsteelstamp)
(4)ThelistofpersonnelengagedinNDE(includingqualifieditems,levelandtermofvalidityintheircertificates)
(5)Thelistofinspectorsengagedinboilerqualityinspection
(6)Boilerdesigndata,technologicaldocumentandinspectionandtestingreportandrecordandasummarizedtableofweldingprocedurequalification
(7)Supervisedmanufacturerproductionplanforboilers
(8)Sub-contractsforboilerproduction
B.PressureVessel
I.Applicablescope
Thisoutlineisappliedtothesupervisoryinspectiononsafetyperformanceofpressurevesselexceptforgascylinders.
II.Contentsofsupervisoryinspection
1.Supervisoryinspectingtheitemsrelatedtothesafetyperformanceoftheproductduringpressurevesselmanufacturing.
2.Supervisoryexaminingtheimplementationofthequalitysystemofthesupervisedmanufacturer
III.Itemsandmethodsofsupervisoryinspection
1.Drawinganddata
(1)Examinethecertificationofpressurevesseldesigner,conformtheeffectivenessofitsqualification
(2)Reviewtheeffectivenessofstandardsonmanufactureandinspectionforpressurevessel
(3)Reviewtheapprovalformalitiesfordesignchange(includingmaterialsubstitution).
2.Materials
(1)Checkmaterialcertificateandmaterialre-testreport
(2)Checkthetransplantationofmaterialidentification
(3)Checktheselectionandformalitiesofsubstitutematerialsformainpressureparts
3.Welding
(1)Checktheweldingprocedurequalificationandtheirrecords,verifythattheweldingtechnologyusedinproductproductionisinaccordancewiththerelevantstandardsandcodes.
(2)Confirmthenumberandmanufacturingmethodoftheweldingtestplate.
(3)Checkthepropertytestreportoftheproductweldingtestplatesandconfirmthetestresults.
(4)Checkidentificationsteelstampsofweldersandweldingoperators.
(5)Checkformalitiesandproceduresforweldingrepair.
4.Visualanddimensionalexamination
(1)Examinetheappearanceofweldedjoints.
(2)Checkthemechanicaldamageonthesurfaceofbasemetal
(3)Checkthedifferencebetweenmaximumandminimumdiametersofshell.Checkthestraightnessofthecylinderofverticalvesselwithheightmorethan30meters,Checkthearrangementofweldsandthedeviationoffigureinheadandrecordtheiractualdimensions.Checkthemaindimensionsoftheformingpetalforsphericalvessels.
5.Non-destructiveexamination
(1)Checkx-rayfilmarrangementmapandNDEreport.VerifytheproportionandpositionofNDE.Forthespot-NDEpressurevessel,checktheextensionRTfortherepairedwelds.AsfortheUTorsurfaceflawdetection,thesupervisoryinspectorshouldconductrandomon-sitesupervisoryinspectioninadditioncheckingthereport.
(2)Checkthex-rayfilms.Thenumberofthex-rayfilmsbeingcheckedshouldnotbelessthan30percentofthewholeandshouldnotlessthan10films(includingthex-rayfilmsatT-joint,doubtfulareaandattherepairedarea).
6.Heattreatment
Checkandconfirmthecorrespondencebetweenheattreatmentcurveandactualheattreatmentparameterandprocedure.
7.Pressuretest
Beforepressuretest,confirmthatallrequireditemshavepassedthesupervisoryinspectionandthesupervisedmanufacturerhaskeptthetestimonyofthewhole-completedwork.Duringpressuretest,thesupe
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