SHELL AND TUBE TYPE Date:05/03/04
INSPECTION GUIDELINES
HEAT EXCHANGERS
OF
SHELL AND TUBE TYPE
0For Approval05/03/2004J. C. Brotton B. Tremain B. Tremain June 2004 Rev.Description Date Prepared Checked Approved Date
数三考研大纲
SHELL AND TUBE TYPE Date:05/03/04
CONTENTS
1PURPOSE
2SCOPE
3PROCEDURE
4DOCUMENTS
5INSPECTION PROCESS
6SHIPPING
7VESSEL DATA DOSSIER
8INSPECTION CHECK LIST
SHELL AND TUBE TYPE Date:05/03/04
1.0 PURPOSE
This instruction covers the inspection, test and verification activities required to validate the
supply, manufacture and test of a Shell and Tube Heat Exchanger.
2.0 SCOPE
This instruction covers all necessary stages in the production of the Shell and Tube Heat
Exchanger from the examination of certification from procurement sources to the final
inspection, prervation and packing to despatch to site.
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Although the methodology in compiling this instruction is to systematically progress through
the construction of a typical Shell and Tube Heat Exchanger. Experienced, inspectors may
interpret the intent of the instruction to accommodate local or novel practices or to utili the
instruction for a one-off, or alternative design of Heat Exchanger. The design having been
approved by the client. Any such variations should be noted on the inspector's report.
3.0 PROCEDURE
3.1 GENERAL
This instruction together with the associated check sheet may be ud on any contract or
order. It is intended to act as a guide to the inspector in the cour of the inspection
programme. Any part of the document may be invoked and the ctions to be ud and
the level of inspection required will be as specified on the check list.
All tests and inspections will be carried out against the approved drawings, purcha order
specifications, purchars or company standards, and within the practices and rules of the
country, state or province and any government decrees, laws, ordinance or regulation as
may apply.
If any conflict or contradictions should be apparent in any of the above then the more
onerous requirement will apply unless the purchar or client directs otherwi in writing.
3.2 REFERENCE DOCUMENTS
Applicable codes and specifications.
•Design code (to be stated on inspection report)
•Purcha order specification
•Purchar's standards
•Approved drawings
•SGS company standards
Applicable codes and standards (sample only)
•EN 16812 : 2003
•ASME VIII Division 1
•TEMA Class R, B or C
•API 660, 605
•AS 1210
•JIS B8249
SHELL AND TUBE TYPE Date:05/03/04 4.0 DOCUMENTS TO BE RECEIVED/AVAILABLE AT INSPECTION
Purcha Order or Contract
Inspection and Test Plan [ITP]
Data Sheet
绿化管理制度
Sub-asmbly drawings
Material test certificates
Weld procedures and Procedure Qualification Records
List of qualified welders or welding operators
Welders' qualifications
Calibration of measuring and test equipment
NDE procedures, (appropriate to material of construction)
List of qualified NDE operators/inspectors
NDE /inspectors' qualifications
Heat treatment procedure
Hydrostatic testing procedure
Water quality document
Preparation and painting procedure
Prervation, packing and shipping procedure
管理科学Supply list (packing list)
5.0 INSPECTION PROCESS
5.1 MATERIAL
5.1.1 REVIEW OF CERTIFICATION
Original or authenticated copies of certificates should be available at the manufacturer's
premis. The should be examined for compliance with specifications and where
appropriate, drawings:
The review will include checks on:-
•Manufacturer's name and location
•Certificate No
•Material Specification
•Heat or cast No
•Makers No or Plate No
•Chemical composition
•Mechanical properties
辐射服•Heat treated condition
•NDE applied and results
•Surface finish
•Structural obrvations, notable defects
5.1.2 VISUAL AND DIMENSIONAL VERIFICATION
Material identification on certificates against product markings.
毕业生就业协议Material supplied against drawing, material list and specification as appropriate.
Transfer identification to cut off components, (Cast No transfer), as specified.
Visual and dimensional compliance with specification.
5.1.3 ADDITIONAL/SPECIAL REQUIREMENTS
May apply on special components, e.g. thick components, clad or dissimilar material,
纪录片镜子alloy steels or non ferrous materials. Check to ensure specification contract
SHELL AND TUBE TYPE Date:05/03/04 requirements have been met. Witness NDE examinations as necessary.
5.1.4 REPORTING
Reporting on the material checks should include
•Conformation of satisfactory document review
•Record of endorment of certification reviewed/witnesd
•Record of all non-conformities
•Record of any tests witnesd and the result
5.2FABRICATION OF HEAT EXCHANGERS (SHELL AND TUBE TYPE)
After clearance of above points to satisfaction of the inspector, then the fabricator will proceed with the manufacturer of sub-asmblies and components of the heat exchanger.
Inspectors will review the following points on a basis to be outlined in the applicable National Standard, purchars documentation, inspection and test plan or other documents, as notified to the inspector.
5.2.1 PREPARATION FOR WELDING
Carry out visual and dimensional check to ensure compliance with WPS and specification. Where specified, weld bevels shall be examined by MT or PT after grinding/machining. Edges and weld
bevels will be clean, dry and free from surface defects, laminations, cracks, voids, notches, etc.
The shall be a cau for rejection unless suitable/satisfactory remedial action can be taken.
Welding repairs to bevels are not permitted, without approval from the client. Inspectors must report excessive or rious defects.
5.2.2 WELD INSPECTION
5.2.2.1 EDGE PREPARATION
Visual and dimensional checks will be performed in accordance with the WPS and specification. MT
or PT will be made on cut edge as required and edges shall be free from lamination, crack, notch,
etc.
5.2.2.2FIT-UP INSPECTION
Shapes, alignment and dimensions will be checked in accordance with approved WPS and drawings.
5.2.2.3VISUAL CHECK AND NDE
Groove and adjacent area will be clean and free from foreign materials, oil, paint, water and rust,
and will also be free from injurious defects such as cracks, and laminations.
Tack welds will be performed using the same procedure of applicable WPS and will be free from defects. NDE will be performed as required for edge and tack weld.
5.2.2.4MONITORING OF WELD
Preheat temperature and method, interpass temperature, weld material control, qualified WPS and
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qualified welder employed, welding operation, cleanliness will conform to approved WPS and specifications.
5.2.2.5BACK GOUGING INSPECTION
