设备制造质量检验规程-Water-Turbines

INSPECTION GUIDELINES

WATER TURBINE

SGS Ref No.Rev.PageDate::::2001 of 819/03/04

INSPECTION GUIDELINES

WATER TURBINE

0Rev.

For ApprovalDescription

19/03/2004Date

J. C. BrottonPrepared

B. TremainChecked

B. TremainApproved

June 2004Date

INSPECTION GUIDELINES

WATER TURBINE

SGS Ref No.Rev.PageDate::::2002 of 819/03/04

CONTENTS

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PURPOSESCOPEPROCEDUREDOCUMENTS

INSPECTION PROCESSSHIPPING

WATER TURBINE DATA DOSSIERINSPECTION CHECK LIST

INSPECTION GUIDELINES

WATER TURBINE

SGS Ref No.Rev.PageDate::::2003 of 819/03/04

1.0 PURPOSE

This instruction covers the inspection, test and verification activities required to validate thesupply, manufacture and test of a Water Turbine for general use.

2.0 SCOPE

This instruction covers all necessary stages in the production of a Water Turbine from theexamination of certification from procurement sources to the final inspection, preservation andpacking to despatch to site.

Although the methodology in compiling this instruction is to systematically progress through theconstruction of a typical Water Turbine. Experienced, inspectors may interpret the intent of theinstruction to accommodate local or novel practices or to utilise the instruction for a one-off, oralternative design of Turbine. The design having been approved by the client. Any suchvariations should be noted on the inspector's report.

3.0 PROCEDURE

3.1

GENERAL

This instruction together with the associated check sheet may be used on any contract or order.It is intended to act as a guide to the inspector in the course of the inspection programme. Anypart of the document may be invoked and the sections to be used and the level of inspectionrequired will be as specified on the check list.

All tests and inspections will be carried out against the approved drawings, purchase orderspecifications, purchasers or company standards, and within the practices and rules of thecountry, state or province and any government decrees, laws, ordinance or regulation as mayapply.

If any conflict or contradictions should be apparent in any of the above then the more onerousrequirement will apply unless the purchaser or client directs otherwise in writing.3.2

REFERENCE DOCUMENTS

Applicable codes and specifications.

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Design code (to be stated on inspection report)Purchase order specificationPurchaser's standardsApproved drawings

SGS company standards

Applicable codes and standards (sample only)

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JIS B8103

4.0 DOCUMENTS TO BE RECEIVED/AVAILABLE AT INSPECTION

Purchase Order or ContractInspection and Test PlanData sheet

Sub-assembly drawingsMaterial test certificates

Weld procedures and Procedure Qualification RecordsList of qualified welders or welding operators

INSPECTION GUIDELINES

WATER TURBINE

SGS Ref No.Rev.PageDate::::2004 of 819/03/04

Welders' qualifications

Calibration of measuring and test equipment

NDE procedures, (appropriate to material of construction)List of qualified NDE operators/inspectorsNDE /inspectors' qualificationsHydrostatic testing procedurePerformance test procedure

Preparation and painting procedure

Preservation, packing and shipping procedureSupply list (packing list)

5.0 INSPECTION PROCESS

5.1 MATERIAL5.1.1

REVIEW OF CERTIFICATION

Original or authenticated copies of certificates should be available at the manufacturer's

premises. These should be examined for compliance with specifications and where appropriate,drawings:

The review will include checks on:-

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Manufacturer's name and locationCertificate No

Material SpecificationHeat or cast No

Makers No or Plate NoChemical compositionMechanical propertiesHeat treated conditionNDE applied and resultsSurface finish

5.1.2 VISUAL AND DIMENSIONAL VERIFICATION

Material identification on certificates against product markings.

Material supplied against drawing, material list and specification as appropriate.Visual and dimensional compliance with specification.5.1.3 ADDITIONAL/SPECIAL REQUIREMENTS

May apply on special components. Check to ensure specification contract requirements havebeen met. Witness NDE examinations as necessary.5.1.4 REPORTING

Reporting on the material checks should include:

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Conformation of satisfactory document review

Record of endorsement of certification reviewed/witnessedRecord of all non-conformities

Record of any tests witnessed and the result

INSPECTION GUIDELINES

WATER TURBINE

SGS Ref No.Rev.PageDate::::2005 of 819/03/04

5.2WATER TURBINE MANUFACTURE

After clearance of the above points to the satisfaction of the inspector, the fabricator will proceedwith the manufacture of the sub assemblies and components for the Water Turbine.5.2.1

FABRICATION INSPECTION

Following the completion of welding and machining operations the Turbine parts will beinspected as required by the specification or contract. The inspection will consist of:

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5.2.2

Visual inspection for damage

Dimensional check to drawing requirementInspection of parts, for cleanliness

Visual examination of welded on connectionsReview of welder qualificationsReview of weld procedure recordConfirmation of satisfactory NDE

Proper documentation of the materials used

Examination/inspection of integral parts such as reduction gears

HYDROSTATIC TESTS

The turbine casing and other pressure containing parts will be hydrostatically tested.

The inspector must verify that the correct test pressure has been applied to the relevant partsdepending on specification requirements.5.2.3

CLEARANCE CHECKS

After completion of fabrication the required clearances will be checked in accordance with thespecification requirement in particular the areas to be examined are:

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5.2.4

Radial clearance between rotor and casing

Axial clearance between the rotor blades and stationary parts

MECHANICAL RUNNING TEST

Many turbines are subjected to a mechanical running test. Where required by the contract orpurchase order the following items will be checked:

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5.2.5

Critical speed

Bearing temperaturesVibration Noise test

FINAL VISUAL EXAMINATION

After completion of all testing a visual examination including a partial strip down of the unit isusually required by the specification. The particular areas of interest are:

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Surface roughnessVane profiles

Internal cleanliness

Location/orientation of terminal flanges