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1、Chapter 5: Examination and Inspection Program第5章 检查和检验程序5.1 General 概述5.1.1 This Chapter describes the manufacturing process examination, testing and inspection on Code Item to ensure that all activities are in compliance with the requirements of the ASME Code and the Customer at shop. 本章叙述了在车间制造过程中
2、对ASME规范产品的检查、试验和检验的控制要求，以保证全部活动符合ASME规范和客户的要求。5.1.2 The QC Engineer shall be responsible for control of the examination and inspection for the Code Items in accordance with the requirements of ASME Code, QC Manual and Customer Specificatio. 质控工程师负责控制规范产品的检查和检验符合ASME规范，本质量控制手册，和客户技术要求。5.2 Process Che
3、ck List工序检查单5.2.1 The Process Engineer shall prepare the “Process Check List” (PCL) (Exhibit 5-1). The PCL shall list all required fabrication operations, examinations, inspections, tests, and specific process according to sequences of fabrication process. The PCL shall have space for the Examiner,
4、the Customer and the AI to sign and date. 工艺工程师应编制“工序检查单”(PCL) (表5-1)。PCL应列出制造过程中所有必需的制造方式、检查、检验、试验、特殊工艺。工序检查单(PCL)应预留专栏以备检验员、客户和AI签名并填写日期。5.2.2 The QC Engineer shall review the PCL and enter all necessary “In House” inspection and customers additional requirements when necessary. Then the PCL shall
5、 be submitted to the Technical Manager for approval with signature and date. The QC Engineer shall present the approved PCL with other relative documents to the AI for review with signature and date and also for the designation of Hold Points (H-point), Witness points (W-point). 质控工程师应审核工序检验单 (PCL)，
6、必要时应输入客户的附加检验要求，PCL应提交技术经理批准并签名和加写日期。质控工程师应该将经过批准的PCL与其他相关文件一起提交给AI审核并指定停工待检点 (H-point) ，现场见证点 (W-point) ，并签名加写日期。5.2.3 When the drawing is revised, the Process Engineer shall revise the PCL accordingly if necessary. When revision to the PCL is made, it shall be controlled in the same manner as the
7、original. The superseded PCL shall be attached to the revised PCL for reference and be submitted to the AI for review. 当设计图纸被修改时，如有需要工艺工程师应修改PCL。修订后的PCL应该与原版本一样审核批准。作废的PCL应该附加在修订后的PCL上用作参考并给授权检验师以供审核时做参考。5.2.4 On completion, the PCL is then forwarded by the QC Engineer to the Doc. Clerk for file and
8、 issue. 审核结束后，质控工程师将PCL转交给资料管理员存档和发放。5.3 Control of Manufacturing Process and Examination制造过程的控制和检查5.3.1 The manufacturing process shall be performed by the Operator and/or Welder under supervision of the Shop Supervisor according to PCL, drawings and procedures. The Shop Supervisor shall inform the
9、 status of fabrication process to the QC Engineer to assign the Examiner to perform the operation. When NDE required, the QC Engineer shall inform the NDE Level III personnel to assign the NDE personnel to perform the operation. 根据PCL，设计图纸和程序文件，生产过程应该由操作员或焊工在车间主管监督下完成。车间主管应该将工序制造的状态告知质控工程师以便指派检验员执行检
10、验。当要求NDE时，质控工程师应该通知NDE三级人员指派NDE人员进行检验。5.3.2 The Examiner shall perform examinations according to applicable examination and test procedures specified on the PCL. The Examiner shall prepare the “Inspection and Examination Record” (Exhibit 5-2) as required. The Examiner shall evaluate the results of t
11、he examinations and tests, then sign and date on the PCL.检验员应按工序检验单 (PCL) 所指定的检验和测试程序进行检验。检验员应按要求准备“过程检验记录”(表5-2)。检验员应评估检验和试验结果，并在工序检验单 (PCL) 上签名、填写日期。5.3.3 Fabrication to a next stage is not permitted unless the relevant examination stage marked on the PCL has been accepted and signed and dated for
12、 the Examiner and /or AI respectively. 只有当相关检查阶段上标明PCL最近已分别被检验员或者授权检验师接受，签名加写日期后，制造才能进入下一阶段。5.3.4 AIs Inspection授权检验师的检验：5.3.4.1 The QC Engineer shall notify the AI reasonably in advance of approaching AIs “H”-point and “W”-point. 在接近授权检验师所指定的停止待检点 (H-point) 和现场见证点 (W-point) 前，质控工程师应提前通知授权检验师。5.3.4.
13、2 The “H”-points designated by the AI shall not be bypassed without presence of the AI. The AIs acceptance shall be indicated by signature and date on the PCL. 由AI确定的停工待检点 (H-point) 不能错过，必须有AI在场, 见证合格后AI在工序检验单过程 (PCL) 上签字并填写日期。5.3.4.3 For “W”-point designated by the AI, generally, the AI shall be in
14、 presence. In certain instance, the AIs “W” points may be waived with the AIs permission. If the AI is unable to attend, the Examiner shall note the date notified by the AI on PCL. In-house inspections will be made and results shall be available and acceptable to the AI during next visit. AI指定的见证点 (
15、W) 一般情况是AI需到场见证, 但如AI不能到场见证, 需事先得到AI的许可通知，检验员应在PCL上注明通知AI的日期，这个检验点由检验员检查合格后认可。检查记录应在AI下一次来厂时提交给AI认可。5.3.4.4 For spot RT according to UW-52, the RT location shall be chosen by AI. If the AI is not free, the QC Engineer will be allowed by the AI to choose the RT location. 对于按UW-52抽样射线检测时，抽样位置应由AI指定。如果
16、AI没空，AI同意质控工程师确定抽样位置。5.3.4.5 The QC Engineer is responsible to provide opportunity for the AI to perform internal inspection prior to final closure, if no access openings are provided. 对于规范产品未设置检查孔时, 质控工程师应在产品最后一条封闭焊缝焊接前, 通知AI对产品内部进行检验。5.3.5 When nonconformity is found, the disposition shall be cont
17、rolled in accordance with Chapter 6 of this Manual. The Examiner shall record the NCR No. on the PCL. 当发现不符合项时，按本手册第6章进行处理。检验员应在工序检验单(PCL)上记录不符合项报告编号。5.3.6 Production Test产品试板5.3.6.1 The Welding Engineer shall prepare a procedure for impact test for welding production test plates according to ASME C
18、ode Section VIII Div.1 when impact test is required. 当要求冲击试验时，焊接工程师应该根据ASME 规范第VIII 卷第1册的要求为焊接试板准备冲击试验程序。5.3.6.2 The impact test will be subcontracted to a vendor who is qualified by the Welding Engineer and holds an impact test machine meeting the requirements of the Code. Prior to testing, the Pro
19、cess Engineer shall be responsible for obtaining from the vendor and maintaining a copy of the valid calibration certificates of Charpy impact test machine and temperature measuring instruments to ensure that the vendors Charpy impact test machine shall have been calibrated annually in accordance wi
20、th the Code latest accepted revision of SA 370 or ISO 148, and temperature measuring instruments used for impact testing shall have been calibrated every six months. 冲击试验将分包给焊接工程师评定的合格供应商，拥有满足ASME规范要求的冲击试验机。测试前,工艺工程师负责从供应商得到有效的夏比冲击试验机和温度测量仪器的的校准证书,以确保供应商的夏比冲击试验机每年依照最新修订的ASME规范版本所接受的SA 370或ISO 148的要求
21、进行计量, 用于冲击测试温度测量仪应当每六个月计量一次。5.3.7 Pressure Testing压力试验5.3.7.1 Prior to the final pressure test of Code Item, the QC Engineer shall verify that all required operations, examinations, tests and inspections have been properly completed and all nonconformity reports have been already closed if existed.
22、在ASME钢印产品最终压力试验前，质控工程师应确认所有必需的操作、检查、试验和检验已正确完成，所有不符合项已被关闭。5.3.7.2 The preparation for final pressure test shall be performed by the Operator under supervision of the Examiner. 车间工人在质检员监督下准备最终压力试验。5.3.7.3 The test gauges used for final pressure test shall be graduated over a range of approximately do
23、uble the intended maximum test pressure, but in no case shall the range be less than 1.5 times or more than 4 times of that pressure. In the hydro pressure test, the pressure gauge shall be connected directly to the Code Items. Pressure gauges and temperature measuring devices shall have been calibr
24、ated in accordance with Chapter 10 of this Manual. 用于最终压力测试压力表量程范围应为大约两倍预期的最大试验压力，但是在任何情况下那个压力表量程范围都不应小于试验压力的1.5倍或者大于试验压力的4倍。在水压试验中，压力表计直接联接到ASME规范产品。 压力表和测温设备应按本手册第10章进行计量。5.3.7.4 During the hydro pressure test for pressure vessel, the metal temperature shall be at least 30F (17) above the Minimum
25、Design Metal Temperature to minimize the risk of brittle fracture of the pressure vessel, but the temperature shall not be higher than 120F (48) . If pneumatic test is used, the metal temperature shall be at least 30F (17) above the Minimum Design Metal Temperature to minimize the risk of brittle fr
26、acture of the pressure vessel. If pneumatic test is to be performed, UW-50 shall be followed. 在水压试验过程中，对压力容器的金属壁温应至少比最低设计金属壁温高出30F（17）以降低压力容器的脆性断裂危险至最低，但该温度不得高于120F（48）。如果采用气压试验，对压力容器的金属壁温应至少比最低设计金属壁温高出30F（17）， 以降低压力容器的脆性断裂危险至最低。如果采用气压，UW-50应该被遵循。5.3.7.5 The final pressure test shall be conducted in
27、 the presence of the AI and in accordance with the requirements of the “Pressure Test Procedure” that complies with the Code. 最终压力试验应该在AI在场的情况下进行，并根据 “压力试验程序”进行。5.3.7.6 The Examiner shall prepare the “Pressure Test Report” (Exhibit 5-3). The QC Engineer shall review the report with signature and dat
28、e, then present to AI for acceptance with signature and date. 检验员应编制“压力试验报告” (表5-2), 质控工程师应审核报告并签名，然后提交授权检验师，授权检验师应签名并填写日期表示确认。5.4 Manufacturers Data Report/ Manufactures Partial Data Report制造厂数据报告/ 制造厂零部件数据报告5.4.1 The QC Engineer shall prepare the appropriate MDR/MPDR in accordance with the design
29、drawings, examination and test data and ASME Section I, B31.1 and Section VIII Div.1. The Technical Manager shall review and certify the MDR/MPDR by signature and date prior to present to AI by the QC Engineer. 质控工程师应该根据设计图纸，检验和试验数据以及ASME 规范第1卷， B31.1和第VIII 卷第1册 编制MDR/MPDR。在质控工程师提交AI审核批准前，应先提交技术经理批准
30、MDR/MPDR并签名和填写日期。5.4.2 When the Customer requires that a MDR/MPDR shall be registered with the NB, the QC Engineer shall assign the NB number, which is issued in sequence starting at 1, without prefix, suffix, skips or gaps of unused number or duplication of a number. And the QC Engineer shall recor
31、d the NB number, manufacturers serial number, as well as MDR/MPDR issuance date and the date of MDR/MPDR mailed to NB in the “NB Number Log Book” (Exhibit 5-4). The NB number shall be assigned only after completion of the final pressure test or final inspection with no pressure test to be performed.
32、 若客户要求MDR/MPDR在美国国家锅炉和压力容器检验师协会 (NB）注册，质控工程师应指定产品NB编号，编号从1开始顺次排列，不要有前缀、后缀、未用号码的跳号或空缺、号码重复。质控工程师应在“NB号码登记注册记录“（表5-4）上记录NB编号、制造序列号、MDR/MPDR的签发日期和MDR/MPDR邮寄去NB的日期。NB编号只能在最终压力试验完成后、或在对于不需压力试验的部件的最终检验后签发。5.4.3 The QC Engineer shall present the MDR/MPDR together with relating documents and records to the
33、AI for review and acceptance. The AI shall indicate acceptance by signature and date on the MDR/MPDR. 质控工程师应该将MDR/MPDR和相关文件一起呈现给AI审核批准。AI应该表明被批准并在MDR/MPDR上签署和填写日期。5.5 Application of Certification Mark / NB Stamp规范标志钢印/ NB钢印的使用5.5.1 The QC Engineer is responsible for custody and control of the ASME C
34、ertification Mark and NB Stamps to prevent the loss and the non-authorized use. 质控工程师负责保管规范标志钢印和NB钢印，以防止钢印的丢失以及非授权使用。5.5.2 With the authorization of the AI, the application of the ASME Certification Mark Stamp, NB Stamp and NB number (if used) shall be hard stamped directly on the nameplate and othe
35、r data required by ASME Code can be pre-stamped casted, embossed or etched on the Nameplate attached to Code Item. 在AI的授权下，ASME规范标志钢印、NB钢印（如需要）应直接打在ASME产品上， 或ASME产品的铭牌上 。其他ASME标准要求的数据可以预先打在或刻在铭牌上。5.5.3 The QC Engineer and the AI shall verify that the information on the Nameplate is in accordance wit
36、h the drawing and that the Nameplate is attached to the correct Code Item. 质控工程师和AI应核对ASME产品的铭牌信息与图纸一致，且铭牌安装到正确的规范产品上。5.5.4 Removable pressure parts shall be permanently marked in a manner to identify them with the vessel or chamber of which they form a part. This does not apply to manhole covers, h
37、and-hole covers and their accessory parts provided the marking requirements of UG-11 or PG-11 are met.可拆卸的或可移动的部件应打上标记追踪到和他们相连的容器。对于人孔盖，手孔盖和满足UG-11或PG-11要求标记的部件不适用。5.6 Distribution and Maintenance of MDR/MPDR制造厂数据报告的分发和存放5.6.1 When requested, the QC Engineer shall send the original certified MDR/MPD
38、R to NB for registration within 60 days after being certified by the AI. 如有要求，质控工程应将已确认的MDR/MPDR正本在授权检验师确认签字后60天内归档并发送到美国国家锅炉和压力容器检验师委员会（NB）登记备案。5.6.2 One copy to the User or his designated Agent, one copy to jurisdiction where the vessel be installed and one copy to the AI upon request.MDR/MPDR的副本应
39、由质控工程师提供给客户、或客户指定的代理、设备安装当地的管辖机构，AI有要求时提供给AI。5.6.3 When registration to the NB is not required, the MDR/MPDR shall be retained by the QC Engineer according to the Chapter 11 of this Manual. 当无需在国家锅炉和压力容器检验师委员会（NB）注册时，质控工程师应按照本手册第11章要求保管MDR/MPDR。5.7 Exhibit 表格 1) Exhibit 5-1: Process Check List (PCL) 工序检查单（PCL） 2) Exhibit 5-2: Inspection and Examination Record过程检验记录 3) Exhibit5-3: Pressure Test Report压力测试报告 4) Exhibit5-4: NB Number Log Book NB号码登记注册记录