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CLIENT: CONSULTANT:

DOC NO. HQSM12-Q13-103-001-A4 REVISION 0

PROJECT NO. HQSM12


HQSM Engineering Pte Ltd
PROJECT TITLE PORT KLANG REFRIGERATED LPG TERMINAL
GPS KLANG TERMINAL SDN BHD
LOCATION PORT KLANG, MALAYSIA SHT NO. SHEET 1 of 1

Inspection &Test Plan for E-101AB


FOR

PORT KLANG REFRIGERATED LPG TERMINAL

IN PORT KLANG, MALAYSIA


FOR COMMENT

REV DATE DESCRIPTIONS PREPARED BY CHECKED BY APPROVED BY

wanghaijun Dingqinghua
0 13/02/2020 FOR COMMENT

THIS DOCUMENT IS THE PROPERTY OF HQSM ENGINEERING PTE LTD


THE INFORMATION CONTAINED HEREON MAY NOT BE USED OR COPIED IN ANY MANNER
WITHOUT THE WRITTEN PERMISSION OF HQSM ENGINEERING PTE LTD
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 1
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

检验点 Inspection point 形成的文件、检验记


检验内容及要求 验收依据及要求 录或检验报告
序号 工序项目 第三方 业主 备注
Inspection content and Acceptance standard Document、
No. process Sunpower Third Owner Remark
requirement and requirement inspection record
party HQSM and report
TPI (if
1 制造准备工作 Manufacturing preparation
Assigned)
1.1 设计文件 Design document

设计单位资质、总图批准手续;
设计及引用标准、总图的内容
Design qualification, general ASME SEC. Ⅷ
1.1.1 图纸 Drawing R R
approval procedures; Div.1,2017
Design and reference standard, H/R
general content
强度计算书 ASME SEC. Ⅷ 强度计算书
签字手续齐全 Signed procedures
1.1.2 Strength Div.1,2017 R R Strength
are completed H/R
calculation TEMA 2007ED calculation
设计变更文件
签字手续齐全 Signed procedures 设计变更单
1.1.3 Design changing R R
are completed. H/R Technical query
document
材料代用单
图纸和图样技术条件
1.1.4
材 料 代 用 Material 审批手续齐全 Review and approval
Drawing technology R
H/R Material
substitution procedures are completed R substitution
condition
requisition

1.2 工艺文件 Process document

检查焊接工艺指导书编写是否符合
焊接作业指导书
1.2.1 要求。Check whether the WPS is in ASME SEC. Ⅸ R R R WPS
(WPS)
line with the requirements.
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 2
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

焊接工艺评定记录审 审查焊接工艺评定是否符合图纸要
查 求 焊接工艺评定
1.2.2 Review weld process Review welding process ASME SEC. Ⅸ R R R 报告
qualification qualification to meet drawing PQR
record requirements
持证项目符合焊接工艺要求 Welder
持证焊工一览表
焊工资质 Welder qualification conforms to the R
1.3 Welder qualification R R
qualification requirements of welding
chart
processes
2 材料入库验收 Material receiving examination
板材、管材、换热管等材料验收
2.1
Material receiving examination for plate、pipe、tube etc.
材料检查 材料检查记录
检查材料外观及尺寸。
2.1.1 Material 图样技术条件 H R R Checking record of
Check material surface and size.
examination Drawing material
按采购要求及材料标准审查材质证 材料标准
材质证明书审查 材料质量证明书
明书 Review material certificate Material Standard
2.1.2 Review material R R R material
according to purchase ASME SEC.Ⅱ
certificate certificate
requirement
2.2 焊接材料 welding material
按采购要求及材料标准审查材质证
质量证明书审查 明书 Review material certificate 焊材标准 焊材质量证明书
2.2.1 Review material according to purchase welding material R R R welding material
certificate requirement and material standard certificate
standard.
材料检查入库 标记检查、实物抽查 焊材标准 焊材检查记录
2.2.2 Material receiving Check marking and welding welding material W R R Checking record of
examination material surface standard welding material
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 3
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

焊材的领用、发放和
回收 按焊材管理制度进行检查 焊材管理制度
2.2.3 Welding material Check according to welding material management R R R
receiving、issuing material management system system
and retrieving

2.3 外购件验收 Purchased partreceiving examination

法兰、管板锻件的检 采购技术条件
尺寸、外观检查;标记检查;质量
验 Purchased technology 法兰检验记录
证明书审核 Check appearance and
2.3.1 Inspection of condition H R R Inspection record
size; check marking; Review
flange and 材料标准 of flange
material certificate.
tubesheet forging Material Standard
螺栓、螺母、密封件
尺寸、外观检查;标记检查;质量
的验收
证明书审核;
Receiving 材料标准
2.3.2 Check appearance and size; W R R
examination of Material standard
check marking; Review material
bolts、nuts and
certificate.
gasket
3 部件制造 Part manufacture
管板、折流板加工后的尺寸、外观
管板、折流板加工 管板加工
检查;标记检查; 图样、工艺流转卡
Tubesheet and 检查记录
3.1 Check appearance and size of Drawing W R R
baffle plate Inspection record
tubesheet and baffle plate after process doc.
processing of tubesheet
machining; check marking;
3.2 封头的制造 head manufacture
检查下料尺寸,核查标记移植 图纸、工艺流转卡
封头的下料
3.2.1 Check cutting size and material Drawing W R R
Cutting of head.
mark removal. process doc.
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 4
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

封头的压制 封头的压制成型 图纸、工艺流转卡


3.2.2 Head forming Check the forming method and Drawing W R R
process. process doc.
封头 R 弧内外表面 100% PT, 按 ASME
Ⅷ-1 附录 8.
封头的无损检测 ASME SEC.Ⅴ 无损检测报告
3.2.3 The inner and outer surface of R R R
NDE for head ASME SEC. Ⅷ Div.1 NDE report
arc 100% PT,according to ASME
Ⅷ-1app.8.
对封头进行成型后检查,包括尺寸、
外观、形状公差等; 图纸、工艺流转卡
封头检查记录
封头成品检查 Head inspection after forming is Drawing
3.2.4 H R R Inspection record
Head inspection preformed, it's including process doc.
of head
appearance, marking, dimension ASME SEC. Ⅷ Div.1
and shape.
3.3 筒体的制造 Shell manufacture
检查下料尺寸,核查标记移植 图纸、工艺流转卡
筒节的下料
3.3.1 Check cutting size and Drawing W R R
Cutting of shell.
material mark removal. process doc.
检查坡口形式、尺寸;外圆展长;
图纸、工艺流转卡
筒节的卷圆组对 错边量等 筒节检查记录
Drawing
3.3.2 shell forming and Check groove shape and size; W R R Inspection record
process doc.
assembly check Outer circle length and of shell
ASME SEC. Ⅷ Div.1
offset .
按 WPS 执行,检查焊材,焊接参
数,焊工资质,焊接质量
筒节的纵缝焊接 According to WPS,Check the
施焊记录
3.3.3 Longitudinal seam welding material, welding WPS W W R
Welding record
welding of shell a. parameters, welder
qualification, welding
quality
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 5
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

图纸、工艺流转卡
筒节的校圆 检查椭圆度、棱角度和外观; 筒节检查记录
Drawing
3.3.4 Roundness correction Check roundness、edge angle and W R R Inspection record
process doc.
of shell. appearance. of shell
ASME SEC. Ⅷ Div.1
纵缝无损检测 FULL RT 符合 ASME Ⅷ-1 UW51.
ASME SEC. Ⅴ 无损检测报告
3.3.5 NDE for longitudinal FULL RT according with ASME Ⅷ R R R
ASME SEC. Ⅷ Div.1 NDE report
seam welding of shell -1 UW51。
4 装配与焊接 Assembly and welding(包括壳体和管箱 Including shell and channel)
图纸、工艺流转卡
筒体环缝组对 坡口、间隙、错边量、总长等; Drawing 筒体组对记录
4.1 Assembly of shell Check groove、gap、offset、total process doc. W R R Shell assembly
circular seam length. ASME SEC. Ⅷ Div.1 record
TEMA-2007 ED
按 WPS 进行焊接,检查焊材,焊接参
数,焊工资质,焊接质量
筒体环缝焊接
Welding according to WPS,Check R 施焊记录
4.2 Circular seam WPS W R
the welding material, welding Welding record
welding of shell
parameters, welder
qualification, welding quality
筒体环缝无损检测 FULL RT 符合 ASME Ⅷ-1 UW51.
ASME SEC. Ⅴ 无损检测报告
4.3 NDE for shell FULL RT according with ASME Ⅷ R R R
ASME SEC. Ⅷ Div.1 NDE report
circular seam -1 UW51。
接管与法兰或焊环组
对、焊接 Assembly 图纸、工艺 Drawing
组对间隙、坡口检查;焊接质量
and welding process doc. 施焊记录
4.4 Check assembly gap 、groove and W R R
fornozzle and ASME SEC. Ⅷ Div.1 Welding record
welding quality.
flange or weld TEMA-2007 ED
ring
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 6
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

接管与法兰或焊环焊 DN≥250mm FULL RT according


缝无损检测 with ASME Ⅷ-1 UW51,
无损检测报告
4.5 NDE for weld of DN≤250mm 100% MT/100%PT ASME SEC. Ⅷ Div.1 R R R NDE report
flange or weld according with ASME Ⅷ-1
ring and nozzle app.6/8
筒体划线开孔 划线开孔位置及开孔尺寸检查 管口方位记录
图纸
4.6 Shell Check Lineation location and H R R Nozzle position
Drawing
scribing,tapping opening size. record
图纸、工艺 管口方位记录
接管与筒体组对 伸出高度、倾斜度;坡口检查
Drawing Nozzle position
4.7 Assembly for nozzle Check groove、projection W R R
process doc. record
to shell highness、gradient degree.
TEMA-2007 ED
按 WPS 进行焊接,检查焊材,焊接参
数,焊工资质,焊接质量
接管与筒体焊缝焊接
Welding according to WPS,Check R 施焊记录
4.8 Welding for welding WPS W R
the welding material, welding Welding record
of nozzle to shell
parameters, welder
qualification, welding quality
100% MT/100%PT,按 ASME Ⅷ-1 附
无损检测 录 6/8 R 无损检测报告
4.9 ASME SEC. Ⅷ Div.1 R R
NDE 100% MT/100%PT , according with NDE report
ASME Ⅷ-1 app.6/8
换热管与管板、折流
板的装配 检查折流板缺口方位、间距等;
图纸
4.10 Assembly for tube、 Check location of baffle breach W R R
Drawing
tubesheet and and spacing.
baffle.
管束穿芯 穿芯前内部检查,方位检查;
图纸
4.11 Through bundle into Shell internal check before W R R
Drawing
shell Through bundle Check location.
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 7
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

管板垂直度、平行度检查;坡口检 图纸、工艺
管板与壳体组对
查 Check the perpendicularity Drawing R R
4.12 Assembly of shell W
and parallelism of tubesheet process doc.
and tubesheet
、gradient degree. TEMA-2007 ED
按 WPS 进行焊接,检查焊材,焊接参
管板与壳体焊接 数,焊工资质,焊接质量
Welding for welding Welding according to WPS,Check 施焊记录 Welding
4.13 WPS W R
of tubesheet to the welding material, welding R record
shell parameters, welder
qualification, welding quality
管板与壳体焊缝无损 100% MT 按 ASME Ⅷ-1 附录 6
无损检测报告
4.14 检测 NDE for weld of 100% MT according with ASME SEC. Ⅷ Div.1 R R R
NDE report
tubesheet and shell ASME Ⅷ-1 app.6
换热管与管板装配焊
换热管与管板装配 图纸、工艺 接记录
换热管的伸出高度
4.15 Assembly of tube to Drawing W R R Assembly and
Projection highness of tube
tubesheet Process doc. welding record for
tube-to-tubesheet
按 WPS 进行焊接,检查焊材,焊接
换热管与管板焊接 参数,焊工资质,焊接质量
Welding for Welding according to WPS. R R
4.16 WPS W
tube-to-tubesheet Check the welding material,
joints welding parameters, welder
qualification, welding quality
换热管与管板焊缝无
损检测 100% PT,按 ASME Ⅷ-1 附录 8
R R 无损检测报告
4.17 NDE for 100% PT, according with ASME SEC. Ⅷ Div.1 R
NDE report
tube-to-tubesheet ASME Ⅷ-1 app.8
joints
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 8
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

贴胀。检查胀接压力及胀管率。
图纸、工艺
胀接 Light expansion. Check 胀接检查报告
4.18 Drawing W R R
Expansion expansion pressure and rate of Expansion report
Process doc.
expansion.
检查附件组装方位,按 WPS 进行焊
接,检查焊材,焊接参数,焊工资
其他附件的组装与焊 质,焊接质量 图纸、工艺
接 Check orientation of attachment Drawing 施焊记录
4.19 W R R
Other attachments Welding according to WPS。 Check process doc. Welding record
assembly and weld the welding material, welding WPS
parameters, welder
qualification, welding quality

附件焊接完成后无损
100% MT/100% PT,按 ASME Ⅷ-1
检测
附录 6/8 R 无损检测报告
4.20 NDE for tube to ASME SEC. Ⅷ Div.1 R R
100% MT/100% PT, according NDE report
attachment after
with ASME Ⅷ-1 app.6/8
welding

5 总装、试压
设备外观尺寸、接管方位、焊缝表
最终外观与几何尺寸 面质量等;检验文件审核 图纸 容器组装
检查 Check vessel appearance、 size、 Drawing R R 检查记录
5.1 H
Check final nozzle location、welding surface ASME SEC. Ⅷ Div.1 Vessel assembly
appearance and size quality; Review inspection TEMA-2007 ED inspection record
document.
补强圈进行 1bar 气密试验 图纸
气密试验 Gas 气密试验报告 Gas
5.2 Gas leak test for reinforcing Drawing W W R
leak test leak test report
pad with 1bar. ASME SEC. Ⅷ Div.1
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 9
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

用水清洁,氯离子含量不超过
25mg/L,水温 8~40℃. The
水压前的准备 图纸 水质报告
hydrostatic test should use R
5.3 Preparation before Drawing W R Water quality
clean water and the CL content
hydrostatic test ASME SEC. Ⅷ Div.1 report
shall be not more than 25mg/l;
the water temperature 8~40℃.
试验压力:5.17MPa.保压 30 分钟。
检查设备泄漏情况。
壳程水压试验 图纸 水压试验报告
Test pressure:5.17MPa. The W R
5.4 Hydrostatic test of Drawing H Hydrostatic test
pressure hold for at least 30
shell side ASME SEC. Ⅷ Div.1 report
minutes.check leakage
condition.
试验压力:2.23MPa.保压 30 分钟。
检查设备泄漏情况。
管程水压试验 图纸 水压试验报告
Test pressure: 2.23MPa. The
5.5 Hydrostatic test of Drawing H W R Hydrostatic test
pressure hold for at least 30
tube side ASME SEC. Ⅷ Div.1 report
minutes.check leakage
condition.
6 包装、发运 package、transport
酸洗钝化 蓝点检测,无蓝点为合格 图纸、工艺
6.1 Pickling and Blue point test. No blue point is Drawing W R R
passivation acceptable. Process doc.
喷砂按照 IS0 851-1 Sa2.5 级,并
碳钢外表面喷砂、油 涂无机富锌底漆(75um) 。Sand
漆 blasting according with level 图纸 油漆报告
6.2 Sand blasting and Sa2.5 of IS0 851-1, and Drawing W R R Sand blasting and
painting for CS painted with inorganic zinc IS0 851-1 painting report
outside. silicate primer.( 75 microns
DFT)
江苏中圣压力容器装备制造有限公司 文件编号 版次 页码
ITP-Y19-164AB 0 10
Doc. NO. Rev. Page
Jiangsu Sunpower Heat Exchanger & 设备名称 C3 HEATER 工作令号 日期
Pressure Vessel Co.,Ltd Y19-164AB 2020.2.13
Equipment name E-101AB Work No. Date

drying and Vessel shall be sealed with a


图纸 W
6.3 preservation minimum of 0.7 bar nitrogen for R R
Drawing
干燥保存 transportation.充氮 0.7bar
备品备件 按备品备件清单检查
备品备件清单
6.4 spare parts Check according to spare parts W R R
Spare parts list
inspection list.
铭牌检查 按图纸核对铭牌数据
图样 铭牌复印件
6.5 Nameplate Confirm nameplate data W R
Drawing R Nameplate copy
inspection according to drawing
出厂(竣工)资料 技术要求 technical 竣工资料
6.6 R R R
AS-built document requirements AS-built document
发运准备与标志 图纸、包装规范
产品包装、防护检查
6.7 Prepare for delive Drawing、 packing W R R
The packing of the products
and mark specification
注释:H-停止检查点 Hold point,W-现场见证点 Witness point, R-文件审查点 Document review point
监检员检验点:A:现场见证 Witness point;B:现场抽查 spot witness point;C:审查确认 Document review;

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