设备制造质量检验规程 Positive Material Identification

INSPECTIONGUIDELINESSGSRefNo.:11Rev.:0POSITIVEMATERIALPage:1of6IDENTIFICATIONDate:23/06/04INSPECTIONGUIDELINESPOSITIVEMATERIALIDENTIFICATION0ForApproval23/06/04J.C.BrottonB.TremainB.TremainJune2004Rev.DescriptionDatePreparedCheckedApprovedDateINSPECTIONGUIDELINESSGSRefNo.:11Rev.:0POSITIVEMATERIALPage:2of6IDENTIFICATIONDate:23/06/04CONTENTS1PURPOSE2SCOPE3PROCEDURE4DOCUMENTS5INSPECTIONPROCESS6INSPECTIONCHECKLISTINSPECTIONGUIDELINESSGSRefNo.:11Rev.:0POSITIVEMATERIALPage:3of6IDENTIFICATIONDate:23/06/041.0PURPOSEThisinstructioncoverstherequirementstobeimplementedwhenPositiveMaterialIdentification[PMI]isarequirementofacontractororder.Thepurposeofthetestbeingtopreventtheincorporationofwrongmaterialsintoafabrication.Note:ThisguidelinecoversthewitnessingofPMItestingonlyatmanufacturersworksorinfieldorsite.2.0SCOPEThisinstructioncoversthenecessarystagestoensurethatPositiveMaterialIdentificationiscorrectlycarriedoutwhenappliedtothecontractrequirements.Theinstructioncoversthephysicalcheckingofalloysteels(ingeneralthosePNumbersare3orhigherintheASMEIXcode).AlthoughthemethodologyincompilingthisinstructionistoprogressthroughthePositiveMaterialIdentificationtechnique,specificationsissuedagainstcontractswillvaryinthedetailtobeapplied.Experiencedinspectorsmayinterprettheintentoftheinstructiontoaccommodatelocalornovelpracticessuchpracticeshavingbeenapprovedbytheclient.Anysuchvariationsshouldbenotedintheinspectorsreport.3.0PROCEDURE3.1GENERALThisinstructiontogetherwiththeassociatedchecksheetmaybeusedonanyorderorcontract.Itisintendedtoactasaguidetotheinspectorinthecourseoftheinspectionprogramme.Anypartofthedocumentmaybeinvokedandthesectionstobeusedandthelevelofinspectionrequiredwillbespecifiedonthechecklist.Alltestsandinspectionswillbecarriedoutagainsttheapproveddrawings,purchaseorderspecifications,purchasersorcompanystandards,andwithinthepracticesandrulesofthecountry,stateorprovinceoranygovernmentdecreeslaws,ordinanceorregulationsasmayapply.Ifanyconflictorcontradictionsshouldbeapparentinanyoftheabovethenthemoreonerousrequirementwillapplyunlessthepurchaserorclientdirectsotherwiseinwriting.3.2REFERENCEDOCUMENTSApplicablecodesandspecifications•Designcode•Purchaseorderspecification•Purchasersstandards•Approveddrawings•SGScompanystandardsApplicablecodesandspecifications(sampleonly).•ASMESectionII•ASTME327•ASMEE353•ASMEE527•ASMEE572INSPECTIONGUIDELINESSGSRefNo.:11Rev.:0POSITIVEMATERIALPage:4of6IDENTIFICATIONDate:23/06/044.0DOCUMENTSTOBERECEIVED/AVAILABLEATINSPECTIONPurchaseorderInspectionandTestPlan[ITP]CalibrationcertificatesforPMIequipmentApplicablePositiveMaterialIdentificationproceduresPersonnelQualifications5.0INSPECTIONPROCESS5.1INSTRUMENTSFORPMIANALYSISTheinstrumentsusedshallbesuitableforidentifyingthematerialetc.,byquantitativemeasurementofthemajoralloyingelementsrequiredintheapplicablematerialspecificationorweldingproceduresspecificationandasapprovedorspecifiedbyclient.5.2POSITIVEMATERIALIDENTIFICATIONGENERALREQUIREMENTSPriortoanyPMItestingisperformedbythematerialsupplierormanufactureorthird-partyInspectionCompanythefollowingpointsshallbechecked•PMIshallbeconductedbeforeanypostweldheattreatment,hydrotest,paintingorInsulationofanyequipment,materialorwelds•Theareatobetestedshallbecleanedtoremoveanygrease,oilorpaint.•Surface[basemetalandwelds]tobeexaminedshallbepreparedbylightgrindingtoremoveanyrustandscaleaspermanufacturesrecommendations•Weldsurfaceofoverlayorcladrestorationshallbepreparedbyremoving2-3mmofweldmetal5.3ALLOYITEMSSUBJECTTOPMIComponentsorweldssubjecttoPMIandpercentagetestedshallbespecifiedbyclient5.4EXTENTOFVERIFICATIONThePMIprogramcoveringmaterialstobetestedwillbespecifiedbyclientbutgenerallywillcoveralloymaterialandpressurecontainingcomponentsinshopandfieldfabricatedequipmentandpiping[bothbasemetalsandwelds]andmaterialsusedforrepairorreplacementofpressurecontainingcomponents5.5ELEMENTSFORVERIFICATIONTheelementsofthebasicalloymaterialstobeverifiedwillspecifiedbytheclientbutGenerallyshallbeinaccordancewithTable1INSPECTIONGUIDELINESSGSRefNo.:11Rev.:0POSITIVEMATERIALPage:5of6IDENTIFICATIONDate:23/06/04TABLE1BASICALLOYELEMENTSTOBEVERIFIEDCarbon-MolybdenumManganese-MolybdenumChromium&MolybdenumChromium-MolybdenumSteelsNickelSteelsNickelRegularCarbonGradeStainlessSteelChromium,Nickel&MolybdenumLow-CarbonStainlessSteelsChromium,Nickel,Molybdenum&CarbonChromium,Nickel,Molybdenum,Titanium&StabilisedStainlessSteelNiobiumNickelBasedAlloysNickel,Iron,Copper,Chromium&MolybdenumCopper,ZincandotherelementsspecifiedinCopperBasedAlloysclientspurchaseorder/specifications5.5ACCEPTANCECRITERIAAcceptanceofmaterial,componentsorequipmenttestedshalldemonstratethattheycontaintheamountsofalloyingelementsshowninmaterialspecification.5.6REJECTIONIfthePMItestingresultsfalloutsidetheacceptablerangeusingtheacceptablemethodapprovedbyclientallmaterialsetcwillberejectedandreplacedwithnewmaterialetcunlessadditionaltestingoracceptanceisacceptedbyclient5.7MARKINGANDCOLOURCODINGEachmaterial,componentorweldanalysedshallbemarkedinaccordancewithclientsspecificationorPMIprocedureasspecifiedMarkingmaterialsshallbefreeoflead,sulphur,zinc,cadmium,mercury,chlorineandorotherhalogensMaterials,weldswithunacceptablePMItestresultsshallbemarkedinaccordancewithClientsspecificationorPMIprocedureasspecified5.8REPORTANDRELEASETheinspectorwillprepareafinalreportsummarisingthePositiveMaterialIdentification,alloyverificationactivitiescarriedout.Itwillbeissuedinaccordancewiththecontractrequirementsandcirculatedwithinthetimelimitsspecifiedinthecontract.Thereportwillbeinaformatapprovedbytheclientandmustclearlyindicatetheacceptanceorrejectionoftheprocessassessed.5.9RELEASENOTEWhenrequiredbythecontractareleasedocumentwillbeissuedtothemanufacturer.INSPECTIONGUIDELINESSGSRefNo.:11Rev.:0POSITIVEMATERIALPage:6of6IDENTIFICATIONDate:23/06/046.0INSPECTIONCHECKLISTINSPECTIONCHECKLIST(1)VISUALINSPECTION/WITNESSINGBYBUYERREPRESENTATIVE(2)CERTIFICATES/RECORDSTOBECHECKEDBYBUYERREPRESENTATIVE(3)CERTIFICATES/DATATOBEPROVIDEDBYVENDOR/SUPPLIER/MANUFACTURERPre-Fabrication/ProductionRequirementsSpecificationDetails/NotesPurchaseOrderRequirementsInspectionandTestPlan(ITP)P.M.IProcedureIn-ProcessInspection&TestingRequirementsMaterialTestCertificates&IdentificationDimensionalCheckSamplingLevel(checktocontractororder)ComponentAcceptance/RejectionMarkingReviewCalibrationCertificatesFinalInspection&TestingRequirementsVisual&DimensionalCheckMarkingandColourCodingFinalP.M.I.ReportAdditional/SupplementaryRequirements