Receiving Inspection Procedure-接收检验程序
《管件及法兰原材料接收检验程序》。该程序参考了 ASME B16.9（管件）、ASME B16.5/B16.47（法兰）、ASME B36.10M/ASME B36.19M以及API 5L的相关要求。
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管件及法兰原材料接收检验程序
1. 目的
为确保供应的管件及法兰符合设计图纸、相关标准及合同要求，防止不合格品入库并流入生产工序，特制定本检验程序。
2. 适用范围
本程序适用于各类钢制对焊管件（弯头、三通、异径管、管帽等）以及钢制管法兰（螺纹、平焊、对焊、盲法兰等）的原材料入厂检验。
3. 检验依据
· ️ 采购合同/技术协议
· 制造标准：ASME B16.9, ASME B16.11, MSS SP-95、ASTM A733、MSS SP-83（管件）；ASME B16.5, ASME B16.47, （法兰）
· 材料标准：碳钢、不锈钢、低温钢、合金钢及双相钢等对应标准
4. 检验工具
· * 量具：游标卡尺、高度尺、螺纹规、卷尺、焊缝检验尺、R规（测量圆弧半径）、测厚仪。
· * 检测仪器：光谱分析仪（PMI，即材料成分现场分析仪）、硬度计、超声波探伤仪（必要时）。
· * 辅助工具：放大镜、手电筒。
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5. 检验流程
5.1 文件与资料核对
在实物检验前，首先进行文件验收：
1. 质量证明书：核对供应商提供的材质证明书或合格证。内容应包括：供方名称、需方名称、合同号、标准号、规格、钢号、批号、数量，以及力学性能和化学成分数据。质证书上的炉批号必须与实物标识一致。
2. 铭牌与标签：检查捆扎或包装上的标签是否清晰，信息是否与单据一致。
5.2 外观与标识检验
1. 标识检查：
· 低合金钢/碳钢/低温钢：应有钢印标识（如材料牌号、标准、规格、批号）。
· 不锈钢/双相钢：通常采用油漆喷涂或低应力打标（严禁深度钢印，防止产生应力腐蚀开裂）。
· 标识内容：应包含制造商代号、材料牌号（如A105、WPB、316）、公称尺寸（如8”）、压力等级（如Class 150或Sch40）、炉批号。
2. 外观缺陷：
· 目视检查：内外表面应光滑，无裂纹、结疤、重皮、折叠、尖锐划痕及过腐蚀。
· 端部坡口：管件及对焊法兰的坡口型式（如V型）应符合标准，坡口表面应平整，无毛刺，并应有保护涂层（如防锈漆，但不包括不锈钢）。
· 密封面（法兰）：法兰密封面（如水线、突台面）是检查重点。密封面严禁有任何径向划痕、磕碰、锈蚀或压痕。 通常要求覆盖保护套。
5.3 尺寸检验
这是最关键的量化步骤。
A. 法兰尺寸检验（依据 ASME/GB/HG/API 标准）
1. 外径与厚度：测量法兰外径（O.D.）和法兰厚度，需符合标准公差。
2. 螺栓孔：
· 中心距：测量螺栓孔中心圆直径，公差通常在±0.5mm至±1.0mm。
· 孔径：测量螺栓孔直径，需符合标准。
· 位置度：检查相邻螺栓孔是否跨中（通常与壳体主轴线对称）。
3. 密封面：
· 测量突台高度（如RF型法兰的突台高度）。
· 检查水线深度（如有要求）。
4. 轮毂/颈部尺寸：对焊法兰需测量颈部大端壁厚和长度。
B. 管件尺寸检验（依据 ASME/GB/API 标准）
1. 外形尺寸：
· 弯头：测量中心至端面距离。对于长半径/短半径弯头，公差需严格控制在±2mm以内。
· 三通：测量中心至端面距离（主管和支管）。
· 异径管：测量总长度及两端外径。
2. 壁厚：
· 重点检查：使用测厚仪在管件背部（弯头背部）、三通肩部等易减薄区域多点测量。最小壁厚必须大于标准要求的最小值（通常要求不小于公称壁厚的87.5%）。
3. 圆度：检查管件端部的圆度，确保不超出标准允许范围，以保证后续焊接对口。
5.4 材质检验
1. 光谱分析（PMI）：
· 必检项：对低温钢（如WPL6/WPHY65）及不锈钢管件/法兰，必须100%或按比例（AQL抽样）进行光谱分析，以验证主要合金元素含量。
· 碳钢：必要时进行复核，防止材料混用。
2. 硬度检测：
· 对于有硬度要求的材料（如高温高压用合金钢），应在本体上进行布氏或里氏硬度测试，防止材料过硬导致焊接开裂或过软导致强度不足。
5.5 检验标识与处置
1. 合格品：粘贴合格证（绿色标签），标注检验员编号及日期，办理入库手续。
2. 不合格品：
· 立即粘贴不合格标识（红色标签）。
· 隔离存放至指定区域。
· 填写《不合格品评审处置表》，联系采购部门进行退货或让步接收处理。
· 特别注意：密封面受损的法兰原则上不得让步接收；壁厚负超标的管件严禁用于高压管系。
3. 记录归档：填写《管件/法兰入库检验记录》，记录实测数据，并归档保存，以便追溯。
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6. 抽样与判定规则
· 外观/标识/材质：通常要求100%检查（或按项目ITP要求进行全检）。
· 尺寸/壁厚：
· 大批量同规格：可按GB/T 2828.1标准进行抽样，如一般检验水平II，AQL值（合格质量水平）按主要项目（如壁厚、密封面）取0.65，次要项目取1.5。
· 关键件：建议加大抽检比例，甚至全检。
· 判定：若发现一件关键尺寸不合格，则加倍复检；若仍不合格，判定该批次不合格。
7. 常见拒收缺陷总结
1. 法兰密封面损伤：有径向划痕、锈坑。
2. 壁厚不足：实测壁厚低于标准下限。
3. 材质不符：光谱分析元素含量偏差过大。
4. 标识不清或错误：无钢印或钢印与质证书不符。
5. 外观裂纹：肉眼可见的线性缺陷。
6. 几何尺寸超差：弯头角度偏差过大，或螺栓孔无法对齐。
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注：具体的验收公差请参考最 新的采购技术规格书（如PID、SP文件）。
Acceptance Inspection Procedure for Pipe and Flange Raw Materials. This program refers to the relevant requirements of ASME B16.9 (Fittings), ASME B16.5/B16.47 (Flanges), ASME B36.10M/ASME B36.19M, and API 5L.
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Acceptance and Inspection Procedure for Pipe and Flange Raw Materials
1. Purpose
To ensure that the supplied pipe fittings and flanges comply with the design drawings, relevant standards, and contract requirements, and to prevent non-conforming products from entering the warehouse and flowing into the production process, this inspection procedure is specially formulated.
2. Scope of Application
This program is applicable for the incoming inspection of raw materials for various types of steel butt welded pipe fittings (Elbows, Tees, Reducers, Pipe,Caps, etc.) and steel pipe flanges (Threaded, WN,SO,RF,flat welds, butt welds, blind flanges, etc.).
3. Inspection basis
·Purchase contract/technical agreement
·Manufacturing standards: ASME B16.9, ASME B16.11, MSS SP-95, ASTM A733, MSS SP-83 (Fittings); ASME B16.5, ASME B16.47, (Flange)
·Material standards: corresponding standards for carbon steel, stainless steel, low-temperature steel, alloy steel, and duplex steel
4. Inspection tools
·*Measuring tools: Vernier caliper, height gauge, thread gauge, tape measure, weld inspection ruler, R gauge (for measuring arc radius), thickness gauge.
·*Testing instruments: Spectral analyzer (PMI, on-site material composition analyzer), hardness tester, ultrasonic flaw detector (if necessary).
·*Auxiliary tools: magnifying glass, flashlight.
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5. Inspection process
5.1 Document and Data Verification
Before physical inspection, document acceptance should be carried out first:
1. Quality certificate: Verify the material certificate or qualification certificate provided by the supplier. The content should include: supplier name, purchaser name, contract number, standard number, specifications, steel grade, batch number, quantity, as well as mechanical properties and chemical composition data. The furnace batch number on the quality certificate must be consistent with the physical identification.
2. Nameplates and labels: Check whether the labels on the bundling or packaging are clear and whether the information is consistent with the documents.
5.2 Appearance and Identification Inspection
1. Identification check:
·Low alloy steel/carbon steel/low-temperature steel: There should be steel stamp identification (such as material grade, standard, specification, batch number).
·Stainless steel/duplex steel: usually sprayed with paint or marked with low stress (deep steel marks are strictly prohibited to prevent stress corrosion cracking).
·Identification content: It should include the manufacturer's code, material grade (such as A105, WPB, 316), nominal size (such as 8 "), pressure rating (such as Class 150 or Sch40), and furnace batch number.
2. Appearance defects:
·Visual inspection: The inner and outer surfaces should be smooth, without cracks, scars, peeling, folding, sharp scratches, or excessive corrosion.
·End groove: The groove type (such as V-shaped) of pipe fittings and butt welded flanges should comply with the standard, and the groove surface should be flat, free of burrs, and have a protective coating (such as anti rust paint, but not including stainless steel).
·Sealing surface (flange): The sealing surface of the flange (such as the water line and protruding surface) is the focus of inspection. The sealing surface must not have any radial scratches, bumps, rust or indentations. Usually requires a protective cover.
5.3 Dimensional Inspection
This is the most crucial quantification step.
A. Flange dimension inspection (according to ASME/GB/HG/API standards)
1. Outer diameter and thickness: Measure the flange outer diameter (O.D.) and flange thickness, which must comply with standard tolerances.
2. Bolt holes:
·Center distance: Measure the diameter of the bolt hole center circle, with a tolerance typically ranging from ± 0.5mm to ± 1.0mm.
·Aperture: Measure the diameter of bolt holes and ensure compliance with standards.
·Position tolerance: Check if adjacent bolt holes are centered (usually symmetrical to the main axis of the shell).
3. Sealing surface:
·Measure the height of the protrusion (such as the protrusion height of RF type flanges).
·Check the depth of the waterline (if required).
4. Wheel hub/neck size: For butt welded flanges, the wall thickness and length of the neck's large end need to be measured.
B. Pipe fitting size inspection (according to ASME/GB/API standards)
1. External dimensions:
·Bend: Measure the distance from the center to the end face. For long radius/short radius elbows, the tolerance must be strictly controlled within ± 2mm.
·Three way connection: measure the distance from the center to the end face (main and branch pipes).
·Reducing tube: measure the total length and outer diameter at both ends.
2. Wall thickness:
·Key inspection: Use a thickness gauge to measure multiple points in areas that are prone to thinning, such as the back of the pipe fitting (elbow back) and the shoulder of the tee. The minimum wall thickness must be greater than the minimum value required by the standard (usually not less than 87.5% of the nominal wall thickness).
3. Roundness: Check the roundness of the end of the pipe fitting to ensure that it does not exceed the standard allowable range, in order to ensure subsequent welding alignment.
5.4 Material Inspection
1. Spectral analysis (PMI):
·Mandatory item: For low-temperature steel (such as WPL6/WPHY65) and stainless steel fittings/flanges, spectral analysis must be performed 100% or proportionally (AQL sampling) to verify the content of major alloying elements.
·Carbon steel: Review if necessary to prevent material mixing.
2. Hardness testing:
·For materials with hardness requirements (such as alloy steel for high temperature and high pressure), Brinell or Leeb hardness tests should be conducted on the body to prevent welding cracking or insufficient strength caused by excessive hardness of the material.
5.5 Inspection Identification and Disposal
1. Qualified products: Paste the certificate of conformity (green label), mark the inspector number and date, and handle the warehousing procedures.
2. Unqualified products:
·Immediately paste the non-conforming label (red label).
·Isolate and store in a designated area.
·Fill out the "Non conforming Product Evaluation and Disposal Form" and contact the procurement department for return or concession acceptance processing.
·Special attention: Flanges with damaged sealing surfaces should not be accepted with concessions in principle; Pipe fittings with negative wall thickness exceeding the standard are strictly prohibited from being used in high-pressure piping systems.
3. Record archiving: Fill in the "Pipe/Flange Inbound Inspection Record", record the measured data, and archive and save it for traceability.
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6. Sampling and Judgment Rules
·Appearance/Identification/Material: Usually requires 100% inspection (or full inspection according to project ITP requirements).
·Size/Wall Thickness:
·Large quantities of the same specifications: Sampling can be carried out according to the GB/T 2828.1 standard. For general inspection level II, the AQL value (qualified quality level) is taken as 0.65 for major items (such as wall thickness and sealing surface), and 1.5 for minor items.
·Key component: It is recommended to increase the sampling ratio and even conduct full inspections.
·Judgment: If a critical dimension is found to be non-conforming, double the re inspection; If it is still unqualified, the batch shall be judged as unqualified.
7. Summary of common rejection defects
1. Damage to flange sealing surface: radial scratches and rust pits.
2. Insufficient wall thickness: The measured wall thickness is below the lower limit of the standard.
3. Material mismatch: Excessive deviation in elemental content in spectral analysis.
4. Unclear or incorrect identification: No stamp or stamp does not match the quality certificate.
5. Appearance cracks: Linear defects visible to the naked eye.
6. Geometric dimension deviation: The angle deviation of the elbow is too large, or the bolt holes cannot be aligned.
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Note: Please refer to the latest procurement technical specifications (such as PID and SP documents) for specific acceptance tolerances.