钢结构和机械部件的生产质量手册.docx
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钢结构和机械部件的生产质量手册.docx
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钢结构和机械部件的生产质量手册
QUALITYMANUAL
FORMANUFACTURINGOFSTEELSTRUCTUREANDMECHANICALCOMPONENTS
Project
C1150PuertoNoevo
Contractor
SandvikMiningandConstructionMaterialsHandlingGmbH&CoKG
Supplier
Misc.
Component
Steelstructure
SMCMHDocumentCode
1150-QA-01
Revision
Date
Prepared
Checked
Approved
Remarks
00
07.04.2011
Prein
Prein
Frischer
FirstIssue
TABLEOFCONTENTS
1GeneralInformation4
1.1Purpose4
1.2Definitions/Glossary4
1.3RegulationsandStandards4
1.3.1General4
1.3.2StandardsandCodes4
2ScopeofWork6
2.1General6
2.1.1Qualificationofmanufacturer6
2.2DescriptionofManufacturer’swork6
2.2.1Workshop6
2.2.2Material6
2.2.3Manufacturing/Fabrication7
2.2.4Machining8
2.2.5Painting9
2.2.6Pre-/TrialAssembly9
2.2.7Packing&Loading9
2.2.8Transport9
3Workexcluded=ServicesbySANDVIK10
3.1EngineeringServicesbySANDVIK10
3.2Supplyofpartsandcomponentsforpre-assembly10
4QualitySystem11
4.1General11
4.2InspectionandTestPlan(ITP)11
4.2.1ITPPlanningRequirements11
4.2.2Inspection&TestPlan(ITP)11
4.2.3ITPFormat11
4.2.4TerminologyusedinITP12
4.2.5QualityRecords12
4.2.6Traceability12
4.3ControlofNon-ConformingItems12
4.3.1IdentificationofNon-conformingUnits13
4.3.2SegregationofNon-conformingUnits13
4.3.3DecisionRegardingNon-conformingUnits13
4.3.4Rectifying/Reworking13
4.3.5Concession13
4.3.6DeliveryreturnedtoSub-Contractor13
4.4Inspection,Measuring&TestEquipment13
4.5Manufacturer'sDataReport(MDR)13
4.6AccesstoManufacturer's/Subcontractor'sPlant14
5StructuralSteelwork15
5.1ManufacturerQualification/Workmanship15
5.1.1QualificationofProceduresandPersonnel15
5.1.2Drawings15
5.1.3WeldingofStructuralSteelwork16
5.1.4PressureTesting16
5.1.5Handrails,WalkwaysandGratings16
5.1.6MaterialofConstruction16
5.1.7WeldingConsumables16
5.2InspectionandTestingofStructuralSteelwork17
5.2.1NDTlaboratory17
5.2.2MaterialTestCertificates17
5.2.3QualityofWelds17
5.2.4Definitionofclassesacc.EN2581717
5.3PreparationforSiteWelding18
5.4MACHINING18
5.4.1Tolerances19
5.4.2CriticalDimensions19
6SurfaceTreatmentandPainting20
6.1Scopeofwork20
6.2Workmanship20
6.3QualityofCoatings20
6.4SurfaceTreatment20
6.4.1SurfacePreparation/20
6.5PaintingSystem21
6.6UnpaintedSurfaces21
6.6.1General/Allgemeines21
6.6.2HighStrengthFrictionGripBoltedJointSurfaces21
6.7ReferenceAreas21
6.8Component&EquipmentProtection22
7Slipresistantconnectionswithhightensilebolts23
7.1Preparation23
7.2Prestressingofbolts23
7.3Checkingofslipresistantconnections23
8WorkshopAssembly26
8.1General26
8.2Pre-Assembly26
8.3Ex-WorkInspection26
8.4DeliveryStatus26
8.5Responsibility26
8.5.1Manufacturer26
8.5.2SANDVIK26
8.6MatchMarking27
9DispatchandDispatchDocuments28
10Annexes28
1
GeneralInformation
1.1Purpose
Thefabricationofmaterials,manufacturingandpaintingofsteelstructuresandmechanicalcomponents(accordingtodivisionofwork),aswellaspre-assemblingtounits,packingandtransportationtoerectionsitewillbesubjectofthisspecification.
1.2Definitions/Glossary
MainContract
AgreementmadebetweenEMPLOYERandCONTRACTOR
EMPLOYERClient
AtlasInvestmentsLtd.
Engineer
TheEmployerhasappointedanengineeringconsultantgrouptofulfiltheroleofthe“Engineer”forthedesign,procurementandconstructionmanagementoftheProject.The“Engineer”willbeauthorisedtoactforandonbehalfoftheEMPLOYERinthemannerprovidedintheMainContract.
CONTRACTOR
SandvikMiningandConstructionMaterialsHandlingGmbH&CoKG(Sandvik)
Manufacturer
SupplierofSandvikforcomponentsasperPurchaseOrder
P.O.
PurchaserOrder;agreement(contract)betweenSANDVIK(Contractor)andManufacturer
Sub-supplier
SupplierofManufacturer
Machine
Equipmentpre-assembledonlyasperspecification
Site
Assemblingarea;atworkshopornearbytheportforshipment
Ex-workInspectionPlan
DefinitionoftheQualityactivitiesatsubcontractor’sworkshopbeforereleaseofshipmenttosite
DeliveryStatus
Definitionofthepre-assembledleveloftheassemblygroupsreadyfortransporttoerectionsite
I.T.P.
Inspection&TestPlan
1.3RegulationsandStandards
1.3.1General
TheManufacturershallagreethatthework(equipmentandmaterial)suppliedbyhimwillbemanufacturedandinspectedonbasisofinternationalcodesandstandardsrelevanttosuchworkandeffectiveatthetimeofthecontractsigning.
1.3.2StandardsandCodes
AllworksperformedbytheManufacturershallbeinstrictaccordancewiththelatestrevisionoftherelevantinternationalStandardandCodesunlessspecificallynotedotherwiseinthecontractdocuments.InparticularthecodesandstandardsincludingthesupplementaryrequirementsnominatedelsewhereinthisSpecificationshallapply.
AnyproposeddeviationsfromtheseStandardsandCodesshallbesubmittedbytheManufacturertoSANDVIKwhoseapprovalmaynotbegrantedunlessthedegreeofstrengthandqualitybeatleastequaltothoserepresentedbytheStandardsandCodesspecified.
EXCERPTofStandard
DINEN729/1,2,3,4
Qualityrequirementsforweldingstructures
DINEN22553
Weldingsymbolsondrawings
EN287-1/EN9606
Welderqualification
EN288/1,2,3
Requirementsandacceptanceofweldingprocedures
EN473
ND-Testing
DINEN571-1
Dyepenetrationtest
DINEN1290
Magneticparticletest
DINEN1435
Radiographictest
DINEN1712-1714
UT-Testingofweldjoints.....
EN25817
Arc-weldedjointsinsteel:
Guidanceofqualitylevelforimperfections
DIN4762
Surfaceroughness,terminology
DIN18800
StructuralSteelwork:
design&Construction
EN10160
TFLformetallicproducts
EN10020
Definitionandclassificationofsteel
EN10025
Nonalloystructuralsteel
EN10029
Hotrolledplates:
tolerancesofthickness.straightness
EN10083
Quenchedandtemperedsteel
EN10204
Inspectiondocumentsformetallicproductssurvey
EN10213
Steelcasting
BS5493
Protectivecoatingofironandsteelstructureagainstcorrosion
ENISO12944-2
PaintsandVarnishes-Corrosionprotectionofsteelstructuresbyprotectivepaintsystems.
Part2:
ClassificationorEnvironments
ISO8501
Preparationofsteelsurfacebeforeapplicationofcoatings-sandblasting
DIN55928
Corrosionprotectionofsteelstructuresbytheapplicationofcoatings
DINENISO2178
Measurementofcoatingthickness;magneticmethod
NOTE:
FurtherStandardsandCodesappliedarespecifiedintherelevantcontractualspecification,whichwillbepartofthePurchaseOrder(PO).
2
ScopeofWork
2.1General
TheManufacturershallsupply:
∙allworkshopengineeringservices,
∙material,equipmentandconsumable,
∙labour,servicesetc.
necessaryfor:
∙pre-treatmentofsemi-finishedproducts
∙manufacturing,
∙testing,
∙painting,
∙pre-andtrail-assembly
∙assembly
∙packaginganddeliverytositeassubjectofthisspecification
2.1.1Qualificationofmanufacturer
∙Manufacturertomaintainaqualitysystemacc.ISO9001.
∙Additionally,forallproductionofmainstructures,themanufacturerhastobecertifiedacc.DIN18800-7classE.
∙Welderstobecertifiedacc.EN287-1,whereasthelastre-qualificationhastobeperformedwithinthelastyear.
2.2DescriptionofManufacturer’swork
2.2.1Workshop
Preparationofallinternalworkshopdrawings,cuttingdrawingsandWorkShopPlanningbasedontheinformationwhichwillbeprovidednamely:
∙Assemblyanddetaildrawingsincludingalldetailslikeweldingsymbols,machiningsymbols,heattreatment,itemnumbers,...............
∙Billofmaterials=partlists
AllotherdetailingnecessaryfortheshopdrawingsandfabricationistheManufacturer'sresponsibility.
2.2.2Material
Provideallmaterial(steelplates,section,profiles,castings,forgings,etc.)asrequiredforthefabricationofthestructures.
PleasenotethattheweightsgivenbyBOMarenetweights(cut-offsmustbeincludedbythecompany).
NodirectpurchaseofmaterialproducedinAsiaorformerRussianfederationallowed,priortoapprovalbythecontractor.
Thecontractorreservestheright,toperformchem.Andmech.testsofmaterialsdeliveredfromthesecountries.
2.2.2.1Material-Plates&Sections
Nearlyallstructuralmaterial(highstressedareasaswellasminorparts)usedforfabricationofthesemachineswillbeofmaterialaccordingtoEN10025asS235J2+NorS355J2+Nunlessotherwisespecifiedondrawingsresp.BOM´s(morestringentrequirementtobeapplied).
2.2.2.2Bolts,Nutsandwashers
AllBolts,nutsandwasherstobehotdipgalvanizedandthethreadsinplatesmustbesuitabletotheboltsize.
Allboltedconnectionstohavetwowashers,oneonthenutsideandoneontheboltheadside.
AllboltsareinManufacturer’sscopeofsupply(alsohighfrictiongripbolts)
BoltsshallbeaccordingtoDINEN-StandardsasDINEN24016orDINEN24017etc.
Highstrengthboltsofqualityclasses10.9and12.9tobedeliveredin“black”condition.
2.2.2.3Materialcertificates
Finalinspectioncertificatesforcomponentstobeissuedbythemanufacturer/sub-supplier:
3.1acc.toEN10204:
∙PressureVessels
∙Transformers
2.2acc.toEN10204:
∙Screensandvibratingequipment
∙Gearunits
∙Shafts,castandforgedparts
∙Compressors
∙Pumps
∙Crusher
2.1acc.toEN10204:
∙Allotherequipment
Certificatesofbasematerialofsteel-structuretobehandedoverfromthemanufacturer/sub-supplierissuedbythe
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