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Outline for Quality Acceptance Inspection of Plate and Shell Heat Exchanger Manufacturing Process 1. General Principles 1.1 Content and Scope of Application 1.1.1 This outline mainly stipulates the basic content and requirements for quality acceptance inspection of the manufacturing process of plate and shell heat exchanger by the purchasing unit (or user unit). It can also be used as the basis for entrusting factory supervision. 1.1.2 This syllabus applies to plate and shell heat exchangers used in the petrochemical industry. 1.2 Main basis for preparation: 1.2.1 "Pressure Vessel Safety Technical Supervision Regulations" ； 1.2.2 GB 150 "Steel Pressure Vessels" ； 1.2.3 GB 151 "Shell and Tube Heat Exchanger" ； 1.2.4 GB 16409 "Plate Heat Exchanger" ； 1.2.5 GB 16749 "Pressure Vessel Corrugated Expansion Joint" ； 1.2.6 JB 4732 "Analysis and Design of Steel Pressure Vessels" ； 1.2.7 Plate and shell heat exchanger design documents and procurement "Technical Agreement" ； 1.2.8 Relevant standards, etc. 2. Raw materials 2.1 The main steel types of the shell are 321, 316L, 16MnR, 2.25Cr1Mo and 1.25Cr0.5MoSi ； The main steel types of plates are 321, 316L, TA2, and 2205. 2.2 Review the quality certificate of the main material (including welding materials) according to the procurement "Technical Agreement". The material grade and specification, forging grade, quantity and supplier should be consistent with the provisions of the procurement "Technical Agreement". 2.3 The main material should be inspected for appearance, heat treatment status, and material markings. 2.4 The chemical composition, temper brittleness sensitivity coefficient, normal temperature mechanical properties, high temperature mechanical properties, Charpy impact test, grain size and non-metallic inclusions (referring to forgings), hardness, temper embrittlement tendency assessment, intergranular corrosion test, non-destructive inspection results and sampling locations, the number of samples, and simulated heat treatment status of the main pressure-bearing parts such as the cylinder, head, equipment flange, manhole flange and cover, inlet and outlet flange and cover, and flange nozzle, shall be consistent with the procurement "Technical Agreement". Material re-inspection shall be in accordance with the "Pressure Vessel Safety Technical Supervision Regulations" and the procurement "Technical Agreement". 2.5 The chemical composition, mechanical properties, intergranular corrosion test and heat treatment status of the plate should be consistent with the provisions of the procurement "Technical Agreement". 2.6 The material grade and specifications, chemical composition, and mechanical properties of corrugated pipes should be consistent with the provisions of the procurement "Technical Agreement". 2.7 The inspection of main bolts, main nuts, supports and other materials should be consistent with the provisions of the procurement "Technical Agreement". 2.8 Bolts processed from Ф≥50 bar stock shall be subjected to ultrasonic inspection after rough machining, and shall be accepted according to the procurement "Technical Agreement". 2.9 The inspection of shell welding materials and stainless steel surfacing materials should be consistent with the procurement regulations of the "Technical Agreement". 2.10 Any main material that changes its heat treatment state during the manufacturing process should undergo performance heat treatment again, and its mechanical property results should comply with the relevant regulations of the base material. 3. Welding 3.1 Welders must hold valid welding qualification certificates of corresponding categories. 3.2 The manufacturer should complete the welding process qualification according to the construction drawings, procurement "Technical Agreement" and the provisions of JB4708 before welding the product. 3.3 The welding process qualification covers at least main material welding joints, cladding welding joints, dissimilar steel welding joints, and plate bundle material welding joints. 3.4 The welding procedure evaluation report should be submitted to the relevant unit for confirmation in accordance with the procurement "Technical Agreement". 3.5 Welding operations should strictly comply with welding process disciplines. 3.6 Cr-Mo steel should be preheated before welding, and hydrogen elimination or stress relief treatment should be carried out in time after welding. 3.7 The number of welding repairs shall not exceed the procurement "Technical Agreement" and all repairs shall be supported by rework process assessment. 3.8 Weld inspection: 3.8.1 The chemical composition of the deposited metal of Cr-Mo steel pressure-bearing welds should be checked, and the sampling quantity and analysis results should be accepted according to the procurement "Technical Agreement". 3.8.2 The hardness testing of pressure-bearing welds (including heat-affected zones and base materials) after final heat treatment shall be in accordance with the procurement "Technical Agreement". 3.8.3 The fillet weld of the nozzle should be welded in the flat welding position as much as possible, and the welding fillet height and smooth transition should be checked. 3.8.4 Defects such as undercuts, cracks, pores, arc craters, slag inclusions, and spatter are not allowed in the appearance of the weld. 3.8.5 The welding of the long sides of the plate and tubes in the plate bundle components, the stacking of the plate and tubes, the welding of the inserts and the ends of the plate and tubes, the welding of the inserts and the compression plates, the welding of the ends of the plates and tubes, the welding of the upper and lower plate tubes and the compression plates, etc., should comply with the welding process requirements of the construction drawings, and should be welded continuously without defects such as burn-through or virtual welding. 3.8.6 The welding methods for the long sides of the plate and tube should be resistance welding and argon arc welding, and the remaining parts of the plate bundle should be argon arc welding. 3.8.7 The chemical composition of the surfacing layer should be analyzed, and the sampling location and quantity should be accepted according to the procurement "Technical Agreement". 3.8.8 The ferrite number of the surfacing layer should be measured. Test methods, sampling parts, and quantities shall be accepted according to the procurement "Technical Agreement". 3.8.9 The expansion joint bellows should be integrally formed, no circumferential welds are allowed, and only one longitudinal seam is allowed. 3.8.10 The hardness of the surfacing layer on the flange sealing surface should be checked and accepted according to the procurement "Technical Agreement". 4. Non-destructive inspection 4.1 Non-destructive inspection personnel should hold valid qualification certificates of the corresponding category (level). 4.2 Ultrasonic inspection after rough machining of pressure-bearing forgings shall be accepted according to the procurement "Technical Agreement". 4.3 Magnetic particle or penetrant inspection after finishing of pressure forgings shall be accepted according to the procurement "Technical Agreement". 4.4 The shell plate should be subjected to ultrasonic inspection in accordance with standard requirements and accepted according to the procurement "Technical Agreement". 4.5 Non-destructive inspection of pressure-bearing welds: 4.5.1 The flaw detection method, flaw detection ratio, and acceptance level of shell class A, B, and D welds shall comply with the provisions of the Procurement Technical Agreement. 4.5.2 Cr-Mo steel Class A and B welds should be 100% radiographic inspected after welding and accepted according to JB/T4730-2005 Level II. 4.5.3 Cr-Mo steel Class A and B welds should be subjected to 100% ultrasonic inspection after welding, heat treatment and hydrostatic testing, and shall be accepted according to JB/T4730-2005 Level I. 4.5.4 Cr-Mo steel Class A, B, and D welds should be subject to 100% magnetic particle inspection after welding, heat treatment, and hydrostatic testing, and shall be accepted according to JB/T4730-2005 Level I. 4.5.5 The flaw detection methods, flaw detection ratio and acceptance level of other steel types shall comply with the provisions of the Procurement Technical Agreement. Among them, shell type A and B welds with δ ≥ 38mm should also undergo 20% ultrasonic inspection after welding, and be accepted according to JB/T4730 Level I. 4.6 The flaw detection method, flaw detection ratio, and acceptance level of the connection joint between the shell and the support and the welding joint of the support cylinder should comply with the provisions of the Procurement Technical Agreement. 4.7 The surfacing section and joints connecting the shell and the skirt, the Cr-Mo steel joints on the skirt, the Cr-Mo steel and carbon steel joints, and the carbon steel joints should be subjected to non-destructive inspections after welding, heat treatment, and hydrostatic testing. The inspection methods, inspection ratios, and acceptance levels should comply with the provisions of the Procurement Technical Agreement. 4.8 The longitudinal seams of corrugated pipes should be 100% radiographic inspected and accepted according to GB/T3323 Level II. 4.9 All welds of expansion joints shall be subject to 100% penetration inspection and shall be accepted according to JB/T4730-2005 Level I. 4.10 All welds between plate bundle inserts and plate tubes, inserts and side plates, and compression plates and side plates shall be subject to 100% penetration inspection and shall be accepted according to JB/T4730 Level I. 4.11 The stainless steel surfacing layer should be subject to 100% penetration inspection and acceptance according to JB/T4730 Level I. 5. Dimensional inspection 5.1 The geometric shape and dimensional inspection of the cylinder should be carried out after machining or rounding. 5.2 After stamping the head, the geometric shape and size should be inspected. 5.3 Dimensional inspection should be carried out after nozzle processing. 5.4 The thickness of all surfacing layers should be checked. 5.5 The overall size, nozzle orientation and protruding height should be checked. 5.6 Plate bundle components: 5.6.1 The corrugation depth and plate size after pressing should be checked. ； 5.6.2 The metallographic structure of the raw material should not be changed after the plate is pressed, and the appearance should be free of scratches and indentations. ； 5.6.3 The plate bundle and the lower shell should be assembled so that the plate bundle slideway is in the middle and faces directly below to bear the load. The assembly orientation is according to the construction drawing. ； 5.6.4 Side rail inserts shall not be welded to plates ； 5.6.5 Verticality of support plates, support plates, side plates and plate bundles ； 5.6.6 The manufacturing, inspection and acceptance of plate bundles should be in accordance with the relevant procurement "Technical Agreement", and the size of the inserts higher than the plate, lower than the size of the end seam of the plate bundle, and the gap between the inserts and the plate tubes should be strictly controlled. 5.7 The geometry and size of expansion joints should be checked. 5.8 The concentricity of the expansion joint, the nozzle, the shell and the plate bundle should be checked. 5.9 The size of the distribution plate and distribution pipe of the distributor should comply with the requirements of the construction drawings, and the distribution holes should not have burrs or other blockages. 6. Heat treatment and test plates 6.1 Heat treatment of base metal: 6.1.1 After the thermoforming of the cylinder body and the head thermoforming, performance heat treatment should be carried out and a base material test plate should be attached. ； 6.1.2 The heat treatment of corrugated pipe forming shall be in accordance with relevant standards and the procurement "Technical Agreement" ； 6.2 The intermediate heat treatment and hydrogen elimination heat treatment of Cr-Mo steel after welding shall be carried out in accordance with the procurement "Technical Agreement". 6.3 Inspection before final heat treatment: 6.3.1 All welded parts and pre-welded parts should be welded to completion ； 6.3.2 The appearance of the inner and outer surfaces should be inspected, and all tooling and welding parts should be cleaned. ； 6.3.3 The base metal test plate and welding test plate should be complete ； 6.3.4 All inspections before the final heat treatment of the product should be completed. 6.4 Final heat treatment: 6.4.1 The number, arrangement and fixation of thermocouples, heat treatment temperature and holding time should be in accordance with the procurement "Technical Agreement". The number of intermediate heat treatments and final heat treatments, holding temperature, holding time and temperature rising and cooling speeds of the main welds should be recorded one by one. 6.5 Test panels ； 6.5.1 The mechanical properties of the base material test plate should comply with the provisions of the procurement "Technical Agreement" ； 6.5.2 The number of welding test plates, inspection items, and mechanical performance results should comply with the procurement "Technical Agreement" and JB4744-2000. 7. Pressure test and packaging for shipment 7.1 The hydraulic pressure test pressure, pressure holding time, water temperature, chloride ion content, etc. of the plate side and shell side should be in accordance with the construction drawings and the procurement "Technical Agreement". 7.2 The shell side air tightness test pressure, pressure holding time and acceptance shall be stipulated in the corresponding standards. 7.3 Ammonia leakage tests should be conducted on the shell side, single plate tubes, and plate bundle stacks after completion. The test pressure, medium concentration, pressure holding time, and acceptance shall be stipulated in the corresponding standards. 7.4 After the plate bundle stacking is completed, an air tightness test should be carried out. The number of tests, test pressure, pressure holding time, and acceptance shall be in accordance with relevant standards. 7.5 A hydraulic pressure test should be carried out before the expansion joint is assembled and welded. The test pressure, pressure holding time, water temperature, chloride ion content, etc. should comply with the construction drawings and the procurement "Technical Agreement". 7.6 The entire equipment shall be dried after the hydraulic pressure test. 7.7 The outer surface of the shell should be sandblasted and rust removed to meet the requirements of Sa2.5 level in GB8923. 7.8 The paint on the outer surface of the shell should comply with the procurement "Technical Agreement" and construction drawings. 7.9 The pickling and passivation of the surface of the stainless steel shell shall comply with the procurement "Technical Agreement" and construction drawings. 7.10 All pipes should be covered and sealed with at least waterproof materials. 7.11 The physical inspection before packing should be consistent with the list. 7.12 The shell should be filled with nitrogen for protection, and the pressure should be as specified in the procurement "Technical Agreement" or construction drawings. 8. Other requirements 8.1 Material substitution and drawing changes should obtain the written consent of the owner or engineering design unit. 8.2 Repair welding of the main pressure-bearing forgings shall require the written consent of the owner. 8.3 Other special requirements shall be implemented in accordance with the procurement "Technical Agreement". 9. Main control points for on-site manufacturing supervision of plate and shell heat exchangers Serial number Components and process name Supervision content Document witness point (R) On-site witness/inspection point (W/S) Stop point (H) 1 Barrel section 1. Material quality certificate review R 2. Chemical composition (smelting analysis, product analysis) R 3. Temper brittleness sensitivity coefficients 6. Temper embrittlement tendency evaluation (2.25Cr1Mo material) R 7. Grain size (referring to forgings) R 8. Non-metallic inclusions (referring to forgings) R 9. Ultrasonic inspection R 10. Groove magnetic particle inspection (referring to Cr-Mo steel) R 11. Pre-bending hardness (referring to Cr-Mo steel), rounding, longitudinal seam welding, intermediate heat treatment inspection RW 12. Rounding, geometric shape (roundness, angle) inspection RW 13. Longitudinal seam appearance, non-destructive inspection (RT, UT, MT) RW 14. Chemical composition analysis of longitudinal seam deposited metal (referring to Cr-Mo steel) R 2 Head 1. Material quality certificate review R 2. Chemical composition (smelting analysis, product analysis) R 3. Temper brittleness sensitivity coefficients X, J (referring to Cr-Mo steel) R 4. Mechanical properties (normal temperature, high temperature) R 5. Intergranular corrosion test (stainless steel) R 6. Temper embrittlement tendency assessment (2.25Cr1Mo material) R 7. Grain size (referring to forgings) R 8. Non-metallic inclusions (referring to forgings) R 9. Ultrasonic inspection R 10. Groove magnetic particle inspection (referring to Cr-Mo steel) R 11. Shape and geometric dimensions after stamping (roundness, diameter, thickness) RW R R 14. Hardness inspection of sealing surface of surfacing layer RW/S 4 plate bundle 1. Review of plate quality certificate, including: Chemical composition, mechanical properties, intergranular corrosion test R 2. Plate geometric dimensions and appearance inspection S 3. Plate bundle assembly dimensions and appearance inspection W 4. Single plate pipe ammonia leakage test inspection RW/S 5. Argon arc welding end seam ammonia leakage test inspection RW/S 6. Plate bundle plate side ammonia leakage test inspection RW/S 7. Plate bundle plate side hydraulic pressure test inspection RH 5 distributor size and appearance inspection W 6 expansion joint 1. Material quality certificate review, including: Chemical composition, mechanical properties, non-destructive testing of welds (RT, PT), heat treatment report R 2. Concentricity and geometric size inspection RW 3. Hydrostatic test RW 7 main bolts 1. Material quality certificate review, including: Chemical composition, mechanical properties, non-destructive testing of welds (UT, MT) R 2. Dimensional and accuracy inspection S 8 main nut 1. Material quality certificate review, including: Chemical composition and hardness inspectionR 2. Dimensional and accuracy inspectionRS 3. Non-destructive inspection (MT) after finishingR 10 General assembly 1. Shell type A/B weld RTR 2. Shell type A/B/D weld MT/PT, UTR 3. Cr-Mo steel type A/B/D weld deposited metal chemical composition inspection R 4. Overlay layer PT/MT inspection R 5. Determination of ferrite number in the surfacing layer (if required) R 6. Chemical composition of the surfacing layer (if required) R 7. Barrel straightness and circumferential seam misalignment inspection W 8. Nozzle orientation and size inspection W 9. Equipment internal and external surface appearance inspection W 10. Plate bundle, expansion joint, and cylinder concentricity inspection W 11. Distributor, fully welded plate bundle and shell assembly size inspection W 12. Support plate and plate bundle verticality inspection W 13. Equipment flange and support plate sealing weld PT inspection W 14. Fillet weld fillet size and appearance inspection W 15. Support and shell connection weld post-weld MTR 11 Heat treatment 1. Cr-Mo steel class A/B/D weld intermediate heat treatment inspection R 2. Overall final heat treatment or segmented heat treatment inspection RW 3. Cr-Mo steel class A/B/D weld seam hardness inspection after final heat treatment RW 4. Cr-Mo steel class A/B/D weld seam after final heat treatment MT, UTR 5. Support and shell connection weld, support barrel section butt weld after final heat treatment MT, UTR 6. MT/PTR after the final heat treatment of the temporary joint removal part 7. PTRW/S after the final heat treatment of the stainless steel cladding layer 12 test plates 1. Base metal performance heat treatment test plate inspection R 2. Product welding test plate inspection R 13 Pressure test 1. Plate side air tightness test RW/S 2. Shell side air tightness test RW 3. Plate side ammonia leakage test RW/S 4. Shell side ammonia leakage test RW 5. Plate side water pressure test RH 6. Shell side hydraulic pressure test RH 7. The overall hydraulic pressure of the equipment is the test RH 8. Cr-Mo steel type A and B welds UTR after hydraulic pressure 9. Cr-Mo steel type A, B and D welds after hydraulic pressure MTR 10. Cr-Mo steel support and shell connection welds after hydraulic pressure MT, UTR 11. Appearance and internal cleanliness inspection W 12. Drying treatment should be carried out after the overall hydraulic test of the equipment W 14 Other purchased parts 1. Gasket certificate inspection R 2. Gasket geometry and appearance spot inspection W/S 15 Factory inspection 1. Flange sealing surface appearance inspection W 2. Sand blasting and rust removal, paint inspection W 3. Stainless steel pickling inspection W 4. Nozzle packaging inspection W 5. Marking inspection W 6. Nitrogen charging protection inspection W