Abstract: pressure vessel is a special equipment with explosive risk. In order to ensure the safety and reliability of the production quality of the pressure vessel, the purpose of establishing the quality assurance system for pressure vessel manufacturing is clearly established in combination with the practice of the enterprise. The enterprise how to establish the quality assurance system of the pressure vessel and the key points of its implementation is expounded, and the enterprise can achieve certain economic and social benefits through the effective operation of the system.
Key words: pressure vessel; manufacturing process; quality assurance system
The general machinery manufacturing plant of PetroChina Changqing oil field (hereinafter referred to as the general manufacturing plant) is an important production base of oil and gas production and transportation equipment and production equipment in the central and Western countries of the state. It is the base of Changqing oil and gas field product R & D and results test transformation, as well as the equipment manufacturing and service base of oil and gas field. The company develops the task of transporting professional equipment. It has the complete production and operation capabilities of pressure vessel product design, processing and manufacturing, product assembly, quality inspection and after sale service. In recent years, there are 10 kinds of pressure vessels, such as horizontal high efficiency separator, slug flow catcher and separation metering device, with an average annual output value of about 30 million yuan. Based on the manufacturing practice of enterprise pressure vessel, the quality assurance system of enterprise pressure vessel and the key points of its implementation are set up, and the enterprise can get the economic and social benefits through the effective operation of the system.
Establishment of quality assurance system for 1. pressure vessel manufacturing
The pressure vessel is a special equipment with explosive danger. According to the People's Republic of China special equipment safety law and the special equipment safety supervision regulations, the establishment and implementation of the quality assurance system for the specification of special equipment manufacturing, installation, reconstruction and maintenance, ensure the effective control of the safety performance of special equipment. The State Administration of quality supervision, inspection and Quarantine issued TSGZ0004— 2007 "the basic requirements for the manufacturing, installation, transformation and maintenance quality assurance system of special equipment", and put forward that the quality assurance system must be established on the basis of the scope, characteristics and actual conditions of the special equipment licensing items for the manufacturing of pressure vessels.
As the only equipment manufacturing enterprise of Changqing oil field company, &ldquo, the main industry of oil and gas service and the demand for the support equipment &rdquo, is the purpose of the enterprise, making the equipment manufacturing and service of the oil and gas field, providing the equipment supply of the oil field company, providing the special equipment to meet the production of oil and gas field, and realizing the oil and gas field Continuous development is the responsibility of the enterprise. Over the years, the supply of all kinds of special equipment required by oil and gas fields has been completed in good quality and quantity, thus ensuring the production needs of oil and gas fields. At the same time, the quality assurance system of the pressure vessel is set up to improve the quality of the pressure vessel and ensure the essential safety of the product. It fully embodies the &ldquo of the group company, the concept of environmental priority, safety first, quality first, and people-oriented &rdquo, so as to ensure the supply and safety requirements of Changqing oil field company.
In the face of the continuous decline in international oil prices, the adjustment of the production capacity of the main oil and gas industry and the market competition are increasing, the internal management of the enterprises is strengthened, the special equipment law and the product quality law are fully implemented, the concept of safety development is set up, the safety &ldquo is strengthened, the red line &rdquo is strengthened, and the quality of the pressure vessel products is improved. Reducing the quality loss has become an important measure for strengthening the internal management of the general machinery factory. At the same time, because of the changes in the regulations and standards of the production and execution of the pressure vessel, the adjustment of the organization and the change of the work duties of the General Factory compel the enterprises to establish the quality assurance system for the manufacture of pressure vessels, strictly according to the current laws and regulations and standards, to standardize the production procedures, clarify their duties and strengthen their duties. Enterprise internal management, to achieve quality and efficiency purposes.
1.1 principles for establishing quality assurance system for pressure vessel manufacturing
The establishment of the quality assurance system for the manufacture of pressure vessels should be in conformity with the relevant state laws, regulations and specifications, and should be combined with the characteristics of the project and the actual situation of the unit. According to the basic requirements of TSGZ0004-2007 "special equipment manufacturing, installation, transformation and maintenance quality assurance system", the following principles should be observed in the establishment of quality assurance system for pressure vessel manufacturing: (1) conforming to national laws, regulations, safety technical specifications and corresponding standards; and (2) the effective control of the safety performance of special equipment; Quality policy and quality objectives fit the actual situation of the unit; (4) the quality assurance system organization can perform its duties independently; (5) the responsibility, authority and quality control system of the quality assurance system responsible personnel (quality assurance engineer and the quality control system responsible personnel) are clearly connected with the work of the quality control system; 6. The quality assurance system is basically required The quality control system, the control link, the control point, the control range, the procedure, the content and the record are complete.
1.2 plan and establish quality assurance system for pressure vessel manufacturing
According to the work deployment of the General Factory, the quality assurance engineer (general industrial) is responsible, the technical supervision section leads, the product R & D center, inspection and testing center and other related units participated, set up the working group of the pressure vessel manufacturing quality assurance system. Invite experts from China special equipment testing institute to train the relevant laws, regulations and standards of "Safety Technical Supervision Regulations for fixed pressure vessels" and other relevant standards for pressure vessel manufacturing. A large table of work arrangements for the quality assurance system of pressure vessel manufacturing is worked out. The work carried out on the system document preparation and the preparation of the process documents is carried out one by one. According to the requirements of the standard and the actual situation of the enterprises, 11 leaders of the quality control system of pressure vessels are appointed, and a special meeting on the responsible persons of the quality control system is held to further listen to the compilation. Opinions, determine the writing principle, complete the unit and time, carry out the work separately, the technical supervision section is responsible for the summary and the manuscript work, and strictly check the systematicness, integrity and compliance of the documents.
1.3 documentation of quality assurance system for pressure vessel manufacturing
According to the requirements of the basic requirements for the manufacturing, installation, renovation, maintenance quality assurance system of special equipment and the technical standards for the manufacture of pressure vessels, the newly issued pressure is quoted in combination with the manufacturing characteristics of A2 grade pressure vessels and the actual situation of the enterprises.The manufacturing regulations, standards and standards of force containers have been established, and the organization of pressure vessel manufacturing organization has been established. The organization chart of the pressure vessel quality control system has been drawn. 11 quality control systems, such as technology, material, welding, heat treatment, nondestructive testing and pressure test, have been set up.
The production quality system documents of pressure vessel include "pressure vessel manufacturing quality manual", 48 "pressure vessel manufacturing procedure documents", 63 "pressure vessel manufacturing management system and process regulations", 109 "pressure vessel manufacturing quality record", all enterprise standard 4 volumes. The newly formulated quality system of pressure vessel manufacturing system, after repeated revision and repeated audit, is approved and implemented by the director of the factory, and the relevant units of the printed General Factory are strictly enforced.
Implementation of 2. pressure vessel manufacturing quality assurance system
The manufacturing plant implements the responsibility system of the pressure vessel manufacturer, and the chief engineer is appointed by the director of the factory as the quality assurance engineer of the pressure vessel, and is fully responsible for the quality of the pressure vessel. Eleven persons responsible for the quality control system of pressure vessel manufacturing have been appointed. Each person responsible for the quality control system has corresponding professional knowledge and rich working experience. Under the quality and Technical Supervision Committee of the factory, the document is issued, the formalities are complete, the duty, responsibility and right are clear, and the work can be carried out according to the corresponding duty, responsibility and power to form an organic whole with clear tasks, mutual coordination and mutual promotion. In order to ensure the quality policy and quality objectives set up by the enterprise, the quality objectives are decomposed at the beginning of each year and will be sent to the relevant units or departments. Each month, the quality objectives of the production units are examined and linked to the operating indexes of the production units to ensure the quality of the pressure vessel.
2.1 Develop internal audit and management review to ensure the effective operation of the system
In order to ensure the effective operation of the established quality assurance system and actively carry out the daily supervision and maintenance of the system, monthly quality assessment of the pressure vessel manufacturing branch and related units is carried out in accordance with the requirements of the "detailed rules for the implementation of quality supervision and assessment" in the general manufacturing plant. The quality goal completion, the process discipline execution, the product quality and so on are supervised and examined, the product quality control injunction is formulated, the quality assessment and punishment are strengthened so as to ensure the quality of the pressure vessel. Actively carry out internal audit and management review activities, find problems and solve them in time to ensure the effective operation of the pressure vessel manufacturing quality assurance system.
2.2 strengthen control and perform contract review procedure
The manufacturing plant has set up a file and record control program to ensure that a site that plays an important role in the quality assurance system can get and use a complete, correct and effective version. Clearly stipulates the scope, procedure and content of the control of documents and records, and specifies the units responsible for the preparation, approval, identification, marking, distribution, recovery, preservation, destruction and modification of documents, and strict control on the quality files, quality plans and process documents, so that the documents are complete and the page number is clear. The status mark is clear, the account is issued, and the invalid documents are recorded and marked. There are corresponding departments to manage the foreign documents. The standard system of pressure vessel manufacturing is compiled, related to the regulations, standards and standards of pressure vessel manufacturing, and the standard information research center of Shaanxi Standardization Research Institute has carried out a total of 624 standards for the implementation of pressure vessel and its related standards. New and confirmed, and with the Shaanxi Institute of standardization, the petroleum industry standardization information network to establish friendly cooperation relations, timely consultation and provision of standard information consultation and standard information. There is a special cost of standardized work to ensure that GB150&mdash, 2011 and other main pressure vessels are distributed to the relevant units in order to get the current effective version in the manufacturing process of pressure vessels. Formulated the pressure vessel manufacturing contract review and management procedures, and strictly comply with its implementation. According to the complexity of product technology and quality assurance requirements, 2 forms of supervisor review and conference review are conducted by the organization of the technical supervision section. The contract for the production of pressure vessel products is guaranteed to be reviewed before the contract is signed to meet the requirements of the customer.
2.3 strengthen design and process control to improve product quality.
In the process of making the new quality system documents, we pay attention to the use of scientific management methods, strengthen process control, and draw the system control chart of the 10 quality control systems, such as welding and inspection, so that the process control is intuitive, clear, concise and accurate. 50 control links and 117 control points are set up. Each control link and control point define the content, the basis and the responsible person. The manufacturing plant is responsible for the design and process management of pressure vessels by the product research and development center, and one engineer is appointed to be the responsible person for the design system and the process system. Increase pressure vessel design team building, strengthen design, process documents control. At present, 4 technicians have obtained the qualification of pressure vessel design approval, and 16 engineers and technicians have the qualification of pressure vessel design.
The control of the process quality control system is mainly centered on the capabilities of the process personnel, process preparation, process implementation, tooling design and manufacturing. To complete the process documents, complete the examination and approval of the signature and complete the procedures for signing and signing of the documents, and according to the requirements of the contract, the process flow chart and the typesetting drawings adapted to the products are compiled, one piece of one piece is implemented for the main compression components, and each procedure made by the main compression element should be signed and approved by the operator and the inspector. The key working procedure of pressure vessel, such as out of sample, after qualified welding of product welding test plate, non-destructive testing after inspection of weld appearance inspection, opening of hole line, heat treatment after welding, and pressure test, seal the marking seal on the product process document, in order to show that this process is a witness or stop point. In order to ensure the quality of the product, the product quality plan is made for each product, the inspection point, the document review point, the witness point and the stop point of the main compression components are clarified, and the control requirements of the inspection points are stipulated. In addition, the process equipment should be uniformly built, numbered, properly kept and classified.
2.4 do a good job in supplier selection and evaluation, and strictly control the quality control of raw materials.
Raw materials are one of the main links that affect the quality of products, so as to ensure the quality of pressure vessel products.6 relevant management documents, such as "procurement planning and management procedures", have been formulated, and all the pressing elements have been set up in the procurement plan, and the procurement documents are strictly purchased in accordance with the drawings, standards and materials procurement documents.
The raw materials are strictly controlled according to the control procedures and operation guidance documents, and the main links of acceptance, warehousing, storage, distribution and substitution are strictly carried out, and the certificates are complete and clear. All the materials can be stored after acceptance or reinspection, and the materials are kept in the storage according to the approval procedure. When cutting, adhere to the principle of first transplantation and segmentation, and mark transplant.
To increase the management of material for pressure vessel products, with raw materials and semi-finished products of plate, pipe, head and other pressure vessels, there are marked three areas (qualified area, unqualified area, inspection area); stainless steel has a special site, it is strictly prohibited from mixing with carbon steel, all materials are clearly identified and complete; welding material library, semi finished warehouse and so on are done. To the account, card, material, certificate.
2.5 strengthen welding, heat treatment and NDT control to ensure product quality.
Welding control is the key point in the manufacturing process of pressure vessels. Enterprises should increase the training of pressure vessel welders and improve the comprehensive strength of pressure vessel welding. At present, there are 26 Personnel engaged in pressure vessel welding, all after professional training and examination, they have obtained the qualification of welding operation of special equipment, and engaged in the welding work corresponding to their qualifications. The welding material is carried out according to the corresponding management system, the special pressure vessel welding material warehouse is set up, the special person is responsible for the storage, the purchase and inspection of the welding materials are strictly carried out according to the corresponding management requirements. The management of the welding material including the baking time and temperature before the welding rod is strictly according to the "pressure vessel welding material management system" Degree is carried out. A welding laboratory has been set up to meet the requirements of product's welding performance and welding procedure qualification. Each pressure vessel has the pressure vessel welding process, the inspector supervises the execution of the process discipline, and the technical supervision department supervises the execution of the process discipline every month.
In terms of heat treatment, we should increase investment in heat treatment equipment, purchase advanced and reliable heat treatment equipment, and heat treatment instruments and instruments in time. All the heat treatment personnel have been trained with professional training. They are responsible for the heat treatment quality control system. They are responsible for the preparation of heat treatment process documents and quality control. The heat treatment process documents and quality records are complete and well preserved.
In the field of non-destructive testing, we should increase resources and personnel allocation and increase non-destructive testing equipment. 3 technicians were allocated to nondestructive testing posts and management posts. At present, there were 10 nondestructive testing personnel, all obtained the corresponding qualification of nondestructive testing. RT and UT had 3 II qualified projects respectively. In the actual work, the non-destructive testing process documents made by the enterprise are strictly carried out, the key control evaluation review and the DNT report are approved by the II qualification personnel, and the evaluation accuracy rate, the ratio execution rate of the flaw detection ratio and the expansion rate are in conformity with the requirements of the drawings and standards.
2.6 strengthen physical and chemical, metrology and equipment management to meet product manufacturing needs.
The management of physical and chemical testing and measuring instruments is managed by the inspection and testing center, and 1 persons in charge of the quality control system are appointed in each process. The instruments and meters used for pressure vessel manufacturing are checked regularly, and the product test boards, raw materials re inspection are all checked on time. A special measuring and physicochemical laboratory has been built and purchased with tensile impact testing machine to ensure the smooth development of the work.
The equipment control is managed by the mobile safety and environmental protection department. It has 1 persons responsible for the quality control system, and is responsible for the daily management of pressure vessel equipment. In order to meet the needs of pressure vessel manufacturing, the equipment is strengthened, and many new automatic electric welding machines and nondestructive testing equipment are put into the production and production of pressure vessel. 5 management systems, such as equipment management procedures, have been formulated and strictly controlled to ensure the manufacturing needs of pressure vessels.
2.7 do well site inspection and control, improve the passing rate of the first pass.
An independent inspection agency shall be set up to be responsible for on-site inspection and testing, and strictly control the quality of products. The following measures are taken as follows: (1) in the inspection of incoming goods, in accordance with the corresponding technical standards or drawings, the data and signs of the entry of the steel plate, pipe, welding material, head and other compression elements are examined in detail to ensure the complete, complete and correct information; after the identification is clear, the 100% inspection of the whole point is carried out, and it finds out that there is no Qualified, immediately rejected, so as to ensure the quality of incoming materials. In the process control, the inspectors strictly follow the requirements of the drawings and process cards, and check the process and process parameters of each process, such as marking, marking, cutting, welding, group pair, opening and so on. After passing the inspection, the inspector can sign the process. If there is any discrepancy with the process documents, the construction shall be stopped immediately. Strictly follow the relevant management regulations of the stop point to ensure the production quality of the stop points. For test pressure fasteners, flanges, blind plates and other categories, pressure grade, nominal diameter and other registration, and the pressure test system responsible person supervision and management, to ensure the use of accurate and accurate. (3) before leaving the factory, the organization and management personnel and on-site inspectors check all the integrity, appearance quality and random appendages of all the inspection data of the container again to ensure the timeliness of the product data and the integrity of the random accessories. (4) identifying, isolating, evaluating and disposing of unqualified products found in the production process strictly according to the "control procedures for disqualified products" formulated by the enterprises. The field inspection work is carried out by the &ldquo of the operator self inspection and the inspector's special inspection, and the double inspection system of ” the key process of the pressure vessel manufacturing, the stopping point is carried out by the operator, the technical personnel of the branch, and the inspection personnel on the floor inspection, so as to ensure the quality of the pressure vessel and improve the rate of the first pass of the product. .
2.8 increase personnel training and promote continuous improvement of quality system.
Pay attention to the improvement of personnel quality, and constantly increase the intensity of personnel training. In addition to the promulgation of new regulations and standards for pressure vessels, in addition to training within the enterprise, we will not spare no effort to send relevant professional and technical personnel to all kinds of qualification training. EndAt present, there are 20 pressure vessel design holders, 10 non-destructive testing personnel, 26 special duty welders and 2 chief quality officials. In addition, we also send the responsible person of the welding quality control system, the responsible person of the quality control system, the head of the quality management, and so on to study the relevant regulations and standards, so as to improve the professional ability of the related professionals. The staff of the whole factory will participate in the network study and answer of China Petroleum Corporation's "safety production law" and "special equipment law". The newly promulgated TSG21 — 2016 "Safety Technical Supervision Regulations for fixed pressure vessels", invites the Chinese special equipment inspection and Research Institute to compile and write the experts for training, explaining and answering questions. The improvement of professional skills has enhanced the professional competence of the staff, promoted the continuous improvement of the quality assurance system, and ensured the continuous and stable quality of pressure vessel manufacturing.
2.9 comply with national laws and regulations, implement special equipment licensing system.
Strict compliance with relevant state laws and regulations, implementation of special equipment licensing system, no violation of special equipment licensing system. In accordance with the regulations and safety technical specifications, they shall be subject to the supervision of the quality and technical supervision departments at all levels and the inspection of inspection institutions. We will do a good job in the management of special equipment licenses and selflessly alter, transfer or lend licenses. Strict compliance with the use of special equipment licenses and special equipment license marks shall be carried out in accordance with the administrative measures for licenses.
3. system operation effect
With the establishment and improvement of quality assurance system for pressure vessels in manufacturing plants, the quality and safety performance of pressure vessel products have been steadily improved. At the same time, it has accumulated rich experience in the manufacturing of pressure vessel, and successfully applied it to digital integrated equipment, heating furnace production and pressure pipeline installation to ensure the quality of the product. At present, pressure vessels and related products manufacturing have become the pillar industries and leading products of the main plant. Since pressure vessel manufacturing qualification was upgraded from one or two to three in 2012, more than 500 production units were produced in 5 years, and the output value was nearly 150 million yuan. Due to the strict operation of the established quality assurance system of the pressure vessel, the quality of the product has been steadily improved, the production efficiency is improved, the quality loss is reduced, the internal and external failures are reduced, the cost of after-sales service is reduced, no quality accident has occurred, and a good comprehensive economic benefit has been obtained.
Since the establishment of the quality assurance system for the manufacture of pressure vessels, the enterprises strictly comply with the requirements of the quality assurance system documents to ensure that the manufacturing plant has successfully approved the production license of pressure vessels through the State Quality Inspection Administration, ensuring the safety of the pressure vessel manufacturing, the standard production, and the safe use of the oil and gas field users for many years. There was no safety accident. The products of the integrated oil and gas transmission unit were selected as the famous brand products of Shaanxi in 2016, and achieved good social benefits and brand effect.