还剩12页未读,继续阅读
本资源只提供10页预览,全部文档请下载后查看!喜欢就下载吧,查找使用更方便
文本内容:
管道焊接施工程序PipelineWeldingProcedureCONTENT
1.SCOPE……………………………………………………………………………………………......
12.PURPOSE…………………………………………………………………………………………….
13.REFERENCES……………………………………………………………………………………….
14.WELDINGPROCESSFLOWCHART……………………………………………………………...
15.REQUIREMENTS…………………………………………………………………………………….
26.WELDINGDOCUMENTSANDRECORDS……………………………………………………….6ATTACHMENTUSEFULFORMS………………………………………………………………………………………..
71.SCOPE范围Thisprocedureincludestherequirementsfortheconstructionandqualitycontrolofthepipelinewelding.ItisapplicabletoassessthequalificationofwelderswhoperformtheweldingofFeedstockStorageTanksPipelineofXX.本程序包括对管道焊接的施工要求和质量控制适用于XX石化原料油罐工程的焊接工作ThematerialofpipeiscarbonsteelincludingA106GrBand20#.管的材质为碳钢A106GrB和20#钢等
2.PURPOSE目的Theprocedureprovidessomeweldingprocessandweldingrequirementstoensureweldingqualityofpipetomeetrequirementsofcontractandappliedspecification/standardtosatisfytheowner.本程序为确保管线的焊接施工质量符合合同、适用规范和标准的要求,使业主满意,特制订焊接工艺和焊接要求
3.REFERENCES参考
3.1“Codeforconstructionandacceptanceoffieldequipmentindustrialpipeweldingengineering”GB50236-98《现场设备、工业管道焊接工程施工及验收规范》GB50236-
983.2“weldingevaluationforsteelpressurevessel”JB4708—2000《钢制压力容器焊接工艺评定》JB4708—
20003.3“WeldingandBrazingQualifications”ASMEIX《焊接和钎焊评定》ASME第IX卷
3.4“RequirementforPipelineconstructioninChemicalPlantandOilRefinery”ASME
31.3《石油化工厂管道施工要求》ASME
31.
33.5PMCRelevantWeldingProceduresPMC相关的焊接文件:XX25“WeldingProgram”焊接计划;XX38“WeldingControl”焊接控制
4.WELDINGPROCESSFLOWCHART焊接工艺流程⑴ReviewDrawing审查图纸→⑵PQR工艺评定→⑶WorkoutWPS制定WPS→⑷WelderQualification焊工考核→⑸WeldingPreparation焊接准备→⑹Fitting/TackWelding组对/点焊→⑺Welding焊接→⑻VisualInspection目测检查→⑼PWHT焊后热处理→⑽NDTrepair→⑾FinalAcceptance最终验收Ifanyweldisnotacceptablestep⑺⑻⑼⑽shallbefollowedagain.如果焊缝发现缺陷,重复步骤⑺⑻⑼⑽
5.REQUIREMENTS要求
5.1PreparationpriortoWelding焊前准备
5.
1.1WeldingMethodSelection焊接方法选择ItshalladoptGTAWtoweldingofrootpassandSMAWtoweldingoffillingandcappingpassforpipelinewithadiametermorethan2”.直径大于2”的管用钨极氩弧焊打底,手工电弧焊填充、盖面ItshalladoptGTAWtoweldingofrootandcappingpassforpipelinewithadiameterlessthan2”.直径小于2”的管用钨极氩弧焊打底,盖面
5.
1.2ManagementofWeldingConsumable焊材管理·Typeofweldingconsumableshallbeaccordancewiththefollowingchart焊材型号选用按下表·Certificationistobecheckedpriortouse.材使用前检查质量证明书·At-siteallweldingconsumablesforpermanentworksaretobestoredinacontrolledlockablestorerodstore.Allweldconsumablesmustremainintheirmanufacturerspackaginguntilrequiredforthework.现场所有用于永久性工程的焊材应存放于受控制的、可上锁的库房(带锁库房-焊材库)内所有焊接消耗品在使用之前,必须存储于制造商的原始包装内·Specialpersonmustbearrangedtomanageweldingconsumablesincludingbakingstorageissuereturn,hemustdoarecord.Andsiteweldingengineermustmonitorandreviewconsumablestrictly.Priortouseallelectrodesshallbenewlyunpackagedorre-driedaccordingtothemanufacturersinstructionsandthebakingfrequencyisnotover2times.指定专人管理焊条,包括烘干、发放、回收,并作好记录现场焊接工程师必须严格监控焊条使用前应拆封按照制造商的说明书进行烘干,烘干次数不得超过2次·TheWeldershallkeeptheweldingrodsintheportablerodovensthatcouldbeheatedbyelectricity.Iftherodovenscouldnotbeheatedtheelectrodescollectedpertimeshouldbeusedin4hours.Duringweldingweldingrodshallbetakenoutonebyone.焊工应将焊条放在可电加热的便携式焊条筒内,如果焊条筒不能加热,则每次领取的焊条应在4小时内用完焊接时一根一根取出焊条·Weldingconsumablesshouldalsomeettherelevantrequirementsof“WeldingControl”
5.
1.3PQRandWPSPQRandWPSwillbepreparedaccordingtotherelevantstandardandproceduresandshallbesubmittedtoPMC/JIANLIforreviewintime.PQR和WPS应根据相应的规范和程序要求进行编制,并要及时报送PMC/JIANLI审核
5.
1.4WelderQualification焊工资格认证Allwelderstoparticipatetheprojectmustbequalifiedaccordingto“welderqualificationprocedure”-Ben-CNS-
0009.Detailsofwelderqualificationsee“weldertrainingandqualificationprocedure”-XX-CNS-
0009.所有参加本项目焊接的焊工必须按照《焊工资格程序》-XX-CNS-0009的要求进行考试,详细要求见焊工培训和资格认证程序》-XX-CNS-
00095.
1.5WeldingEquipments焊接设施Theweldingequipmentsmustpossesssufficientpowerforweldingwork.Itscharacteristicshallmeetrequirementofconstruction.Eachweldingmachineshallbeprovidedwithsuitablecablesandattachmentsholdersearthclampsetcthatareingoodsafeworkingorderanyfoundtobeunsafeshallberemoved.焊接设备对于所承担的工作必须具有足够的功率,性能能够满足施工现场的需要每台焊接机器应具备状态良好的合适的电缆及附件(保持器、接地夹等),应停止使用发现的任何不安全的机器XXpreparetoputintouseofweldingequipmentssee“CEP”offeedstockstoragetanks.准备投用的焊机参见原料油罐项目《施工执行计划》
5.
1.6Clean-uppriortoWelding焊前清理Basematerialwithinrangeofgrooveandbothsides20mmeachshallbecleareduppriortowelding.Allsurfacedirtsuchasrustpaintgreaseandwateretcmustbecleareduptoshowmetalluster.焊接之前应对焊缝坡口及坡口两侧20mm范围内的母材进行清理,清除表面的锈、油漆、油脂、水等污物,直至露出金属光泽
5.2WeldingProcessControl焊接过程控制
5.
2.1WeldingWeatherConditions焊接气象条件Underanykindoffollowingweldingenvironmentweldingworkshallnotbeallowedtoperformunlesseffectiveprotectionmeasuresaretaken:下列任一情况下,如果没有有效的防护措施,不得进行焊接工作·Rain下雨·Windspeed≥8m/sforSMAW,Windspeed≥2m/sforGTAW风速≥8m/s(手工电弧焊);风速≥2m/s(钨极氩弧焊)·Ambienthumidity≥90%空气相对湿度≥90%
5.
2.2TackWelding点焊Lengthandquantityoftackweldingshallbeaccordancewiththefollowingchart:点焊长度和数量应参考下表Tackweldshallbemadebyqualifiedweldersusingthequalifiedparameters.WeldfillermetalsusedfortackweldingmustbethesameastheintendedWPS.点焊由合格的焊工按照批准的焊接程序规范参数进行点焊采用的焊材必须与焊接工艺指导书相同
5.
2.3OtherRequirement其它要求·PurityofArgasshallnotlessthan
99.99%.氩气的纯度不低于
99.99%·Arcshallbeonlystrickeninweldingarea.Whenusinglowhydrogenelectrodeweldersshallapplyshortarcwelding.引弧只能在焊接区内进行,当用低氢焊条时应采用短弧焊·Itshallnotintermittheweldingofrootpassunlessitneedstoreplacetheelectrodeorpermitswelderstotaketheirplaceagain.除非更换焊条或允许焊工换位置,否则打底焊道不得中断·Applymaximumdistancetoseparatecircularbuttweldsandthedistancebetweenthemisnotlessthan
1.5timesofpipediameter.焊缝间距不小于
1.5倍的管径·Weldersshallconductvisualinspectiontotheformerwelds.Allthedefectssuchasslagcrackandporositiesshallberemovedandrepairedbeforenextpasswelding.焊工应对前一层焊缝进行外观检查,焊渣、裂纹、气孔等缺陷在下一层焊接前应打磨去除
5.3WeldingSeamInspection焊缝检查
5.
3.1VisualInspection目视检查Allweldsshallbevisuallyinspected.Aweldshallbeacceptablebyinspectionifexaminationshowsthefollowing:所有的焊缝应进行目视检查,一条焊缝如果符合下列要求,则认为合格·ThesurfaceofweldingseamandHAZhasnocratercracksorothersurfacecracksporosityweldingspattersslagsabruptridgesandvalleys;焊缝表面及热影响区没有弧坑裂纹或其它表面裂纹、气孔、飞溅、焊渣、焊瘤和凹陷;·Theedgesoftheweldsshallmergesmoothlywiththesurfaceoftheplatewithoutasharpangle.Thereshallbeamaximumpermissibleundercuttingof
0.5mmforbuttjoints;焊缝边缘应平滑过渡到钢板表面,无尖角对接焊缝的最大咬边允许深度
0.5mm;·Thethicknessofthereinforcementshallnotexceed3mm:焊缝余高不超过3mm
5.
3.2NDT无损检测AcceptancestandardisaccordingtoJB4730-94“Non-destructivetestingofpressurevessels”atsametimeASMEcodeshouldbeaccordance.无损检测标准按JB4730-94,同时符合ASME标准ProportionacceptancecriterionofNDTshallbeaccordancewiththedesigndrawing.无损检测的比例、合格级别符合设计图纸的规定
5.4WeldingSeamRepairing焊缝返修·Thedefectsexistedaxxerthesurfacegrindingshallbefullyeliminatedthroughmechanicalgrindingorarcairgouging.对于通过表面打磨还不能消除的所有缺陷,焊接前应用机械研磨或刨槽直到完全消除为止·AlltherepairworkneedstobedonebythequalifiedwelderusingtheWPSapprovedbyPMC/JIANLI.应由合格的焊工采用经PMC/JIANLI批准的焊接工艺规范,进行所有的返修工作·AllrepairedweldsshallbeinspectedbyX-rayexaminationandthefilmsshallbeputtogetherwithoriginalfilmsastherepairevidence.返修的焊缝用射线检查,底片与原来的底片放在一起·Allrepairweldinginspectionandtestingshallbefullyrecordedanddocumented.没有单位技术总负责人的批准,同一部位的返修次数不得超过两次·Nomorethantworepairattemptspermittedatonelocationwithoutengineeringapproval.所有返修、检查、试验都应做好记录形成文件
6.WELDINGDOCUMENTSANDRECORDS焊接文件和记录Duringweldingthefollowingdocumentsandrecordsshouldbedonetheyshouldbetrulyintegrityandintime.焊接工作工程中应进行以下记录,记录应及时、真实、完整·WPSandPQR焊接工艺指导书,焊接工艺评定记录;·QualifiedWelderRegister焊工登记表;·WeldingMaterialDryingRecord焊条烘干记录;·WeldingMaterialDistributingandReturningRecord焊条发放回收记录;·WarehouseTemperatureHumidityRecord焊材库温度、空气湿度记录;·WeldingSeamSurfaceDetectionReport焊缝表面质量检查报告;·NDEReportofWeld无损检测报告;·WeldingRecords焊接记录;·WeldingRepairRecords焊接返修记录;·OtherNecessaryRecords其它必要的记录。