塔架焊接工藝規(guī)程

1、NO： 3MW-012-T 焊 接 工 藝 規(guī) 程 產(chǎn)品名稱 SL3000項(xiàng)目塔架 產(chǎn)品編號(hào) 3MW-012-T 圖 號(hào) T6010002編 制 年 月 日 審 核 年 月 日青島海洋熱電化工設(shè)備有限公司NO： 3MW-012-T Welding Procedure Specification Product Name: Tower of SL3000 Project Product No. 3MW-012-T Drawing No. T6010002Prepared by Wang Peng August 5th ,2011Reviewed by year month dayQingdao

2、Haiyang Thermoelectrical Chemical Equipment Co., Ltd.焊接工藝規(guī)程目錄 序 號(hào)名 稱頁 數(shù)備 注1接頭編號(hào)表82焊接材料匯總表23接頭焊接工藝卡584焊縫返修工藝要求25技術(shù)要求267 編制： 年 月 日 審核： 年 月 日Welding Procedure Specification Contents No.DescriptionPagesRemark1Joint No. Sheet42Welding Consumables Summary13Joint Welding Procedure Card294Weld Repair Techno

3、logy Requirement15Technical Requirement167 Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 頭 編 號(hào) 表 接頭編號(hào)示意圖 編制： 年 月 日 審核： 年 月 日J(rèn)oint No. SheetJoint No. sketch ： Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 頭 編 號(hào) 表焊 接 工 藝 規(guī) 程接頭編號(hào)接頭焊接工藝卡編號(hào)無損檢測要求注:1、內(nèi)件焊接用焊接材料按焊

4、接材料匯總表，焊角高度按圖紙要求。 2、無損檢測要求如下：(1)所有焊縫必須進(jìn)行100%的VT檢查,按照EN ISO 5817 B級(jí)執(zhí)行。(2)超聲波檢驗(yàn)，按照J(rèn)B4730-2005標(biāo)準(zhǔn)I級(jí)要求執(zhí)行。塔筒縱向焊縫、環(huán)向焊縫、塔筒法蘭和筒體過渡處的環(huán)向焊縫、門框和焊接筒體之間過渡處的連續(xù)焊縫都必須進(jìn)行100%UT檢查。 （3）塔架法蘭和筒節(jié)的T型焊縫接頭處根據(jù)JB4730-2005均布片射探；筒節(jié)與筒節(jié)處的T型焊縫接頭按照100%數(shù)量進(jìn)行布片射探，每個(gè)T型布片2張，膠片長度為300mm，級(jí)別為級(jí)。（4）塔筒法蘭和筒體之間環(huán)向焊縫、門框和筒體之間連續(xù)焊縫須進(jìn)行100%MT檢查,結(jié)果符合JB4730

5、-2005.4級(jí)合格；附件連接板焊接焊縫總數(shù)的20% 進(jìn)行100%PT檢查，結(jié)果符合JB4730-2005.5級(jí)合格。3、經(jīng)射線或超聲檢測的焊接接頭，如有不允許的缺陷，應(yīng)在缺陷清除后進(jìn)行補(bǔ)焊，并對該部位采用原檢測方法重新檢查直至合格。進(jìn)行局部探傷的焊接接頭，發(fā)現(xiàn)有不允許的缺陷時(shí)，應(yīng)在該缺陷兩端的延伸部位增加檢查長度，增加的長度為該焊接接頭長度的10%，且不小于250mm。若仍有不允許缺陷時(shí)，則對該焊縫做100%檢測。4、焊縫需要返修時(shí)，其返修工藝應(yīng)符合焊接工藝要求。焊縫同一部位的返修次數(shù)不應(yīng)超過兩次，如超過兩次，返修前應(yīng)經(jīng)用戶單位技術(shù)總負(fù)責(zé)人批準(zhǔn)，返修次數(shù)，返修部位和返修情況應(yīng)如實(shí)記入質(zhì)量證明

6、資料。 5、僅產(chǎn)品編號(hào)為3MW-01-T代產(chǎn)品試板，其余以批代臺(tái)。A1（帶試板）A2 HJ-01見注2A3（帶試板） HJ-02見注2A4（帶試板）HJ-03見注2A5（帶試板）HJ-04見注2A6（帶試板）HJ-05見注2A7（帶試板）HJ-06見注2A8（帶試板）HJ-07見注2A9（帶試板）HJ-08見注2A10（帶試板）HJ-09見注2A11（帶試板）A12HJ-10見注2A13（帶試板）HJ-11見注2A14（帶試板）HJ-12見注2A15（帶試板）A16HJ-13見注2A17（帶試板）HJ-14見注2A18（帶試板）HJ-15見注2A19（帶試板）HJ-16見注2A20（帶試板）H

7、J-17見注2A21（帶試板）A22HJ-18見注2A23（帶試板）A24 A25HJ-19見注2A26（帶試板） A27HJ-20見注2A28（帶試板）A29 A30HJ-21 編制： 年 月 日 審核： 年 月 日J(rèn)oint No. SheetWelding Procedure SpecificationJoint No.Joint Welding Procedure Card No.NDT RequirementNote：1.The welding consumables for internals welding as per Welding Consumables Summary,

8、the fillet weld height as per drawing requirement. 2、NDT requirements are as follows:：(1) All welds must be performed 100% VT, as per EN ISO 5817 B Class.(2) UT as per JB4730-2005 I Class.Perform 100% UT to LW and CW of towers 、CW of transition between tower flange and tube、continuous weld on transi

9、tion between doorframe and welding tube. （3）Perform NDT to T weld joint of flange and tube as perJB4730-2005；Perform test on 100% quantity of T weld joint between tubes, arrange 2 films for each T type, with length 300mm, II class.（4）Perform 100% MT to CW between flange and tube、continuous weld betw

10、een doorframe and tube, result complying with JB4730-2005.4 I Class is acceptable. Perform 20% PT to 20% amount of welds of attachments connection plate, result complying with JB4730-2005.5 I Class is acceptable.3、For the welding joint tested with RT or UT, if there is defect, perform welding repair

11、 after clearing the defect, and re-test the part with original method until accepted. For the welding joint tested partly, if there is defect, add length of the extended part of the two ends of defect, the added length should be 10% of the welding joint length, and not less than 250mm. if there is s

12、till defect, perform 100% test to the welding joint. 4、The repair technology should comply with the welding technology requirement when weld needs repair. The same part on weld should not exceed twice repair, if exceeds, it should be approved by the technology general responsible person of user befo

13、re repair. The repair times、repair position and repair situation should be recorded in quality certificate. 5、Only the product No. 3MW-01-T shall have test plate, others in lot in place of set.A1（with template）A2 HJ-01see see Note 2.A3（with template） HJ-02see Note 2.A4（with template）HJ-03see Note 2.

14、A5（with template）HJ-04see Note 2.A6（with template）HJ-05see Note 2.A7（with template）HJ-06see Note 2.A8（with template）HJ-07see Note 2.A9（with template）HJ-08see Note 2.A10（with template）HJ-09see Note 2.A11（with template）A12HJ-10see Note 2.A13（with template）HJ-11see Note 2.A14（with template）HJ-12see Not

15、e 2.A15（with template）A16HJ-13see Note 2.A17（with template）HJ-14see Note 2.A18（with template）HJ-15see Note 2.A19（with template）HJ-16see Note 2.A20（with template）HJ-17see Note 2.A21（with template）A22HJ-18see Note 2.A23（with template）A24 A25HJ-19see Note 2.A26（with template） A27HJ-20see Note 2.A28（wit

16、h template）A29 A30HJ-21Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 頭 編 號(hào) 表焊 接 工 藝 規(guī) 程接頭編號(hào)接頭焊接工藝卡編號(hào)無損檢測要求A31（帶試板）A32 A36HJ-22見注2A33（帶試板）A34 A35HJ-23見注2B1HJ-24見注2B2HJ-01見注2B3HJ-02見注2B4HJ-03見注2B5HJ-04見注2B6HJ-05見注2B7 B8HJ-25見注2B9HJ-07見注2B10HJ-08見注2B11HJ-09見注2B12 B13HJ-10見注2B14HJ-

17、11見注2B15HJ-12見注2B16 B17HJ-26見注2B18HJ-13見注2B19HJ-14見注2B20HJ-15見注2B21HJ-16見注2B22HJ-17見注2編制： 年 月 日 審核： 年 月 日J(rèn)oint No. SheetWelding Procedure SpecificationJoint No.Joint Welding Procedure Card No.NDT RequirementA31（with template）A32 A36HJ-22see Note 2.A33（with template）A34 A35HJ-23see Note 2.B1HJ-24see

18、Note 2.B2HJ-01see Note 2.B3HJ-02see Note 2.B4HJ-03see Note 2.B5HJ-04see Note 2.B6HJ-05see Note 2.B7 B8HJ-25see Note 2.B9HJ-07see Note 2.B10HJ-08see Note 2.B11HJ-09see Note 2.B12 B13HJ-10see Note 2.B14HJ-11see Note 2.B15HJ-12see Note 2.B16 B17HJ-26see Note 2.B18HJ-13see Note 2.B19HJ-14see Note 2.B20H

19、J-15see Note 2.B21HJ-16see Note 2.B22HJ-17see Note 2.Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 頭 編 號(hào) 表焊 接 工 藝 規(guī) 程接頭編號(hào)接頭焊接工藝卡編號(hào)無損檢測要求B23 B24HJ-18見注2B25 B28HJ-19見注2B26 B27HJ-27見注2B29 B30HJ-20見注2B31 B32 B33HJ-21見注2B34 B35HJ-22見注2B36 B37 B38 B39HJ-23見注2B40HJ-28見注2D1HJ-29見注2編制：

20、年 月 日 審核： 年 月 日J(rèn)oint No. SheetWelding Procedure SpecificationJoint No.Joint Welding Procedure Card No.NDT RequirementB23 B24HJ-18see Note 2.B25 B28HJ-19see Note 2.B26 B27HJ-27see Note 2.B29 B30HJ-20see Note 2.B31 B32 B33HJ-21see Note 2.B34 B35HJ-22see Note 2.B36 B37 B38 B39HJ-23see Note 2.B40HJ-28se

21、e Note 2.D1HJ-29see Note 2.Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day焊 接 材 料 匯 總 表 焊 接 工 藝 規(guī) 程母 材焊 條 電 弧 焊 SMAW埋 弧 焊 SAW氣 體 保 護(hù) 焊 GTAW/GMAW焊條規(guī)格烘干溫度/時(shí)間焊絲規(guī)格焊劑烘干溫度/時(shí)間焊絲/規(guī)格保護(hù)氣體純 度Q345E、Q345E-Z25+Q345E、Q345E-Z35、Q345E-Z25H10Mn24SJ101300-400/2hTHY-51A/1.2CO299.8%編制： 年 月 日 審核： 年 月 日

22、Welding Consumables SummaryWelding Procedure SpecificationBase metalSMAWSAWGTAW/GMAWWelding rodespecificationsDrying temperature/timeWelding wirespecificationsfluxDrying temperature/timeWelding wire/specificationsShielding gaspurityQ345E、Q345E-Z25+Q345E、Q345E-Z35、Q345E-Z25H10Mn24SJ101300-400/2hTHY-5

23、1A/1.2CO299.8%Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day焊 接 工 藝 規(guī) 程焊 縫 返 修 工 藝 要 求1、焊縫外觀經(jīng)檢查不合格，返修時(shí)其工藝要求應(yīng)遵照下表規(guī)定進(jìn)行。 規(guī) 格 類 型返 修 工 藝 要 求焊縫尺寸不符合要求，弧坑及缺陷采用熔化極氣體保護(hù)焊，按相應(yīng)要求進(jìn)行補(bǔ)焊，并用砂輪認(rèn)真修磨，使其與原焊縫或母材圓滑過渡。咬邊焊接接頭不允許有咬邊。氣孔、砂眼、裂紋先用碳弧氣刨，將缺陷清除干凈（包括前后20mm），并用砂輪修磨后再補(bǔ)焊，最后用砂輪修磨。高低不平，寬窄不一或焊縫高度突變先用碳弧

24、氣刨，根據(jù)具體情況清除，用砂輪修磨，再用熔化極氣體保護(hù)焊補(bǔ)焊，最后再用砂輪進(jìn)行修磨，使其與母材或焊縫圓滑過渡。注：1、焊接材料及規(guī)范參數(shù)同原工藝。2、對于內(nèi)在缺陷，應(yīng)用碳弧氣刨清除，確認(rèn)后，用砂輪修磨后再補(bǔ)焊，焊后檢查項(xiàng)目及要求同原要求，最后再用砂輪修磨，使其與原焊縫和母材圓滑過渡。焊補(bǔ)工藝應(yīng)遵照焊接接頭返修、申請?zhí)幚韱蔚囊?guī)定進(jìn)行 。3、焊縫返修時(shí)，焊工應(yīng)具有原焊縫焊接資格，且應(yīng)由技術(shù)熟練者擔(dān)任。在返修過程中應(yīng)接受檢驗(yàn)人員的監(jiān)督，返修后按規(guī)定打上返修焊工鋼印。編制： 年 月 日 審核： 年 月 日Welding Procedure SpecificationWeld Repair Techno

25、logy Requirement1、 If the weld appearance is not accepted, the technology requirement during repair as per the specification in the table below. Specification and TypeWeld Repair Technology RequirementThe weld size doesnt comply with the requirement, crater and defectApply GMAW, welding repair as pe

26、r corresponding requirement, polish with grinding wheel to ensure smooth transition with original weld or base metal.undercutUndercut on welding joint is not allowed.blowhole、sand hole、crackClean the defect with carbon arc gouging,(including 20mm front and back), polish with grinding wheel and then

27、welding repair.Uneven, varies in width or weld height prominentClean with carbon arc gouging as per specific situation, polish with grinding wheel, welding repair with GMAT, and finally polish with grinding wheel finally, to ensure smooth transition with base metal or original weld .Note: 1. The wel

28、ding consumables and specifications are the same with original technology.2、For inner defect, cleaned with carbon arc gouging, polished with grinding wheel after confirmation and then perform welding repair. The check items and requirement after welding is the same with original requirement, to make

29、 smooth transition between original weld and base metal. Welding repair technology should followWelding joint repair、disposal application sheet. 3、 During the repair of the weld, the welder should be qualified to the original weld and with experienced skill. Receive the supervision of inspector duri

30、ng repair, die-stamping the repair welder stamp after repair according to the specifications.Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 頭 焊 接 工 藝 卡接頭簡圖：注：對于不等厚的對接，較厚處按圖紙削薄。操作注意事項(xiàng)：1、坡口角度及間隙要符合工藝要求。2、埋弧焊焊接時(shí)注意不要焊偏。3、每層焊完后應(yīng)認(rèn)真清除熔渣，如發(fā)現(xiàn)表面存在缺陷應(yīng)用砂輪清除后進(jìn)行補(bǔ)焊，并修磨平整，再繼續(xù)施焊。4、焊件施焊前，應(yīng)在始焊處100

31、mm范圍內(nèi)預(yù)熱到100-125以上。5、定位焊采用熔化極氣體保護(hù)焊，焊接材料為THY-51A。 接頭焊接工藝卡編號(hào)HJ-01接頭形式對接焊接工藝評定報(bào)告編號(hào)PQR-02B母 材Q345E-Z25厚度，mm53Q345E-Z2553焊 縫金 屬厚度，mm焊工持證項(xiàng)目SAW-1G（K）-07/09 焊接位置平焊層焊接方法填充材料焊接電流電弧電壓(V)焊接速度(m/h)線能量(kJ/cm)背面清根方式碳弧氣刨、砂輪機(jī)牌 號(hào)直徑極性電流(A)預(yù)熱溫度()1001、2、3SAWH10Mn2/SJ1014DC-550-63028-3128.3-3224.8層間溫度()1001404、5、6SAWH10Mn

32、2/SJ1014DC-550-63028-3128.3-3224.8焊后熱處理消除應(yīng)力7、8、9SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7后 熱10、11、12SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7鎢極直徑13、14SAWH10Mn2/SJ1014DC-550-63028-3525.7-3530.8噴嘴直徑脈沖頻率脈寬比(%)氣體成分氣體流量 編制： 年 月 日 審核： 年 月 日J(rèn)oint Welding Procedure CardJoint sketch：Note: For butt welding

33、with differenrt thickness,the thickner position should be tapered as per drawing.Operation notes：1、The bevel angle and clearance shall comply with technology requirement.2、Do not appear slanting welding during SAM.3、Clean carefully the slag after welding each layer, if there is surface defect, clean

34、 with grinding wheel and then welding repair, polish to flat, then continue welding.4、Preheat within range of 100mm of the welding starting position to above 100 -125 before welding.5、Tacking welding with GMAW, welding consumable is THY-51A。Joint Welding Procedure Card No.HJ-01Joint typeButt-welding

35、PQR No.PQR-02Bbase metalQ345E-Z25thickness，mm53Q345E-Z2553Weld metalthickness，mmweldercertifieditemSAW-1G（K）-07/09 welding positionflat weldinglayerwelding methodfilling materialwelding currentarc voltage (V)speed (m/h)energy input (kJ/cm)Back gouging methodCarbon arc gouging、grinding wheelbranddiam

36、eterpolaritycurrent (A)preheat temperature ()1001、2、3SAWH10Mn2/SJ1014DC-550-63028-3128.3-3224.8interlayer temperature ()1001404、5、6SAWH10Mn2/SJ1014DC-550-63028-3128.3-3224.8post-weld heat treatmentEliminate stress7、8、9SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7post heat10、11、12SAWH10Mn2/SJ1014DC-550-

37、63028-3428.8-3526.7tungsten electrode diameter13、14SAWH10Mn2/SJ1014DC-550-63028-3525.7-3530.8nozzle diameterimpulse frequencypulse width ratio (%)gas ingredientgas flow Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 頭 焊 接 工 藝 卡接頭簡圖：注：對于不等厚的對接，較厚處按圖紙削薄。操作注意事項(xiàng)：1、坡口角度及間隙要符合工藝要求。2、埋

38、弧焊焊接時(shí)注意不要焊偏。3、每層焊完后應(yīng)認(rèn)真清除熔渣，如發(fā)現(xiàn)表面存在缺陷應(yīng)用砂輪清除后進(jìn)行補(bǔ)焊，并修磨平整，再繼續(xù)施焊。4、焊件施焊前，應(yīng)在始焊處100mm范圍內(nèi)預(yù)熱到100-125以上。5、定位焊采用熔化極氣體保護(hù)焊，焊接材料為THY-51A。 接頭焊接工藝卡編號(hào)HJ-02接頭形式對接焊接工藝評定報(bào)告編號(hào)PQR-02B母 材Q345E厚度，mm41Q345E41焊 縫金 屬厚度，mm焊工持證項(xiàng)目SAW-1G（K）-07/09 焊接位置平焊層焊接方法填充材料焊接電流電弧電壓(V)焊接速度(m/h)線能量(kJ/cm)背面清根方式碳弧氣刨、砂輪機(jī)牌 號(hào)直徑極性電流(A)預(yù)熱溫度()1001、2、

39、3SAWH10Mn2/SJ1014DC-550-63028-3128.3-3224.8層間溫度()1001404、5、6SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7焊后熱處理消除應(yīng)力7、8SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7后 熱9、10SAWH10Mn2/SJ1014DC-550-63028-3525.7-3530.8鎢極直徑噴嘴直徑脈沖頻率脈寬比(%)氣體成分氣體流量 編制： 年 月 日 審核： 年 月 日J(rèn)oint Welding Procedure CardJoint sketch：Note: Fo

40、r butt welding with differenrt thickness,the thickner position should be tapered as per drawing.Operation notes：1、The bevel angle and clearance shall comply with technology requirement.2、Do not appear slanting welding during SAM.3、Clean carefully the slag after welding each layer, if there is surfac

41、e defect, clean with grinding wheel and then welding repair, polish to flat, then continue welding.4、Preheat within range of 100mm of the welding starting position to above 100 -125 before welding.5、Tacking welding with GMAW, welding consumable is THY-51A。 Joint Welding Procedure Card No.HJ-02Joint

42、typeButt-weldingPQR No.PQR-02Bbase metalQ345Ethickness，mm41Q345E41Weld metalthickness，mmweldercertifieditemSAW-1G（K）-07/09 welding positionflat weldinglayerwelding methodfilling materialwelding currentarc voltage (V)speed (m/h)energy input (kJ/cm)Back gouging methodCarbon arc gouging、grinding wheelb

43、randdiameterpolaritycurrent (A)preheat temperature ()1001、2、3SAWH10Mn2/SJ1014DC-550-63028-3128.3-3224.8interlayer temperature ()1001404、5、6SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7PWHTEliminate stress7、8SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7post heat9、10SAWH10Mn2/SJ1014DC-550-63028-3525.7-3530.

44、8tungsten electrode diameternozzle diameterimpulse frequencypulse width ratio (%)gas ingredientgas flow Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 頭 焊 接 工 藝 卡接頭簡圖：注：對于不等厚的對接，較厚處按圖紙削薄。操作注意事項(xiàng)：1、坡口角度及間隙要符合工藝要求。2、埋弧焊焊接時(shí)注意不要焊偏。3、每層焊完后應(yīng)認(rèn)真清除熔渣，如發(fā)現(xiàn)表面存在缺陷應(yīng)用砂輪清除后進(jìn)行補(bǔ)焊，并修磨平整，再繼續(xù)施焊。4、焊件施焊前，應(yīng)在始焊處100mm范圍內(nèi)預(yù)熱到100-125以上。5、定位焊采用熔化極氣體保護(hù)焊，焊接材料為THY-51A。 接頭焊接工藝卡編號(hào)HJ-03接頭形式對接