焊前預(yù)熱、焊后熱處理程序

1、Procedure for Prewelding Preheating and postwelding heat treatment Procedure No.：HY-WP-W-001Revision：1Procedure Number程序編號HY-WP-W-001Rev. No版本1Page頁碼1 of 20Document Status：文件狀態(tài)： PRE/準備 CFC/執(zhí)行Reference procedure No./Rev./參考程序編號/版本： N/A不適用Document Title文件名稱：Procedure for Prewelding Preheating and post

2、welding heat treatment焊前預(yù)熱、焊后熱處理程序Document Type/文件類型 ：Working Procedure工作程序Name &Title姓名及職務(wù)Signature/Date簽名及日期Approved by批準Prepared by編制職務(wù)：Title：Reviewed by審核Signature/Date：簽名及日期QA ReviewerQA審核Translator翻譯Translation reviewer譯審Copyright Declaration:版權(quán)聲明 ：This document is the property of the SNPE

3、MC. It must not be used, reproduced, transmitted or disclosed without the prior written permission of SNPEMC。本程序未經(jīng)山東核電設(shè)備制造有限公司書面批準不得外用、復(fù)制和泄露 Shandong Nuclear Power Equipment Manufacturing Co. Ltd. Page 20 of 20Historical Records of Modification修改歷史記錄版本Rev.發(fā)布日期Issue date修改范圍及依據(jù)Scope and Basis of the

4、Modification1Table of Contents目 錄1 Purpose目的42Scope范圍43References參考文件44Responsibilities職責45Pre-requisite先決條件56Steps of Operation操作步驟57. Detailed Description詳細描述67.1 Detailed Description詳細描述67.2 Heat Treatment熱處理98Appendix 附錄161 Purpose目的The procedure is defined as the criteria in preheating, heat tr

5、eatment and heating straightening of Shandong Nuclear Power Equipment Manufacturing Co., Ltd for ensuring the smooth implementation of the work.為山東核電設(shè)備制造有限公司進行焊前預(yù)熱、熱處理以及熱矯直提供工作依據(jù)，保證工作的順利進行，特制定本程序。2 Scope范圍The procedure is applicable for the prewelding preheating and stress-relief heat treatment of a

6、ll welding joints and heating straightening of the non-centered pipes of Shandong Nuclear Power Equipment Manufacturing Co., Ltd. 本程序適用于山東核電設(shè)備制造有限公司中的所有的焊接接頭的焊前預(yù)熱、消應(yīng)力熱處理以及不對中管的熱矯直。3 References參考文件ASME Standards B3.1 Power Pipeline Edition 2001, including 2002 AddendaASME標準B3.1 動力管道2001版，2002增補ASME S

7、tandards Volume IX Criteria for Welding and Braze Welding Edition 2001, including 2002 AddendaASME標準第IX卷 焊接和釬焊評定標準2001版，2002增補ASME Standards Volume III Construction Rules of Nuclear Power Equipments Edition 2001, including 2002 AddendaASME標準第III卷 核動力設(shè)備建造規(guī)則2001版，2002增補Welding control procedure焊接控制程序

8、HY-MP-COP-001Welding Procedure for CV Bottom SchemeCV底封頭焊接方案 HY-WP-W-00054 Responsibilities職責4.1 Technical Department技術(shù)部4.1.1 The heat treatment engineer of Technical Department should be liable for the technical guidance for preheating, post heating treatment & heating straightening of welding

9、products. 技術(shù)部熱處理工程師負責焊接產(chǎn)品焊前預(yù)熱、焊后熱處理和熱矯直工作的技術(shù)指導(dǎo)4.1.2 Be liable for carrying out the operations of preheating, heat treatment and heating straightening according to the data sheet of heat treatment; 負責按照熱處理數(shù)據(jù)單的要求執(zhí)行預(yù)熱、熱處理和熱矯直操作；4.1.3 Be liable for collecting temperature curve of heat treatment and fill

10、ing in the record list of heat treatment; 負責收集熱處理溫度記錄曲線并填寫熱處理記錄表；4.1.4 Submit relevant records to Quality Management Dept.; 將相關(guān)記錄送質(zhì)量管理部；4.2 Quality Management Department質(zhì)量管理部4.2.1 Perform inspection & supervision responsibility for the heat treatment and qualification of heat treatment personnel

11、; 對熱處理工作和熱處理人員資格履行檢查、監(jiān)督職責；4.2.2 Inspect and confirm if the heat treatment is in conformity with process regulations, and sign on the heat treatment records for confirming; 檢查熱處理工作是否按工藝規(guī)程執(zhí)行，并對熱處理記錄簽字確認；Collect the records on preheating, heat treatment and heating straightening. 收集預(yù)熱記錄、熱處理記錄及熱矯直工作記錄。5

12、 Pre-requisite先決條件5.1 Procedure and instruction are approved and addressed 所有相關(guān)的程序批準并執(zhí)行。5.2 The operating personnel of heat treatment must be trained and tested as qualified. 熱處理操作人員須經(jīng)過培訓(xùn)并考核合格。5.3 All measuring technical conditions must stay in good working conditions. 所有測量技術(shù)條件必須滿足的工作要求。5.4 Calibrat

13、ion of measuring and instrument, within the effective calibration period測量設(shè)備經(jīng)過標定,并處在有效的標定期內(nèi).6 Steps of Operation操作步驟6.1 General Operation Steps通用操作步驟Inspection of Pre-requisite preheating welding postwelding heating treatment NDE檢查先決條件 焊前預(yù)熱 焊接 無損檢測 焊后熱處理 NDE6.2 Operation Step of Preheating焊前預(yù)熱操作步驟In

14、spection of Pre-requisite confirm preheating temperature heating temperature measuring records檢查先決條件 確定預(yù)熱溫度 加熱 測溫 記錄6.3 Operation Step of Heat Treatment熱處理操作步驟6.3.1 Operation Steps of Partial Heat Treatment局部熱處理操作步驟Inspection of Pre-requisite fix thermal couple（K） wind heating rope thermal insulatio

15、n connect tranHYission wire turn on power do heat treatment recording diHYantle heating coil and thermal couple inspect the thermal cycle檢查先決條件固定熱電偶（K型） 纏繞加熱繩 保溫 連接傳輸導(dǎo)線 送電 進行熱處理 記錄 拆除加熱圈及熱電偶 檢查熱循環(huán)6.3.2 Operation Steps of Overall Heat Treatment整體熱處理操作步驟Inspection of Pre-requisite reception of working

16、 piece material load carry out heat treatment recording discharge檢查先決條件 工件接受 裝料 進行熱處理 記錄 出料7. Detailed Description詳細描述7.1 Detailed Description詳細描述7.1.1 Inspection of Pre-requisite檢查先決條件1) Inspect if the parts are cleaned and degrease (cleanness have to be performed on the bevel and within 2 inches o

17、n each side of the bevel); 檢查部件是否清潔和去脂（應(yīng)將破口兩側(cè)2英寸范圍內(nèi)清理干凈。）；2) Inspect the preparation of bevel; 檢查坡口制備狀況；3) Inspect and confirm if the surface thermodetector or metal tempilstick 檢查表面測溫計或金屬測溫筆。7.1.2 Confirm Preheating Temperature確定預(yù)熱溫度The preheating temperature cannot exceed the highest interpass tem

18、perature specified in the welding procedure for preventing unfavorable influence while interpass temperature cannot be lower than the preheating temperature.預(yù)熱時注意預(yù)熱溫度不能超過在焊接程序中規(guī)定的最高層間溫度，防止產(chǎn)生不良影響；但層間溫度不能低于預(yù)熱溫度。7.1.3 According to ASME Volume Division 1 Subsection NE Class MC Components, the lowest pre

19、heating temperature of all P1 and P3 materials with nominal thickness exceeding 19mm should be 95 and moreover, the highest interpass temperature cannot exceed 150. 對于P1和P3材料，按ASME第卷 第一冊 NE分卷 MC級部件的規(guī)定，所有公稱厚度超過19mm的材料，最低預(yù)熱溫度為95并且最大層間溫度不能超過150。7.1.4 No preheating is required for P8 material in general

20、. For the correct preheating and interpass temperatures, please refer to corresponding WPS.對于P8材料，一般不需要預(yù)熱，關(guān)于正確的預(yù)熱和層間溫度的要求，參見相應(yīng)的WPS。7.1.5 For correct preheating and interpass temperatures of all other materials, please refer to corresponding WPS.對于所有其它材料，正確的預(yù)熱和層間溫度的要求，參見相應(yīng)的WPS。7.1.6 Confirm the Prehe

21、ating Method確定預(yù)熱方法Electric heating or direct flame heating can be applied. However, during workshop manufacturing, electric heating should be applied as possible under the Pre-requisite of temperature balance.采用電加熱或火焰直接加熱，但在車間制造過程中，為了確保溫度均衡的前提下，盡量采用電加熱。7.1.7 Confirm the Area of Heating確定加熱區(qū)域1) The m

22、inimum heating scope in preheating is 100mm(100mm on both sides of joint);預(yù)熱時加熱范圍最小為100mm(指接頭兩側(cè)各100mm)；2) When an electric heating method is used for heating, thermal couple and heating coil should be installed closest to the bevel while should not hinder the access of welder to the joint.采用電加熱法加熱時，

23、需注意熱電偶及加熱圈的安裝要盡可能靠近坡口，但不得妨礙焊工接近接頭。7.1.8 Heating加熱1) Necessary measures are required for enabling heat to diffuse along the heated joint evenly (especially in direct flame heating), so as to prevent partial overheating that may cause sharp temperature gradients, produce unfavorable result and deterio

24、rate the metal performance in the preheating area;采取必要措施，使熱量沿被加熱的接頭均勻擴散（特別是采用火焰直接加熱時），防止局部過熱產(chǎn)生過大的溫度梯度，造成不良后果，影響預(yù)熱區(qū)金屬性能；2) Preheating shall not cause pollution on the surface of joints and related parts;預(yù)熱不得在接頭和所涉及的部件表面引起污染；3) In case that direct flame heating can hardly enable the weld along the ent

25、ire length to reach the preset preheating temperature if the pipeline diameter is large, the whole area to be heated can be evenly heated for one time, and the part to be welded can be further heated in the scope of at least 100mm away from the weld center for welding. Confirm the temperature after

26、heating according to the preset temperature;在管道直徑比較大時，采用火焰直接加熱很難保證焊縫的整個長度上都能達到規(guī)定的預(yù)熱溫度，可以先將整個要加熱的區(qū)域均勻加熱一遍，然后在待焊接的部位集中加熱，范圍為距待焊的焊縫中心至少100mm。加熱后核實溫度是否達到規(guī)定的溫度；4) Due to the fact that air circulation in the pipe shapes air current, a tamper can plug up the end head of pipeline or other opening method is

27、used for eliminating air current if possible. The tamper cannot pollute working piece and be easy for removal.由于空氣在管內(nèi)流通造成氣流，在可能的情況下可采用堵塞物堵住管道端頭和其它開孔的方法消除，堵塞物不得污染工件，且要便于去除。7.1.9 Temperature Measuring測溫1) In direct flame heating, four points evenly allocated along the whole length of a weld can be spe

28、cified once the flame taken away. Surface thermodetector or metal tempilstick can be used for verifying the preheating temperature;當用火焰直接加熱時，移走火焰后，在焊縫的整個長度上確定均勻分布的四個點，用表面測溫計或金屬測溫筆核實預(yù)熱溫度；2) The temperature should be continuously kept and monitored till welding operation is over. Preheating temperatur

29、e should be inspected at interval for ensuring a temperature within the scope defined for the welding;溫度要連續(xù)保持并監(jiān)視直至焊接作業(yè)結(jié)束，隔一段時間檢查一次預(yù)熱溫度，以保證該溫度在焊接規(guī)定的范圍之內(nèi)；3) When heating coil is used for heating, thermal couple must be used for temperature measuring.使用加熱圈加熱時，測溫必須使用熱電偶。7.1.10 Records記錄Records on prehea

30、ting operation should be kept. Relevant personnel should fill in a list of preheating records (See Appendix A) for future inspection. However, if outdoor temperature is comparatively low, the records preheating arent required for the welding operation preheating to room temperature.進行預(yù)熱操作應(yīng)作相應(yīng)記錄，相關(guān)人員

31、應(yīng)填好焊前預(yù)熱記錄表（見附錄A），以備檢查。但由于室外溫度比較低，要求預(yù)熱到室溫后再進行焊接操作的焊前預(yù)熱可不作記錄。7.2 Heat Treatment熱處理Partial heat treatment in adoption of electric ceramic heater & overall heat treatment in heating treatment oven are included; and, overall heat treatment is recommended if the conditions permit.包括采用陶瓷電加熱器加熱的局部熱處理和采用

32、熱處理爐處理的整體熱處理；條件適合的情況下優(yōu)先采用整體熱處理。7.2.1 Inspection of Pre-requisite檢查先決條件Besides the Pre-requisite s in Part 5, the following requirements must be met:除滿足節(jié)5中的先決條件外還必須滿足以下要求：1) The parts for heat treatment must be clean and degreasing treatment is requirement if necessary;熱處理部件必須清潔，如果有必要應(yīng)進行脫脂處理；2) Inspe

33、ct the mark and serial number; 檢查標記和編號；3) Inspect and confirm if the previous process is completed; 檢查前道工序是否完成；4) The technical parameters of heating oven for overall heat treatment should comply with the requirements. 整體熱處理時加熱爐技術(shù)參數(shù)應(yīng)符合要求。7.2.2 Partial Heat Treatment局部熱處理A rope-shaped (crawler-type)

34、electric ceramic heater is used for heating; and thermal couple is applied for temperature monitoring. 采用繩狀（履帶式）陶瓷電加熱器加熱；使用熱電偶監(jiān)測溫度。1) Inspection of Pre-requisite檢查先決條件2) The above-said requirements should be met應(yīng)滿足前述的要求3) Installation of thermal couple熱電偶的安裝a) The quantity and position of thermal co

35、uple is defined according to the direction and diameter of the pipe. If the pipe lies in horizontal position with Dn4in, a thermal couple should be installed at the position 30° vertical to standing axis (See Figure 1 in Appendix E); if 4in<Dn10in, each of two opposite points of pipeline is

36、installed with one thermal couple (See Figure 2 in Appendix E); if Dn>10in, three thermal couples are installed (See Figure 3 in Appendix E); and, if the pipeline lies in vertical position, three thermal couples are installed (See Figure 4 in Appendix E);根據(jù)管子的方向和直徑來確定熱電偶的數(shù)量和位置。當管子處于水平位置時，若Dn4in，在

37、垂直于豎軸30°角的位置安裝一個熱電偶(見附錄E中圖1)；若4in<Dn10in，在管道的相對兩點各安裝一個熱電偶(見附錄E中圖2)；Dn>10in時，安裝3個熱電偶(見附錄E中圖3)；當管子處于垂直位置時，安裝3個熱電偶(見附錄E中圖4)；b) A standby thermal couple (marked as R in the figure) should be prepared, of which the position of installation is included in Appendix E. It can replace the damaged

38、thermal couple;準備一個備用熱電偶（圖中標為R），安裝位置見附錄E，可用它來代替壞損的熱電偶；c) The head of thermal couple lies in the heat-affected area of weld and closely sticks to the surface of the part. The thermal couple should be fixed in proper method.熱電偶頭部位于焊縫熱影響區(qū)且緊貼部件表面，用適當方法固定熱電偶。4) Installation of heating coil加熱圈的安裝a) Heatin

39、g rope (sheet) is wound on both sides with the crater as center; 以焊口為中心在兩側(cè)均勻纏繞加熱繩（片）；b) The heating rope should be tightly wound, and closely stick to the surface of parts, instead of any overlap, crossover, floating or looseness. 纏繞加熱繩時要確保纏緊，加熱繩須緊貼部件表面，不得重疊、交叉、懸空或松動。5) Thermal insulation保溫a) 50

40、5;600mm aluminum silicates fiber carpet is used for thermal insulation; 采用50×600mm硅酸鋁纖維毯保溫；b) Aluminum silicates fiber carpet must be bound up with iron wire for preventing any fall-off; 硅酸鋁纖維毯必須用鐵絲綁緊以防止脫落；c) Both ends of the pipeline can be plugged up for preventing air current in the pipeline

41、 during heating while the tamper in use must be easy to remove. 加熱時為防止管內(nèi)空氣流動，可將管道兩端堵死，但必須注意使用的堵塞物要便于去除。6) Installation of TranHYission Wire傳輸導(dǎo)線的安裝After the heating coil and aluminum silicates fiber carpet are installed, relevant wires will be used for connecting the heating coil and thermal couple w

42、ith corresponding part of the console. 加熱圈及硅酸鋁纖維毯安裝好后，用相應(yīng)導(dǎo)線把加熱圈及熱電偶和操作臺的相應(yīng)部位連接起來。7) Turn-on of Power Supply送電Carefully inspect and confirm the circuit after the wire connected, switch on the power supply of console, turn on the temperature recording instrument, input process curve as per the paramet

43、ers of the process, and tranHYit power supply to heating coil and start heating. 接好導(dǎo)線后，仔細檢查一遍線路，確認無誤后接通操作臺電源，打開溫度記錄儀，按照工藝參數(shù)輸入工藝曲線，向加熱圈送電，開始加熱。8) Carry out Heat Treatment進行熱處理The process of heat treatment should be subject to the following regulations: 在熱處理過程中應(yīng)遵守以下規(guī)定：a) Heating rate, thermal insulati

44、on temperature, holding time and cooling rate must be subject to Article 7.2.4;升溫速率、保溫溫度、保持時間以及冷卻速率必須按節(jié)7.2.4中的要求執(zhí)行；b) All heat treatment temperature must be consecutive and be automatically recorded.所有熱處理溫度必須連續(xù)并且自動記錄。9) Records記錄Fill in the list of heat treatment records (See Appendix B) after heat

45、treatment is over.在熱處理結(jié)束后填寫熱處理記錄表(見附錄B)。10) DiHYantle Heating Coil and Thermal Couple拆除加熱圈及熱電偶DiHYantle heating coil & thermal couple after the parts are completely cooled down. 當部件完全冷卻后拆除加熱圈及熱電偶。11) Inspect the Thermal Cycle檢查熱循環(huán)The records on temperature and time should be inspected according

46、to the specified conditions and at the same time, the heat treatment records should be inspected as well. 溫度和時間的記錄應(yīng)對照規(guī)定的條件進行檢查，同時也應(yīng)檢查熱處理記錄。7.2.3 Overall Heat Treatment整體熱處理Heat treatment ov en is used for heat treatment. Thermal insulation materials have to be free of any detrimental material.采用熱處理爐

47、進行熱處理。1） Inspection of Pre-requisite檢查先決條件Besides the above-said Part 5 and Article 7.2.1, the lifting equipment (traveling crane and chain block) must comply with the technical requirements. 除滿足前述節(jié)5及節(jié)7.2.1中所有要求外，吊裝設(shè)備(天車和倒鏈)必須滿足技術(shù)要求。2） Reception of Parts部件接收Inspect and confirm the labels on the part

48、s in conformity with the regulations. 檢查部件上標記是否符合規(guī)定的要求。3） Material Loading裝料A traveling crane is used for lifting, and the parts should be loaded into the furnace in conformity with the following requirements: 采用天車吊裝，部件裝入爐內(nèi)應(yīng)該注意以下幾點：a) The parts should be evenly distributed in the hearth; 部件均勻分布在爐膛內(nèi)；

49、b) The parts should be flatly placed and supported for preventing any deforming; 部件應(yīng)平放并支撐以防變形；c) The parts are placed on the foundation (fire-retardant tile or bed); 部件放置在支座上(耐火磚或座)；d) The parts cannot be in touch with each other for ensuring good thermal convection; 部件之間不得相互接觸，以便于良好的熱對流；e) The part

50、s should be in the heating area. Thermal insulation materials have to be free of any detrimental material.部件應(yīng)位于加熱區(qū)內(nèi)，熱的絕緣材料不能有有任何的有害材料。4） The thermal couple of heat treatment furnace itself should be used采用熱處理爐自帶的熱電偶5） Inspect the Material Load檢查裝料The inspector should confirm if the parts are placed

51、in conformity with the requirement before the furnace closes. 在爐子關(guān)閉前檢查員應(yīng)核實部件擺放是否符合要求。6） Carry out Heat Treatment進行熱處理The process of heat treatment should abide by the following regulations: 在熱處理過程中應(yīng)遵守以下規(guī)定：a) Heating rate, thermal insulation temperature, holding time and cooling rate must be subject

52、to Article 7.2.4; 保溫溫度、保溫時間、升溫速率以及冷卻速率必須按節(jié)7.2.4中的要求執(zhí)行；b) All heat treatment temperature must be consecutive and be automatically recorded except the cooling outside the furnace. 所有熱處理溫度必須自動連續(xù)記錄，但爐外冷卻除外。7）Records記錄Fill in the list of heat treatment records (See Appendix B) after heat treatment is ove

53、r. 在熱處理結(jié)束后填寫熱處理記錄表(見附錄B)。8）Discharge出料After the parts are completely cooled down, the same equipment for loading material can be used for discharge. 當部件完全冷卻后使用裝料所用的相同設(shè)備出料。9）檢查熱循環(huán)Inspect the Thermal CycleThe records on temperature and time should be inspected according to the specified conditions and

54、 at the same time, the heat treatment records should be inspected as well. 溫度和時間的記錄應(yīng)對照規(guī)定的條件進行檢查，同時也應(yīng)檢查熱處理記錄。7.2.4 Parameters of Postwelding Heating Treatment焊后熱處理參數(shù)1）Insulation Temperature保溫溫度According to AHYE V.III List NB/NC/ND-4622.1-1, thermal insulation temperature of the welds of nuclear-grade

55、 1, 2 & 3 with P1 & P3 materials is 600°C670°C; according to ANSI/AHYE B31.1 Table 132, that of non-nuclear-grade weld with P1 & P3 materials is 600°C-650°C.對于材料為P1及P3的核1,2,3級焊縫，根據(jù)AHYE 第卷 表NB/NC/ND-4622.1-1，保溫溫度為600°C670°C；對于材料為P1及P3的非核級焊縫，根據(jù)ANSI/AHYE B31.1表

56、132，保溫溫度為600°C650°C。According to ASME Section Subsection NE and WEC's design requirement, the preheat temperature for all CV welds should be 100-200 .For those welds which should go through PWHT, the holding temperature for PWHT should be 593-620 and the temperature holding time should

57、 be 10 hours.根據(jù)ASME規(guī)范NE分卷和WEC的設(shè)計要求，CV安全殼的焊縫均需要預(yù)熱到100-200 C，對于需要做焊后熱處理工藝的安全殼焊縫，焊后熱處理保溫溫度為593-620 C，保溫時間10小時。2）Holding Time保溫時間The shortest thermal insulation time is defined according to the thickness of pipe wall (See Table 1 for details). 根據(jù)管壁的厚度確定最短保溫時間（詳見表1）。Table 1 Relationship Chart of Thickness and Shortest Thermal Insulation Time表1 厚度與最短保溫時間關(guān)系表Nominal thickness公稱厚度Shortest thermal insulation time最短保溫時間£2in1h/in，最少30min1h/in, 30min at min.>2in2h+15min/inTable 2 Relationship Chart of Temperature and Shortest Thermal Insulation