SL3000塔架焊接工艺规程.docx

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1、NO： 3MW-012-T 焊 接 工 艺 规 程 产品名称 SL3000项目塔架 产品编号 3MW-012-T 图 号 T6010002编 制 年 月 日 审 核 年 月 日青岛海洋热电化工设备有限公司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.焊接工艺规程目录 序 号名 称页 数备 注1接头编号表82焊接材料汇总表23接头焊接工艺卡584焊缝返修工艺要求25技术要求267 编制： 年 月 日 审核： 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 头 编 号 表 接头编号示意图 编制： 年 月 日 审核： 年 月 日Joint No. SheetJoint No. sketch ： Prepared by：Wang Peng August 5th ,2011 Reviewed by： year month day接 头 编 号 表焊 接 工 艺 规 程接头编号接头焊接工艺卡编号无损检测要求注:1、内件焊接用焊接材料按焊

4、接材料汇总表，焊角高度按图纸要求。 2、无损检测要求如下：(1)所有焊缝必须进行100%的VT检查,按照EN ISO 5817 B级执行。(2)超声波检验，按照JB4730-2005标准I级要求执行。塔筒纵向焊缝、环向焊缝、塔筒法兰和筒体过渡处的环向焊缝、门框和焊接筒体之间过渡处的连续焊缝都必须进行100%UT检查。 （3）塔架法兰和筒节的T型焊缝接头处根据JB4730-2005均布片射探；筒节与筒节处的T型焊缝接头按照100%数量进行布片射探，每个T型布片2张，胶片长度为300mm，级别为级。（4）塔筒法兰和筒体之间环向焊缝、门框和筒体之间连续焊缝须进行100%MT检查,结果符合JB4730

5、-2005.4级合格；附件连接板焊接焊缝总数的20% 进行100%PT检查，结果符合JB4730-2005.5级合格。3、经射线或超声检测的焊接接头，如有不允许的缺陷，应在缺陷清除后进行补焊，并对该部位采用原检测方法重新检查直至合格。进行局部探伤的焊接接头，发现有不允许的缺陷时，应在该缺陷两端的延伸部位增加检查长度，增加的长度为该焊接接头长度的10%，且不小于250mm。若仍有不允许缺陷时，则对该焊缝做100%检测。4、焊缝需要返修时，其返修工艺应符合焊接工艺要求。焊缝同一部位的返修次数不应超过两次，如超过两次，返修前应经用户单位技术总负责人批准，返修次数，返修部位和返修情况应如实记入质量证明

6、资料。 5、仅产品编号为3MW-01-T代产品试板，其余以批代台。A1（带试板）A2 HJ-01见注2A3（带试板） HJ-02见注2A4（带试板）HJ-03见注2A5（带试板）HJ-04见注2A6（带试板）HJ-05见注2A7（带试板）HJ-06见注2A8（带试板）HJ-07见注2A9（带试板）HJ-08见注2A10（带试板）HJ-09见注2A11（带试板）A12HJ-10见注2A13（带试板）HJ-11见注2A14（带试板）HJ-12见注2A15（带试板）A16HJ-13见注2A17（带试板）HJ-14见注2A18（带试板）HJ-15见注2A19（带试板）HJ-16见注2A20（带试板）H

7、J-17见注2A21（带试板）A22HJ-18见注2A23（带试板）A24 A25HJ-19见注2A26（带试板） A27HJ-20见注2A28（带试板）A29 A30HJ-21 编制： 年 月 日 审核： 年 月 日Joint 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 头 编 号 表焊 接 工 艺 规 程接头编号接头焊接工艺卡编号无损检测要求A31（带试板）A32 A36HJ-22见注2A33（带试板）A34 A35HJ-23见注2B1HJ-24见注2B2HJ-01见注2B3HJ-02见注2B4HJ-03见注2B5HJ-04见注2B6HJ-05见注2B7 B8HJ-25见注2B9HJ-07见注2B10HJ-08见注2B11HJ-09见注2B12 B13HJ-10见注2B14HJ-

17、11见注2B15HJ-12见注2B16 B17HJ-26见注2B18HJ-13见注2B19HJ-14见注2B20HJ-15见注2B21HJ-16见注2B22HJ-17见注2编制： 年 月 日 审核： 年 月 日Joint 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 头 编 号 表焊 接 工 艺 规 程接头编号接头焊接工艺卡编号无损检测要求B23 B24HJ-18见注2B25 B28HJ-19见注2B26 B27HJ-27见注2B29 B30HJ-20见注2B31 B32 B33HJ-21见注2B34 B35HJ-22见注2B36 B37 B38 B39HJ-23见注2B40HJ-28见注2D1HJ-29见注2编制：

20、年 月 日 审核： 年 月 日Joint 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 汇 总 表 焊 接 工 艺 规 程母 材焊 条 电 弧 焊 SMAW埋 弧 焊 SAW气 体 保 护 焊 GTAW/GMAW焊条规格烘干温度/时间焊丝规格焊剂烘干温度/时间焊丝/规格保护气体纯 度Q345E、Q345E-Z25+Q345E、Q345E-Z35、Q345E-Z25H10Mn24SJ101300-400/2hTHY-51A/1.2CO299.8%编制： 年 月 日 审核： 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 艺 规 程焊 缝 返 修 工 艺 要 求1、焊缝外观经检查不合格，返修时其工艺要求应遵照下表规定进行。 规 格 类 型返 修 工 艺 要 求焊缝尺寸不符合要求，弧坑及缺陷采用熔化极气体保护焊，按相应要求进行补焊，并用砂轮认真修磨，使其与原焊缝或母材圆滑过渡。咬边焊接接头不允许有咬边。气孔、砂眼、裂纹先用碳弧气刨，将缺陷清除干净（包括前后20mm），并用砂轮修磨后再补焊，最后用砂轮修磨。高低不平，宽窄不一或焊缝高度突变先用碳弧

24、气刨，根据具体情况清除，用砂轮修磨，再用熔化极气体保护焊补焊，最后再用砂轮进行修磨，使其与母材或焊缝圆滑过渡。注：1、焊接材料及规范参数同原工艺。2、对于内在缺陷，应用碳弧气刨清除，确认后，用砂轮修磨后再补焊，焊后检查项目及要求同原要求，最后再用砂轮修磨，使其与原焊缝和母材圆滑过渡。焊补工艺应遵照焊接接头返修、申请处理单的规定进行 。3、焊缝返修时，焊工应具有原焊缝焊接资格，且应由技术熟练者担任。在返修过程中应接受检验人员的监督，返修后按规定打上返修焊工钢印。编制： 年 月 日 审核： 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 头 焊 接 工 艺 卡接头简图：注：对于不等厚的对接，较厚处按图纸削薄。操作注意事项：1、坡口角度及间隙要符合工艺要求。2、埋弧焊焊接时注意不要焊偏。3、每层焊完后应认真清除熔渣，如发现表面存在缺陷应用砂轮清除后进行补焊，并修磨平整，再继续施焊。4、焊件施焊前，应在始焊处100

31、mm范围内预热到100-125以上。5、定位焊采用熔化极气体保护焊，焊接材料为THY-51A。 接头焊接工艺卡编号HJ-01接头形式对接焊接工艺评定报告编号PQR-02B母 材Q345E-Z25厚度，mm53Q345E-Z2553焊 缝金 属厚度，mm焊工持证项目SAW-1G（K）-07/09 焊接位置平焊层焊接方法填充材料焊接电流电弧电压(V)焊接速度(m/h)线能量(kJ/cm)背面清根方式碳弧气刨、砂轮机牌 号直径极性电流(A)预热温度()1001、2、3SAWH10Mn2/SJ1014DC-550-63028-3128.3-3224.8层间温度()1001404、5、6SAWH10Mn

32、2/SJ1014DC-550-63028-3128.3-3224.8焊后热处理消除应力7、8、9SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7后 热10、11、12SAWH10Mn2/SJ1014DC-550-63028-3428.8-3526.7钨极直径13、14SAWH10Mn2/SJ1014DC-550-63028-3525.7-3530.8喷嘴直径脉冲频率脉宽比(%)气体成分气体流量 编制： 年 月 日 审核： 年 月 日Joint 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-550-63028-3428.8-3526.7tungsten 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 头 焊 接 工 艺 卡接头简图：注：对于不