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1、WELDING & NDE OF PRESSURE VESSELS, HEAT EXCHANGERS, COOLERS, BOILERS AND HEATERS (INCLUDING PIPING OF PACKAGED UNITS)压力容器、换热器、冷却器、锅炉和裂解炉（包括成套装置的配管）的焊接和无损检测1.0 Scope 范围1.1 This specification covers the requirements for welding, post weld heat treatment, weld examination and inspection of pressure ves
2、sels, heat exchangers, coolers, boilers, heaters and attachments welded thereto (including equipment and piping of package units) for the IPS Project本规范适用于ISP工程中压力容器、换热器、冷却器、锅炉、裂解炉及与其焊接的附件（包括成套装置的设备和管线）的焊接、焊后热处理、焊接检查和检验。1.2 All welding, welding procedure specifications, qualifications, and welders p
3、erformance qualifications shall be in accordance with the applicable fabrication code and the additional requirements herein.所有的焊接、焊接工艺规程、焊接工艺评定及焊工资格考试均应符合相关的制造规范和本规范附加的要求。1.3 No deviations shall be made from this specification without written approval from the Purchaser.无买方的书面同意，不得违背本规范要求。1.4 All p
4、rovisions of the ASME Boiler and Pressure Vessel Code shall be considered a part of this specification where applicable for the concerning pressure vessel, heat exchanger, boiler, cooler, boiler, heater or piping. 必要时，ASME锅炉和压力容器规范中关于压力容器、换热器、锅炉、冷却器、裂解炉或管道的所有规定将作为本规范的一部分。1.5 Welding Procedure Specif
5、ications, including qualifications are also required for Internals for pressure vessels. These Welding Procedure Specifications need only to comply with the ASME code.压力容器内件的焊接同样需要制定焊接工艺规程以及工艺评定。这些焊接工艺规程必须符合ASME规范。1.6 Definitions:定义Vendor: The word Vendor will be used for the main supplier responsib
6、le for Welding供货商（卖方）：指负责焊接的主供货商。Owner: The word Owner will be used for BASF-YPC 业主：指BASF-YPC。Licensor: The Licensors are BASF or BASELL etc 专利商：指BASF或BASELL等。Purchaser:Party responsible for issuing the Purchase Order. This may be the main Engineering, Procurement and Construction (EPC) Contractor a
7、cting as an agent for the Owner.买方：负责发出采购订单的一方。这可以是作为业主代理商的主工程设计、采购和施工（EPC）承包商。2.0 Codes and Standards 标准和规范The following codes, and standards are to be considered where applicable. All conflicts between the requirements of these relevant documents shall be referred to Purchaser for resolution.必要时应考
8、虑以下规范和标准。这些相关文件中的要求之间的所有冲突应提交买方解决。1) ASME Boiler and Pressure Vessel Code.ASME锅炉及压力容器规范。2) Project Specification 40-010-00-0-0-00-015: Tube/Tubesheet joint requirements.项目规范：管/管板 接头要求（40010000000015）3) Project Specification 40-010-00-0-0-00-016: General Requirements Welding Engineering.项目规范：焊接工程通用技术
9、要求（40010000000016）4) ASTM A262: Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steel.ASM A262：奥氏体不锈钢晶间腐蚀敏感性检测。5) ASTM A435: Standard Specification for Straight Beam Ultrasonic Examination of Steel. Plates.ASM A435: 钢板直射超声波检测技术规范。6) ASTM A770-86: Standard Specification for T
10、hrough Thickness Tension Testing of Steel Plates for Special Applications.ASM A770-86:特殊用途钢板全截面拉伸试验技术规范。7) ISO 14731 1997: Welding Coordination Tasks and ResponsibilitiesISO 14731 1997: 焊接工作的协调任务及职责。3.0 Welding Documents 焊接文件3.1 The Welding documents prepared by the Vendor (for each weld or group of
11、 welds) shall comprise:由供货商（对每一道焊缝或一组焊缝）准备的焊接文件应包括：1) A weld map.一份焊缝布置图2) A Welding Procedure Specification (WPS) with detailed instructions to the welders and welding machine operators on how to perform the welding of the equipment or piping.一份对焊工和焊接设备操作工详细说明怎样进行设备或管道焊接的焊接工艺规程。3) A detailed Weldin
12、g Procedure Qualification test Record (PQR).一份详细的焊接工艺评定试验报告。3.2 All welding documents shall be submitted by the Vendor for review and approval by the Purchaser. Production welding shall not commence before written receipt of the Purchasers approval.供货商应向买方提供所有焊接技术文件，供其审核和批准。在收到买方的书面批准以前不得开始焊接工作。3.3
13、Purchaser will not give a final approval of welding documents unless they are completed with the results of the required Procedure Qualification Record(s). Approval by Purchaser of Welding Procedure Specifications and Procedure Qualification Records shall in no way relieve the Vendor of the responsi
14、bility of providing welds which are sound and suited for the services for which they are intended.如果焊接文件中未包括所需的工艺评定记录，买方将不对焊接技术文件做出最终批准。买方对焊接工艺规程和工艺评定报告的批准并不能解除供货商提供完好的和满足其用途的焊缝的责任。3.4 All Welding Procedure Specifications and Procedure Qualification Records for purchased items subcontracted by the p
15、rime Vendor shall be reviewed by the prime Vendor for content and Contract / Purchase Order compliance prior to submittal to Purchaser. Welding shall not commence until documents are returned to the Vendor with authorization to start.由主供货商分包购买的设备的焊接工艺规程和焊接工艺评定记录，应由主供货商对内容和合同/订货单的符合性进行审核后提交买方。只有技术文件批
16、复后，才可开始焊接。3.5 Basis for rejection of welding procedures shall be non-compliance with the applicable requirements, or violation of industry practice.焊接工艺被否定的依据是与相关要求不符，或违反行业惯例。3.6 Vendor shall minimize the selection of welding procedures for the orders placed for this project to simplify the engineer
17、ing and inspection function, but must fully take into account the applicable requirements.供货商应尽量减少本工程定购单的焊接工艺的选择性，以简化工程及检验工作。但必须充分考虑相关要求。3.7 Each individual Vendor shall prepare and qualify his own welding procedures. Combining procedure qualifications by two or more companies, even if there exists
18、a combined operational control, is not permitted unless specific approval is given by the Purchaser.每一个供货商应准备并评定自己的焊接工艺。除非有买方的特别批准，即使在两家或多家公司之间存在联合管理控制，也不允许则两家或多家公司进行联合焊接工艺评定。3.8 For each equipment item a separate set of welding documents shall be prepared and submitted.对每台设备，应准备并提交一套单独的焊接技术文件。3.9 V
19、endor shall supply a fabrication drawing or sketch of each item (e.g. pressure vessel or heat exchanger), showing the reference numbers of the welding procedure specifications selected for each weld (weld map).供货商应提供每一台设备（如压力容器或换热器）的制造图或示意图，图中表示出每一道焊缝所选用的焊接工艺规程的编号（焊缝布置图）。4.0 Welding Procedure Specif
20、ication (WPS) 焊接工艺规程（WPS）4.1 Each WPS submitted must include the following information (as applicable):提交的每一份WPS必须包括以下内容（根据适用范围）1) Purchase order number or contract number and equipment item number.定购单号或合同号及设备位号。2) Vendors WPS number and supporting qualification number.供货商的WPS 编号及相关焊接工艺评定的编号。3) The
21、actual materials to be welded in production, the actual range of plate/pipe thickness and diameter covered and the application of the procedure, i.e. for welding longitudinal or circumferential seams, nozzles into shells, etc. and whether the WPS is applicable for shop or field welding.生产中需焊接的材料，所涉及
22、的钢板/钢管厚度和直径的实际范围，焊接工艺用于焊接纵缝或环缝、接管与壳体的焊接等的情况以及WPS是否适合车间或现场焊接。4) Sketch or sketches showing the type and dimensions (including allowable tolerances) of joints to be welded including root faces size and root opening and method of preparing welding edges.标出要焊接的接头的类型和几何尺寸（包括允许偏差）,包括钝边和间隙尺寸及坡口加工方法的示意图。5)
23、Welding technique to be applied with size of electrodes or wires for each bead, deposition sequence of beads, string or weave bead, initial and interpass cleaning (brushing, grinding, etc.), method of back gouging, oscillation, method of tack welding, multipass or single pass per side, single or mul
24、tiple electrodes, one side welding or rewelding at backside, all welding parameters such as current (AC or DC), polarity, amps (range) volts (range), travel speed (range) and the required heat input (range). For weld overlay operations, the minimum overlap of adjacent beads must be specified. For ta
25、ck welding, all relevant information and parameters shall also be specified in the WPS.所采用的焊接技术的相关因素：每道焊缝的焊条或焊丝直径，焊缝的焊接次序，直线或横向摆动，根部和层间清理（钢丝刷、打磨等），背部清根，摆动幅度，点焊方法，每面多道或单道焊，单焊条（丝）或多焊条（丝），单面焊或双面焊，所有的焊接参数，如电流（交流或直流）、极性、电流（范围）、电压（范围）、焊接速度（范围）和要求的热能量。对于搭接焊缝，必须给出相邻焊缝的最小搭接长度。对于点焊，所有相关的要求及焊接参数也应在WPS中做出规定。6)
26、Name(s) of welding process( es) to be used, (e.g. SMAW, SAW, GTAW, etc.). In case of a combination of welding processes it shall be clearly specified which part (thickness) of the weld(s) will be performed by which welding process.所使用的焊接方法的名称（如SMAW、SAW、GTAW等）。如果使用组合焊接方法，应明确规定哪一部份的焊缝（厚度）使用哪一个焊接方法。7)
27、Details of welding consumables including the make and brand of electrodes, fluxes, wires and other consumables and adequate filler metal classification according to AWS.焊接材料的详细情况：焊条、焊剂、焊丝和其他焊接材料的类型牌号，熔敷金属按照AWS标准的分类。8) Shielding gas with percent composition (mixtures), flow-rate (liter/minute), backi
28、ng gas composition and flow rate (liter/minute) and size of gascup to be used.保护气体的组成百分比（混合气体），流量（升/分钟），背面保护气体的组成百分比和流量（升/分钟）以及所用气罩的尺寸。9) Welding position (position of groove) and welding progression (upward, downward).焊接位置（坡口位置）和焊接方向（向上、向下）。10) Minimum preheat and maximum interpass temperature with
29、 method of heating and method of temperature measurement.最小预热温度和最大层间温度及所使用的加热方法和测温方法。11) Post Weld Heat Treatment (PWHT), listing holding temperature range, holding time range and method of heating (e.g. electric furnace, gas furnace, resistance locally etc.).焊后热处理(PWHT)：列出保温范围，保温时间范围和加热方法（如电炉加热、气炉加
30、热，局部电阻丝加热等）12) Name and signature of Vendors welding engineer or other authorized person with date.供货商的焊接工程师或其他授权人员的姓名和签名及日期。13) For each automatic welding process, the WPS shall specify all applicable equipment settings.对每一个自动焊的焊接工艺，WPS应明确所有适用的设备设定值。4.2 Welding procedure specifications are required
31、 for repairing welds. If a production welding procedure is utilized for repair welding this shall be stated in that procedure.要求焊接工艺规程适用于焊缝的返修。如果产品的焊接工艺适用于焊缝的返修，应在焊接工艺中说明。4.3 Production welding shall be performed using the same name, brand and classification of electrodes, rods, wire and flux combin
32、ation and range of amperage, voltage and travel speed as used for the procedure qualification, unless otherwise agreed upon.除非经过同意，产品的焊接应采用焊接工艺评定时所使用的同一名称、牌号和类别的电焊条、光焊条、焊丝、组合焊剂，以及电流范围、电压范围、焊接速度。5.0 Welding Procedure Qualification Record (PQR) 焊接工艺评定PQR tests are required conform to ASME IX, and the
33、following additional requirements of this specification:焊接工艺评定应符合ASME IX，及本规范的以下附加规定：5.1 Each combination of welding processes, PQRs, or both requires qualification as a combination unless specifically approved by Purchaser.除非经买方批准，每一个组合焊接方法，焊接工艺评定报告或两者均需作为一个组合进行评定。5.2 All non-destructive testing wh
34、ich is required to the relating production welds unless otherwise agreed upon with Purchaser.除非买方同意，应对相关产品焊缝进行所要求的所有无损检测。5.3 Charpy-V impact tests based on the Minimum Design Metal Temperature (MDMT) as specified in the equipment specification.按照设备规格书规定的金属设计最低温度（MDMT）进行夏比-V形缺口冲击试验。5.4 Macro examinat
35、ion and (for ferritic steels) hardness tests on a cross section through the weld and related heat affected zones and adjacent base metal(s). The hardness measurements shall be made on the polished and etched cross section of the weld. Hardness traverses shall be taken maximum 2mm from both surfaces
36、of the test-sample. The hardness traverse shall include hardness testing of both the base metals, both the heat affected zones and the weldmetal. Each hardness testing shall include a minimum of three hardness readings.在焊缝与热影响区和相邻母材的横断面进行宏观金相检查和铁素体钢的硬度检测。硬度检测应在经抛光和侵蚀后的横断面上进行。硬度横切线最长为试样两面的距离加2mm。硬度试验
37、的横切线应包括焊缝两侧的母材、热影响区和熔敷金属。各硬度试验至少取三次硬度读数。5.5 The maximum allowable hardness of welds in steam and water service shall be 290 HV10 and the maximum hardness in process service shall be 248HV10.焊缝的最大允许硬度为：蒸汽或水介质时290HV10，工艺介质时248HV10。5.6 A complete chemical analysis (and a ferrite content determination o
38、f austenitic stainless steel) of clad restoration and of weld overlay per the following requirements: The top layer, 0.75 of the required minimum cladding thickness, shall meet the complete chemical requirements of the specified stainless steel grade, or other alloy, (the above requirement applies t
39、o the top weld layer after machining, where applicable), unless otherwise specified on data sheet.除非数据表中另有规定，应按下列要求对修复的覆层和焊缝堆焊层进行完整的化学分析（包括奥氏体不锈钢的铁素体含量测定）：面层，所需要的最小覆层厚度的0.75应完全符合规定等级的不锈钢或其他合金的化学要求，（对需要焊后表面加工的焊缝，以上要求适用于机械加工后的面层焊缝）。5.7 The ferrite content of austenitic weldoverlay and clad restoration
40、 shall be confined with the limits of 3% minimum and 8% maximum. The composition related to the Schaeffler/Delong Diagram.奥氏体堆焊层和修复的包覆金属的铁素体含量应限定在3%至8%之间。其组成符合舍夫勒/德隆图表。5.8 For weld overlay, the overlap of adjacent beads shall be specified in the welding procedure qualification.对于堆焊焊缝，相邻焊道的堆焊深度应在焊接工艺
41、评定中做出规定。5.9 Applied overlap for the qualification shall be recorded and included in the applicable Welding Procedure Specification(s). The overlap may not be less than qualified.评定采用的堆焊应记录并写进相应的焊接工艺规程中。堆焊层厚度不应低于评定值。5.10 The weld overlay or clad restoration surface of the Procedure Qualification test
42、 shall be liquid penetrant examined.工艺评定试验的堆焊层或覆层修复应进行渗透探伤。5.11 Weld overlay and clad restoration procedure qualifications for equipment which has to be post weld heat treated, shall be subjected to the intergranular corrosion test in accordance with ASTM-A262 Practice E, after post weld heat treatm
43、ent.需焊后热处理的设备，堆焊或覆层修复工艺评定应按照ASTM-A262中E法，在热处理后进行晶间腐蚀试验。5.12 Procedure qualification tests in cladplate shall be made in cladplate of the same base and clad material grade as used for production or an equivalent.复合钢板的焊接工艺评定试验应在用于生产的相同母材和覆层等级的复合钢板或类似材料上进行。5.13 Before start of production welding of tub
44、e-to-tube sheet connections sample welds shall be made and tested in accordance with Project Specification: 40-010-00-0-0-00-015. However, the polished and etched macro shall show the throat thickness or leak path not less than the nominal wall thickness of the tube. Vendor shall prepare a complete
45、plan, including assembly, cleaning, weld preparation, welding sequence, expansion after welding and testing.在进行管/管板设备焊接之前，应按照项目技术规范（40-010-00-0-0-00-015）进行试件的焊接和试验。但是抛光和侵蚀后显示出的角焊缝高度和熔深不得低于管的公称壁厚。供货商应准备一份完整的方案，其中应包括装配、清洁、焊缝准备、焊接次序、焊接及试验后的膨胀。5.14 All welding procedure qualification records (PQRs) shal
46、l include all required details (such as: material(s), thickness, welding consumables, applied welding process and measured parameters, PWHT, etc.) to establish their validity on basis of this specification. Where complete and valid procedure qualifications are not available, the Vendor shall perform
47、 therequired additional qualification tests. The test results shall be submitted to purchaser.所有的焊接工艺评定应包括所有的详细要求（例如：材料、壁厚、焊材、焊接工艺、测量参数、焊后热处理等）以确定其技术规范的有效性。如果没有完整有效的工艺评定，供货商应进行所要求的补充试验。试验结果应提交买方。5.15 Purchaser reserves the right to witness welding and/or testing of procedure qualifications.买方保留对焊接和/
48、或焊接工艺评定试验见证的权利。5.16 Additional procedure and performance qualifications are required whenever the accessibility, the restrain or the environment of the standard qualification fails to simulate production welding conditions. The need of additional testing shall be agreed upon with the Purchaser.只要标准工艺说明书的操作难易度、障碍限制、周围环境与产品实际焊接条件不一致，就要求做补充工艺试验。所需补充试验应征得买方同意。6.0 Welding Performance Qualifications焊接操作资格考试6.1 Welder performance qualifications are required for all welders and welding operators involved with the fabrication of all equipment and piping covered by this specificati
