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1、焊工培训及资格评定程序Welder Training & Qualification Assess Procedure目 录1.目的Purpose:32.范围Scope33.职责Responsibility34.焊工资格评定现场测试程序Field testing procedure for welder qualification evaluation35.焊工资格评定程序Welder qualification assessment procedure76.记录Records87.参考资料References81. 目的Purpose:本程序制定了xx项目施工承包商对所有现场焊工以及焊接操作
2、员的资格评定和培训的标准工作流程。The procedure is intended to provide standard work processes for the training and qualification assessment for all field welders and welding operators conducted by xxi petrochemicals project construction contractors. 2. 范围Scope本程序适用于xx项目施工承包商的所有现场焊工及焊接操作员的现场资格评定和培训。This procedure ap
3、plies to the field training and qualification assessment for all field welders and welding operators conducted byxxpetrochemicals project construction contractors. 3. 职责Responsibility3.1. 现场焊接工程师负责按照批准的焊工资格评定程序和标准执行资格培训和现场测试；Field welding engineer is responsible for performing qualification training
4、 and field test according to the approved welder qualification evaluating procedure and criteria.3.2. 公司焊工考试委员会负责CC焊工现场测试前的培训，并取得中国政府部门颁发的合格证；The companys welder exam committee is responsible for training CC welders before field test and obtaining the qualification certificates issued by the concern
5、ed authority of the Chinese government. 4. 焊工资格评定现场测试程序Field testing procedure for welder qualification evaluation4.1. CC施工承包商焊工测试设施；Proving facility for evaluating the welders of CC construction contractor;4.1.1. 对每种拟测试的焊接方法，测试设备应安全可靠，且已经经过BB检测，所有焊接设备应始终保持良好的工作状态；For each welding method to be teste
6、d, the proving facilities should be safe and reliable, and shall have passed BB test. All the welding equipments shall work well all the time.4.1.2. 每台焊机应具备良好的合适的电缆及附件、焊钳、接地夹等；Each welding machine should be equipped with proper power cable, accessories, welding gun, ground clamp, etc. 4.1.3. 测试设施应具备
7、焊条烘箱、焊条保温筒等；The proving facility should be equipped with welding rod dry oven, temperature holding pot, etc.4.1.4. 现场焊接测试设施应充分排烟，每个焊工应有独立的遮蔽测试间。The fume generated in the field weld proving facility should be fully exhausted and each welder should be provided with a separate shielded test room. 4.2.
8、CC适用于AA南海石化项目，焊工测试的焊接方法、母材、焊材、位置、试件尺寸、适用的WPS如下表1：且焊工考试项目必须在取得相应位置的有效合格项目。For CCs welding methods, parent materials, welding materials, locations, sizes of test pieces and the applicable WPS, please see Table 1. Welders test position shall per welders original Chinese certificate.4.3. 焊接试件的具体要求The sp
9、ecified requirements of welding test pieces:4.3.1. 试件坡口光洁，坡口及坡口两侧50mm表面锈、水、油等清理干净；The welding groove of test pieces should be bright and clean. The rust, water and oil stain on the welding groove and the areas 50mm on its both sides should be cleaned. 4.3.2. 焊接材料要按规范要求烘干，焊工领用时要登记并放在焊条保温筒内，随用随取；The w
10、elding materials should be dried as required. The materials welders applied for use should be recorded and kept in the welding rod temperature holding pot for easy use.4.3.3. 测试用试件按规范领取，定位焊位置应在焊缝两端20mm范围内，允许试件在定位焊时预留反变形量；Test pieces should be applied for use as per criterions. Tack weld should be se
11、t in the area 20mm from the both ends of the welding seam. Presetting an amount for reversed deformation during tack welding is permissible.4.3.4. 焊接试件前，现场焊接工程师在试件上打上焊工考试代号和基本焊接方法代号；Before welding test pieces, site weld engineer shall stamp the exam code of welder and basic welding method code on th
12、e test pieces. 4.3.5. 焊接时试件必须从单面焊接，背面不得加垫板；While welding test pieces, it is necessary to conduct one-side welding. Backing a stool plate is not allowable. 4.3.6. 开始焊接后，其各部位的焊接位置不得改变；While welding, the welding positions at all parts must not be changed. 4.3.7. 焊工考试期间，要记录焊接层间温度及焊接电流。 During the in-pro
13、cess supervising, check the welding parameter and inter-pass temperature etc.4.3.8. 焊工考试过程中，只能在打底焊接后以及其它接头处打磨，而在其他焊道及焊层焊接后不能打磨。During the welding test process, grinding could only be used for the root pass and other layers joint. After welding no grinding is allowed.表1 Table 1焊接方法Welding methods测试用母
14、材Parent materials for test厚度Thickness测试用焊接材料Welding materials for test焊接位置Testing positions试件尺寸Size of test pieces适用的PQRApplicable PQR适用的WPS Applicable WPSSMAW手工电弧焊SMAW manual arc welding16MnR12J507横焊 Horizontal welding300150CC-003CC-Lh-01立焊Vertical welding300150仰焊Overhead welding300150CC-003CC-Lh-0
15、11Cr18Ni9Ti12A132横焊Horizontal welding300150CC-008CC8-A-Lh-05立焊 Vertical welding300150仰焊Overhead welding300150CC-008CC8-A-Lh-05CO2气体保护焊CO2 gas-shielded welding16MnR12H08Mn2SiA横焊Horizontal welding300150CC-004CC1-M-Cdg-02立焊Vertical welding300150混合气体保护焊Mixed gases shielded1Cr18Ni9Ti12H0Cr21Ni10Ti横焊Horiz
16、ontal welding300150CC-009CC8-M-Ag-06立焊Vertical welding3001504.4. 测试结果评定Test result assessment 4.4.1. 试件的外观检查采用目视或5倍放大镜进行，板材试件两端20mm内的缺陷不计，检查数量见表2：Inspect the appearance of test piece by visual check or 5X magnifier. The defects in the areas 20mm from the both sides of the test piece are permissible.
17、 For the number of inspections, please see Table 2.表2Table 2试件类别Type of test piece试件形式Shape of test piece试件厚度(mm) Test piece thickness(mm)检验项目Inspecting items备注外观检查Appearance inspection射线透照Radiographic接焊缝试件Welding test piece板Plate1211试件焊缝外形尺寸见表3：For the outside measurements, please see Table 3:表3 Ta
18、ble 3焊接位置Weldingposition焊缝余高The remaining height of welding seam焊缝余高差The remaining height difference of welding seam焊缝宽度差The width difference of welding seam比坡口每侧增宽The broadening on both sides of welding groove平焊 Horizontal welding03mm2mm3mm0.52.5mm其他位置Other position04mm3mm3mm0.52.5mm焊缝表面不得有裂纹、未熔合、夹
19、渣、气孔和未焊透。The weld face should be free of crack, lack of fusion, slag inclusion, air hole and incomplete fusion.焊缝表面的咬边和背面凹坑不得超过表4规定：The undercuts on the weld face and dents on the backside should meet the requirements as set in Table 4:表4 Table 4缺陷名称Defects允许的最大尺寸Permissible max size咬边Undercut深度0.5m
20、m，焊缝面侧咬边总长度不得超过焊缝长度的10Depth 0.5mm. The total length of the side undercut of welding seam must not be greater than 10% of the seam length背面凹坑Backside dent深度2mm，总长度不超过焊缝长度的10Depth 2mm. The total length must not be greater than 10% of the seam length.板材试件焊后变形角度不大于3，试件的错边量不大于1.2mm。The deformation angle
21、after plate test piece welding must not be greater than3 and the staggered amount must exceed 1.2mm.试件的射线透照应按JB4730压力容器无损检测标准进行检测射线透照质量不应低于AB级，焊缝缺陷等级不低于级为合格。 The radiographic analysis on test piece should be conducted as per JB4730 Pressure Vessel Nondestructive Evaluation and the inspected quality
22、must not be under AB Class. The grade of welding defect not under Grade II is acceptable. 5. 焊工资格评定程序Welder qualification assessment procedure5.1. CC施工承包商在进行焊工现场测试前至少24小时知会BB，说明测试地点、要测试的焊工人数及适用的PQR&WPS；CC construction contractor shall notify BB 24 hours prior to field welder test and specify the tes
23、t venue, number of welders to be tested and applicable PQR&WPS.5.2. 焊工现场测试必须在BBFEW的监督下执行，以确保焊工能胜任AA南海石化合同下的焊接工作；The welder field examination should be performed under the supervision of BB FEW to ensure that the welders may be competent for the welding tasks required in AA Nanhai Petrochemicals Cont
24、ract. 5.3. 一个焊工最多只允许进行两次焊接资格认定。如果认为某位焊工可以进行再次测试，在再次测试前，这位焊工应参加经过协商的进一步培训，再次培训后，仅允许焊工进行一次再次测试，如果该焊工仍不能通过测试，则应禁止其在AA南海石化项目中工作。A welder is allowed to take welding qualification examination twice at most. If some welder is allowed to sit the exam again, the welder needs to undergo the further training a
25、greed through negotiation prior to the reexamination. The welder is only permitted be tested once after that. He will not be allowed to work in the AA Nanhai petrochemicals project if he fails to pass the test again. 5.4. 资格认定合格后，CC向焊工颁发个人识别卡，上面附有焊工最近的照片及唯一的识别号，并在反面（另一面）说明相关的批准的资格认定清单。焊工在AA南海石化项目工作期
26、间，应始终佩戴此识别卡；识别卡和进场证放在一起。If the welder passed the qualification assessment, he will get a ID card from CC, on which has the welders latest photo and only ID number, and has a list regarding the corresponding approved qualification certification on the backside (the other side). The welder shall wear
27、the ID card at any time working in AA Nanhai petrochemicals project as well as their entry ID cards.5.5. 焊工识别卡样本见下图：Here is a sample of the Welder ID Cards略5.6. 焊工考试合格后，焊接工程师对合格焊工进行正式焊接前的焊接培训，使其掌握AA南海石化项目通用焊接作业要求。 When the welders successfully passes the qualification tests, they shall attend a trai
28、ning class organized by the weld engineer to understand the welding general work requirements of the AA Nanhai projects.6. 记录Records6.1. CC应每日保存所有焊工资格认定，测试记录清单，每周资格认定维护记录，焊工的焊接按不合格记录以及焊工测试和资格认定相关的任何其他记录。CC shall file all the welder qualification certifications, test information, weekly qualification
29、 certification maintaining records, the history of welders rejected welding and any other records regarding welder examination and qualification certification every day. 7. 参考资料References7.1. AA项目程序xxAA Project Procedure xx7.2. 锅炉压力容器压力管道焊工考试与管理规则（国家质量技术监督检验检疫总局锅炉压力容器安全监察局）Regulations on Boiler, Pre
30、ssure Vessel and Head Conduit Welder Examination and Management (by CBPVI)焊 工 登 记 表Welder registration table项目：Project装置：Unit工号：Section序 号Sequence No. 姓 名Name钢 印 号Welders Stamp No.身份证号ID Card No.合格项目(代号)Qualified items(code No.)焊接检查员Weld inspector焊工焊接操作技能考试检验记录表Data Sheet of Welder Welding Skill Exa
31、mination姓名： 试件编号： Name: Test Piece No.:焊接方法Welding method焊机操作工，手工焊焊工Welding machine operator Hand welding operator 焊接工艺规程编号Welding technical schedule No.母材钢号Parent Steel No.试件板材厚度Thickness of testing plate试件管材外径和壁厚Outside diameter of testing tube and thickness of its wall螺柱直径Diameter of pillar bolt焊
32、材名称及型号Designation and type of welding material考试项目代号Code of examination item试 件 外 观 检 查Exterior inspection of test piece焊缝表面状况Status of weld surface焊缝余高Remaining length of welding line焊缝余高差Difference of the remaining line length比坡口每侧增宽Broadening width on both side of end bevel宽度差Width difference焊缝边缘
33、直线度Linearity of welding edge背面焊缝余高Remaining height of welding seam on backside裂纹Cracks未熔合Lack of fusion夹渣Included slag咬边Undercut未焊透Incomplete fusion背面凹坑Remaining height of welding seam on backside气孔Air hole焊瘤Weld nugget变形角度Deformation angle错边量Staggered amount通球检验Spheroid inspection角焊缝凹凸度Levelness of
34、 fillet weld焊脚Fillet weld leg堆焊焊道接头平面度Levelness of beading joint堆焊焊道高度差Height difference of beading堆焊凹下量Beading concavity外观检查结果（合格、不合格）Result of exterior inspection (Qualified or unqualified)检验员Inspector无 损 检 验NDE射线透照质量等级Qualitative grade of radiographic analysis焊缝缺陷等级Grade of Welding defect报告编号及日期Number and date of the report结 果Result（合格、不合格）(Qualified or unqualified)渗透检测方法Penetration inspection method渗透检测结果Grade of Welding defect报告编号及日期Number and date of the report结果Result（合格、不合格）(Qualified or unqualified)无损检测人员Nondestructive inspector无损检测人员证书号Number of nondestructive inspectors certificate
