焊接技术培训AWS.ppt

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1、AWS D1.1&EEMUA 158 不同要求,焊接技术培训,之,质量部 焊接室,AWS D1.1&EEMUA 158 不同要求,内 容,A 课程培训概述（Preface）B 内 容(Content)1.标准的范围（Scope）2.材料（Material）3.焊接工艺和焊工的评定（Qualification of WPS and welder）4.建造（Construction and Fabrication）5.外观检测（Visual inspection）,焊接技术培训,A.课程培训概述,通过本次培训，让各位了解AWS D1.1 2010和 EEMUA 158:1994 标准的基本内容，了

2、解两标准中一些重点要求及其不同。了解建造过程中的相关要求，以免违反标准和工艺文件要求。减少船东、船检的Comments、投诉等，提高产品质量，加快报验过程，在建造和检验过程中，减少因不了解EEMUA 158标准中的要求而出现不必要的问题和麻烦。,焊接技术培训,1.标准的范围（Scope）,AWS D1.1&EEMUA 158 不同要求,AWS D1.1 This code contains the requirements for fabricating and erecting welded steel structures.When this code is stipulated in c

3、ontract documents,conformance with all provisions of the code shall be required,except for those provisions that the Engineer(see 1.4.1)or contract documents specifically modifies or exempts.钢结构建造的基本要求。EEMUA158:1994This Specification defines the basic requirements for the fabrication work on primary

4、 structures of offshore installations.These will normally include,but not be limited to,the following:jacket structure including nodes,cones,braces,legs and conductor framing piles and followers J-tubes and caissons riser clamps flotation tanks and buoyancy tubes module support frame including nodes

5、,cones,braces,padears,module framing including nodes,columns,fabricated beams and padears.Flareboom helideck-when constructed of steel any other areas designated primary on the Drawings.海洋工程重要结构建造的基本要求。结构（TKY节点、管子节点、拉筋支撑、桩腿、导管架、浮箱、浮筒、框架模块、吊耳、直升机平台等重要结构）。,2.Material 材料,AWS D1.1&EEMUA 158 不同要求,AWS D1.

6、1-2010/2008 Clause 3 Prequalification of WPSs 按材料等级和强度进行了分类。AWS D1.1 的 5.2 和 5.3 条款比EEMUA 158 1994 section 3 更详细的讲述了，焊材、钢板等材料的替代、储存、标识、发放等。这些都要严格按程序的要求控制好。EEMUA 158:1994 中规定，生产中所用的母材的供货状态必须与材料评定试验中所用的母材有相同的供货状态。（N389项目用板供货状态TMCP）,3.Qualification of WPS and welder 焊接工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,AW

7、S D1.1-2010/2008 Section 4 Qulification Part B 对焊评做了详细的规定和要求。Part C 对焊工资质考试做了相关的规定和要求。而 EEMUA 158：1994 section 4 Qualification of welding procedures and personnel 在焊接工艺评定中对一些重要变素和限制条件进行了比AWS D1.1 更为严格的要求。当然AWS D1.1 也有比EEMUA 158 要求严格的条款。下面先来了解对其中一些不同要求。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D

8、1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.3 Restrictions on Welding Practices 焊接过程中的限制（选10条）(a)SMAW for heat inputs exceeding 3 kJ/mm.手工电弧焊热输入不允许超3 kJ/mm。(b)SMAW bead widths exceeding the lesser of 16 mm or four times the core wire diameter.焊条电弧焊根部打底焊道宽度不能超4倍焊条直径或16mm.我们WPS要求2.5倍。很多海工产品的规格书也是这样规

9、定的，尤其对重要结构、特殊结构。AWS D1.1 对SMAW的焊道宽度没有作出要求。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.3 Restrictions on Welding Practices 焊接过程中的限制(h)SSFCAW and GSFCAW for heat inputs exceeding 1.5 kJ/mm except for vertical-up root passes.药芯气体保护焊（气体保护和自保护）热输入除根部立焊焊道外

10、，不得超1.5 kJ/mm。所以立焊时，要控制焊道宽度不得超宽(WPS要求小于12mm)。还要按WPS控制好焊接参数。AWS D1.1 根据坡口宽度，要求分道。非管材1G,2G,4G位置，坡口间距16mm时，分道焊接。非管材3G，或管材几个位置焊接，25mm,分道焊接。(l)Heat inputs exceeding 3.5 kJ/mm for steels up to and including Grade 355 and exceeding 3 kJ/mm for grades above 355.埋弧焊（SAW），焊接屈服强度355Mpa以下钢材时热输入3.5 kJ/mm，超过355Mp

11、a时，热输入3 kJ/mm。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.3 Restrictions on Welding Practices 焊接过程中的限制(o)Included angles of bevelled welds below 45 degrees(except as covered by 4.5.2(g).焊缝的坡口角度不得小于45（除已经成功评定覆盖小角度外）(p)Included angles below 60 degrees

12、for closing welds in tubulars above 40 mm thick.40mm以上板厚的管道上，封闭焊接接头的坡口角度不得小于 60。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.3 Restrictions on Welding Practices 焊接过程中的限制(S)Maximum interpass temperature exceeding 250C.最高层间温度250。现场按适用的WPS要求来控制温度。AWS D1.

13、1 对材料的最高预热和层间温度不得高于PQR中最高层间温度56以上。AWS D1.1 表4.5规定了最低预热温度和层间温度最多可以降低15。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.3 Restrictions on Welding Practices 焊接过程中的限制(T)Single-pass fillet welds(other than by SAW)with a design leg length greater than 6 mm.单道角

14、焊缝（除了SAW）焊脚大于6mm，重评。,AWS D1.1 中，表5.8,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.3 Restrictions on Welding Practices 焊接过程中的限制(V)Use of backing strips.背部使用带（钢）状衬垫，重评。(U)Use of ceramic inserts.使用陶瓷衬垫，重评。AWS D1.1 中，表4.5 中第34条：取消衬垫或取消背部清根，要重评。5.10 衬垫 有坡口焊

15、缝或角焊缝的根部可用铜、焊剂、玻璃纤维带、陶瓷、铁粉或类似材料作衬垫以防熔穿。N389项目提交的焊评没有使用衬垫评定的。所以现场严禁使用衬垫。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5 Essential Variables（基本变素）现场生产中，若与4.5.1到4.5.5 中规定的不同，要重新做评定试验。以下是选的一些规定，建造过程中需要注意，并严格按批准的适用的WPS执行。4.5.1 Materials Related Variables（材料

16、相关的变素）(f)If flame-cut weld bevels are not ground to bright metal.火焰切割后的焊缝坡口面打磨至光亮的金属。（否则重评）(g)If a protective finish applied to the weld bevel is changed.如果坡口采用的底漆，底漆不可更换。（否则重评）我们做焊评的试件坡口都是打磨干净的。没有做过 涂坡口漆的焊评。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4

17、4.5 Essential Variables 4.5.2 Weld Geometry Related Variables(坡口尺寸相关的变素)(f)If the shape of the weld preparation changes,except that:a single bevel qualifies a single V;K qualifies X;and 2:1 and 1:1 preparations qualify each other and all intermediate geometries.坡口覆盖。按WPS选用。1/2 V只能支持1/2V或V型坡口；K型只能支持K

18、和X型坡口。,AWS D1.1 Section 3 table 4.坡口覆盖。图3.4 改变坡口类型(例如：单面 V 形坡口 改为双 V 形坡口，重评)。坡口形式按提交的WPS选用。顺便提下，EEMUA 158 规定对接焊板或T型接头腹板超过8mm时，都要开坡口。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geometry Related Variables(坡口尺寸坡口尺寸相关的变素)

19、(g)If the included angle of the groove is less than the value tested and qualified by the WPS.Acute angles in stub to barrel welds,where the included angle is less than 45,are qualified by the test in 4.4.2.3(b).坡口的角度不小于WPS中的规定。否则重评。在TKY接头中，支管和主管的夹角小于45，要通过试验评定。（N389项目已经评定过了）,AWS D1.1 TKY接头坡口角度（）小于

20、30时，不免除评定。要通过试验评定。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5.2 Weld Geometry Related Variables（坡口尺寸相关的变素）(h)For single-sided welds:if the root face is more than 0.5 mm above or 1.5 mm below that qualified,or if the root gap is more than 3.0 mm abo

21、ve or 0.5 mm below that qualified.单边坡口：根部钝边公差 f(+0.5,-1.5);根部间隙公差 R(+3,-1.5);(i)For double-sided welds:if the root face is more than 2 mm above or below that qualified or if the root gap exceeds 6 mm.双边坡口：根部钝边公差 f(+2,-2);根部间隙公差 R(6);,AWS D1.1 中不按单边坡口、双面坡口分，而是按以下三种情况：,背部碳刨 f(+2,-2);R(+2,-3);(+10，-5),

22、3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geometry Related Variables(坡口尺寸相关的变素)(j)For fillet welds,any increase in root gap.角焊缝，不得增加根部间隙。However,for multipass fillet welds any root gap shall be compensated for by a c

23、orresponding increase in fillet leg length up to a maximum of 6 mm.除非多道角焊缝要深熔，间隙增加，焊脚应加大相应增加。增量最大不超过6mm.For single-pass fillet welds the root gap shall be limited to 3 mm maximum,and the weld leg length shall be increased by the same amount.单道角焊缝根部间隙最大不超过3mm.AWS D1.1 5.22 规定 角焊缝和PJP坡口焊缝间隙5mm。间隙尽量小。除

24、特殊情况外，当板厚大于75mm，加衬垫允许8mm.,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geometry Related Variables(坡口尺寸相关的变素)(k)If the joint misalignment on tubulars and skid beams exceeds the following:在管子和梁的焊接接头中的错边要求：-for single-side

25、d joints:the smaller of 3 mm or 10%of the joint thickness,except that a 2 mm misalignment is permitted regardless of thickness.单面坡口焊缝：错边最大3mm或0.1T，取较小者。允许错边2mm以内时，可以不考虑板厚。-for double-sided joints:the smaller of 6 mm or 10%of the joint thickness,except that a 2 mm misalignment is permitted regardless

26、 of thickness 双面坡口焊缝：错边最大6mm或0.1T，取较小者。允许错边2mm以内时，可以不考虑板厚。If the joint misalignment on sections other than those in(k)exceeds the smaller of 5 mm or 12%of the joint thickness,except that a 2 mm misalignment is permitted regardless of thickness.除了（k）中的接头形式，在型材对接的接头中，错边最大5mm或12%T，取较小者。错边在2mm以内时，可以不考虑板

27、厚。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,AWS D1.1 5.22.3.1 圆周焊缝对齐（管材）环缝对接处相邻边缘的径向偏差严禁超过 0.2 t t 为较薄者的壁厚，且最大容许偏差必须为 6mm，任何偏差超过 3mm时要从两面施焊。现场的板较厚，所以单面焊不准超过3mm,双面坡口焊允许超过3mm，但要小于6mm.,AWS D1.1 5.22.3 对接接头的校直（对准）以对接接头连接的部件必须仔细校直（对准）。如果校直之中因偏心而弯曲的部件，造成对其强力地约束，则相对于理论校直线的偏离值严禁超过连接

28、的较薄件厚度 10%，或3mm，取两者中之较小值。,3.Qualification of WPS and welder 接工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5 Essential Variables 4.5.3 Consumables Variables(焊材变素)焊接评定时，盖面焊道使用相同直径的焊条。生产中焊条直径可以增加但要符合以下要求：(d)If the core diameter of a SMAW electrode is increased to one which did not make at

29、 least 25%of the passes in the qualifying weld.现场使用的焊条直径增加到评定试验中使用的不超过25%焊缝道数的焊条。重评。在焊接评定试验中，使用增加直径的焊条焊接道数在总焊道中超过25%，现场才允许直径增加。没有超过25%,生产中 不允许增加焊条直径。(e)If the core diameter of a SMAW electrode used for the capping passes is reduced.生产中，用于盖面的焊条直径大小不能减少。整个盖面焊道使用焊条直径工艺要求多少就是多少。,AWS D1.1 表4.5 规定焊条直径增加值0

30、.8mm，重评。,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5 Essential Variables 4.5.4 Procedural Variables（工艺要求上的变素）(a)If the welding process used for any part of the weld(i.e.root,second pass,fill or cap)is changed.焊缝分根部焊道，第二道，填充焊道，盖面焊道，每层每道要按WPS来。(g)If t

31、he first side to be welded in an unequal double-sided preparation(or one using different consumables on either side)is changed.焊接顺序：双面不等边坡口，先焊大坡口侧，还是小坡口侧，要按WPS来。（两侧用什么焊材，是不是相同等等，不能用错）,3.Qualification of WPS and welder 工艺和焊工评定,AWS D1.1&EEMUA 158 不同要求,EEMUA 158：1994 Section 4 4.5 Essential Variables 4

32、.5.4 Procedural Variables（工艺要求上的变素）对打磨和碳刨的要求也比AWS D1.1 严格。(c)If grinding between passes is omitted or if back-gouging is omitted.取消层间焊道打磨或取消背面碳刨。重评。(d)If the depth of back-gouging/grinding is reduced.碳刨和打磨的深度减少。重评。(e)If the depth of back-gouging/grinding is increased to more than 10 mm.碳刨或打磨的深度增加超过1

33、0mm.重评。(f)If the back welding used in qualification is omitted.评定中采用背面焊接，取消。重评,4.construction and Fabrication 建造 EEMUA 158 Clause5 提出以下要求：所有建造相关的工人都要有相应的从事各自工作的资格。焊工考试满足EEMUA 158 的相关规定。所有建造、组装、合拢应依照业主认可的程序。,AWS D1.1&EEMUA 158 不同要求,AWS D1.1 第5章.制造 5.1 范围 由本规范认可的任何方法生产的焊接组件和结构的制作和安装，必须遵守本章所有适用条款（见3.2

34、和 4.15）。,4.construction and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.4 Design of Welded Connections 除非图纸上标明，否则所有的焊缝都是连续地，全焊透双面坡口焊缝。内径小于600mm，才采用单面坡口焊缝。（具体还得看设计图纸）Where point-to-point construction is employed,consideration shall be given to the possible effects

35、 of this method of construction on root quality.对于管接头，采用对称分段焊接时，要注意根部焊道的质量。Consideration shall also be given to the practicality of performing NDT in the root region of such joints,together with appropriate acceptance criteria.对这些接头，要考虑根部区域便于做 NDT。（RT）,4.construction and Fabrication 建造 EEMUA 158,AWS

36、 D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.5 Forming（加工成型要求）,The forming of T-sections into flanged ring stiffeners of any diameter will require mechanical tests(to demonstrate that the properties required by the purchase specification are maintained after trial forming)to justify acceptan

37、ce,regardless of the proposed diameter.T型材加工成环状加强筋，不论直径大小，都要做力学性能试验。,4.construction and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.5 Forming（加工成型要求）,冷加工卷管，应变不超5%，热卷管的升温，保温，降温，要合程序要求。If hot straightening is proposed,the temperature shall not exceed 500C unless ot

38、herwise approved by the Purchaser.These limits also apply to re-rolling of cans after welding to restore shape to within tolerance limits.热矫正，钢板温度不应超过500，除非经业主同意。这些限制条件适用于焊后为了恢复到尺寸公差要求内形状的管子。ABS part 2：forming in the range between 205C(400F)and 425C(800F)should be avoided.在205到425之间禁止热矫正。,4.construc

39、tion and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly 5.2.6 Edge Preparation（坡口准备）,Surfaces to be welded shall be visually examined to ensure freedom from laminations,cracks,slag inclusions and cutting notches.Any such defects observed shall be dressed out by grindin

40、g.If the depth of excavation exceeds 5 mm,a weld repair shall be made using an Approved WPS.检查钢材坡口及表面状态，不能有分层，裂纹，夹渣，切割槽口。所有可以观察到的缺陷通过打磨去除。缺陷深度超过5mm，应按照认可的WPS进行返修。,AWS D1.1,4.construction and Fabrication 建造,AWS D1.1&EEMUA 158 不同要求,AWS D1.1,5.15.4.4 凹槽或缺口限制 表面深度 3/16 in.5mm 的缺口或凹槽，均必须用机械加工或打磨方法消除。深度超过

41、 3/16 in.5mm的缺口或凹槽，如果标称横截面积的减少不大于 2%，则可打磨修正。经打磨或机加工的表面必须以不超过 1/10 的坡度向原表面过渡。切割面和邻近边缘必须无挂渣。经工程师同意，热切割表面偶有的缺口或凹槽可用焊接返修。,4.construction and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.6 Edge Preparation（坡口准备）,The surface of the steel within 75 mm of the proposed wel

42、d shall be dry,clean and free from loose scale or paint(except that the use of a protective primer may be qualified by use in all welding procedure qualification tests).Flame cut edges which are not subsequently welded shall be ground smooth to remove nicks and burrs,The use of flame gouging or wash

43、ing is not permitted.打磨坡口为两侧加一起75mm范围内，干燥，干净，没有疏松的分层和氧化皮或油漆（除经过评定合格的坡口底漆，没经过评定的要打磨坡口去底漆）。不允许用割刀熔削坡口，不准烊坡口面。而AWS D1.1要求的打磨坡口边缘两侧至少20mm。,4.construction and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints 焊接接头装配对中,For any through

44、member whose thickness exceeds 25 mm,the portion which will lie under,or within 50 mm of,a T-butt weld(or a fillet weld with leg length exceeding 20 mm)shall be examined by ultrasonic testing in accordance with BS 5996.穿插件厚度超过25mm，位于T型接头下面50mm以内（或角焊缝焊脚超过20mm），要做UT，检验材料内部缺陷。Z向低硫钢材不做UT检查。Single-sided

45、closure butt weld root gaps of 12 mm maximum up to 150 mm in length are permitted even if this exceeds the tolerance on the basic welding procedure.单面对接焊允许150mm长度内最大12mm根部间隙，即使不符合基本的焊接工艺程序对公差的要求。,4.construction and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.7 Al

46、ignment and Fit-up of Welded Joints 焊接接头装配对中 堆焊（长肉）All components should be trial fitted before welding,since no in-situ grinding or buttering of the weld preparation shall be permitted.所有的构件在焊接之前应进行试安装，装配好后，不允许在装配位置上进行打磨或堆焊。Where root gaps are out of tolerance,except as permitted above,the joint sh

47、all be dismantled to permit local grinding,or buttering followed by grinding,back to the required profile.如果根部间隙超公差范围，要拆下来，在不合格处打磨，长肉和打磨，达到要求的形状。The depth of buttering on any member shall not exceed 15 mm.长肉厚度不能超15mm。4.4.2.2(d)weld metal buttering deposited with qualified full penetration butt weld

48、parameters.全焊透焊缝的焊接工艺可以用于堆焊。,AWS D1.1 根部间隙大于WPS规定，小于2倍较薄板厚或20mm（取较小者），可以通过焊接长肉来达到尺寸要求。,4.construction and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints 焊接接头装配对中定位点焊接注意事项：Fit-up using clamps or other fabrication aids may be us

49、ed where appropriate.When tack welds are necessary they shall be at least 50 mm long and shall consist of at least two passes of sufficient cross sectional area to resist restraint cracking.装配可采用临时辅助夹具或其他辅助物（码板，楔子等）。定位点长度不小于50mm，至少有两道足够横断面避免出现裂纹的焊道组成。4.4.2.2(c)tack welds made with qualified root pas

50、s parameters 根部焊道的焊接参数用于定位焊焊接。,4.construction and Fabrication 建造 EEMUA 158,AWS D1.1&EEMUA 158 不同要求,5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints 焊接接头装配对中,定位点焊接注意事项：The preheat shall not be less than for welding the joint.焊定位点前预热温度最低不低于100。WPS 中的预热温度和100，取较大值。Tack welds whic