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1、【精品文档】如有侵权，请联系网站删除，仅供学习与交流大型储罐现场制作安装焊接施工方案Welding Construction Procedure，中英对照.精品文档.大型储罐现场制作安装焊接施工方案Welding Construction Procedure 目 录Table of Contents1工程概况 Project Overview32编制依据 Preparation Basis33焊接质量保证措施 Welding Quality Assureance Measure44焊接方法及一般技术要求 Welding Methods and General Technical Require
2、ments55罐底的焊接 Welding of Tank Bottom166罐壁的焊接 Welding of Tank Shell237固定顶顶板的焊接 Welding of Fixed Roof268其他部位的焊接 Welding of Other Parts279焊接缺陷产生及其预防措施 Generation of Welding Defects and the Preventive Measures2710焊接检验 Inspection of Welding2811焊缝的修补 Repair of Welding Lines34412焊接验收 Examination and Accepta
3、nce of Welding3571 工程概况 Project Overview1.1 该项目是由xx有限公司（AA）合资建设的xx石化工程的IP罐区，位于xx。根据合同规定，该项目由CC设计、供货、现场制造及安装罐区xx个储罐。The project is the I&P tank area of Xx Petrochemical Project invested and constructed jointly by China National Offshore Oil Corp. and AA. It is located in xxe. CC shall offer the follo
4、wing services for the projects in accordance with the contract, including design, supply, site manufacture and installation of xx storage tanks. 1.2 主要工程实物量如下：The main construction load is as follows:储罐数量：xx个； Quantities of Storage Tanks: xx容积：28. 9万m3Volume: 289,000 m3钢材： Q235：3270吨； Steel: Q235: 3
5、270T; 16MnR：2870吨； 16MnR: 2870T; SS316、316L及SS304：430吨SS316、316L and SS304: 430T铝格顶：6个； Aluminum Dome: 6 GRE(玻璃钢)内浮盘：9个GRE (Glass Fiber Reinforced Plastic) Inner Floating Plate: 9 2 编制依据 Preparation Basis2.1 立式圆筒形钢制焊接油罐施工及验收规范 GB50128Construction and Acceptance Specifications of vertical Tube-shaped
6、 Steel Welded Oil Tank GB501282.2 石油化工立式圆筒形钢制焊接储罐设计规范 SH3046Design Specifications of Petrochemical Vertical Tube-shaped Steel Welded Storage Tank SH30462.3 承压设备无损检测 JB4730Nondestructive Testing of Pressure Vessels JB4730施工图Drawings issued for Construction3 焊接质量保证措施 Welding Quality Assurance Measures
7、3.1 按照质量保证体系程序的要求，对施工现场焊接工程实行全员、全过程、全方位的质量控制施工前，检查焊接工艺评定和焊工资格，保证焊接工艺评定覆盖率和焊工持证上岗率为100%。Check the welding procedure qualification and welders qualification in accordance with the quality assurance system procedures before the quality control construction is conducted on the welding works on the site,
8、 thus to ensure that the coverage rate of welding procedure qualification reaches 100% and all welders go to post with certificates. 3.2 施焊前应由工程技术人员对作业班组进行技术交底，做到人人心中有数。The engineering technicians should make a technical impartation to the working team before the welding work is conducted so that ev
9、ery one knows fairly well.3.3 焊接材料设专人负责烘干、保管、发放和回收，同时必须做好记录。焊材库必须保持干燥，相对湿度不得大于60%。Assign a person responsible for drying, keeping, extending and reclaiming the welding materials. He has to make proper record at the same time. The warehouses for welding materials has to be kept dry and its relative h
10、umidity may not exceed 60%.3.4 施焊前焊工应对照图纸检查要领用的焊材是否与母材相匹配。The welders shall check if the welding materials to be drawn match the base materials before the welding work is conducted.3.5 无损探伤工作由第三方实施。The NDE work should be conducted by the third party.3.6 认真做好焊接记录，焊道上应标出焊缝编号、焊工代号，并注明探伤部位，现场焊缝、图纸焊缝和探伤报
11、告（底片）的编号应一致。Make welding record carefully. Mark the welding line number, welder ID number and distinguish the parts for NDE on welding line， welding line number on site, welding line number on the drawing and the NDE report (film) should be the same number .3.7 施工中还应进行自检、 互检、加强专业检查，出现的焊缝质量问题，由焊接责任工程
12、师组织专业人员，准确地作出判断，及时制定改进措施。Take self-inspection and mutual inspection as well as strengthen specialized inspection during construction. If there appear quality problems in welding lines, the welding engineer responsible shall organize professionals to make accurate judgment and work out improvement me
13、asures promptly.3.8 建立焊工档案，实行动态管理，掌握每个焊工的焊接技能状况。对于焊接质量经常不合格的焊工，焊接质量员有权停止其焊接工作，下岗重新培训。Establish files of welders, practise dynamic management and understand the skills of each welder. If a welder does poor welding work frequently, the welding inspector has the right to suspend his qualification and t
14、o have him accept training off duty.3.9 对焊接质量实行奖惩制度，激励焊工提高焊接技能，重视焊接质量，提高焊接一次合格率。Implement the system of award and punishment on welding quality, encourage the welders to improve their skills and attach importance to welding quality, and enhance the rate of first-time acceptability.3.10 根据合同文件要求，为正确实
15、施及控制现场焊接计划，配备现场管理人员，包括现场焊接工程师和焊接质量控制工程师。 To carry out and control site welding plan correctly, arrange the site management as required by the contract documents, including site welding engineers and welding quality control engineers. 4 焊接方法及一般技术要求Welding Methods and General Technical Requirements4.1
16、 焊前准备Pre-welding Preparation4.1.1 储罐施焊前，根据图纸要求，按钢制压力容器焊接工艺评定和立式圆筒形钢制焊接油罐施工及验收规范 GB50128-2005的规定进行焊接工艺评定。According to the drawing requirement, make out the PQR in accordance with the standard and GBJ128-90 before welding the tanks.4.1.2 根据图纸要求和罐体母材选用合适的焊接工艺指导书和焊接工艺评定如下表：Selecting correct welding WPS
17、and PQR in accordance with the drawings and tank base material, as follow matrix: lue4.1.3 焊工培训和资质审查Training and Qualification Check of Welders4.1.3.1 参加本项工程施焊的焊工，必须经过现场考试，考试前应通知PMC，合格焊工应有一个唯一的ID号码。详见焊工培训及资格评定程序XXCC-0000-3024。All the welders for this project must be tested on the jobsite ,inform PMC
18、 in advance as a witness ,then ,each welder should have a unique ID number. See xxCC-0000-3024.4.1.3.2 由焊接工程师审查焊工资质，认定焊工合格、资格、焊工编号，并将合格证复印件交业主代表代表备案。The welding engineer shall check the qualification of welders by looking over the certificate of quality and qualification and the welder number. The e
19、ngineer shall give the copies of quality certificate to AA/PMC for record.4.2 材料验收Examination and Acceptance of Materials4.2.1 材料工程师汇同驻地监理监理工程师对进场焊材进行验收，验收的项目包括：The material engineer shall examine the entry welding materials with the stationed 监理 supervision engineer. The items for examination and a
20、cceptance include:4.2.2 材料出厂合格证及材料质量证明书等证明文件。材质是否与设计图纸一致；The certificates, including the certificate of ex-factory quality and the certificate of material quality. Check if the materials are consistent with the design drawings.4.2.3 焊接材料（焊条、焊丝）应具有质量合格证明书。焊条质量合格证明书应包括熔敷金属的化学成分和机械性能；低氢型焊条还应包括熔敷金属的扩散氢含
21、量；The welding materials (welding rods and wire) shall bear appropriate certificate of quality. The certificate of welding rod should contain the chemical contents and mechanical performance of the melting materials. For hypo-hydrogen, it should also contain the contents of diffused hydrogen.4.2.4 焊材
22、入库须严格验收，对部分焊材外观进行抽查，是否存在生锈和药皮脱落现象，并作好标记；不得使用生锈和药皮脱落的焊材。Strictly check the welding materials to be put into storage. Make spot test on the appearance of partial welding materials and make proper record to check if there are rusts and if the coating breaks off. The welding materials with rust and brea
23、k-off may not be used.4.2.5 存放焊材的库房必须干燥通风，温度不得低于5，空气相对湿度不应高于60%，焊材存放位置距离地面和墙壁均不得少于300毫米，并严防受潮。The storehouses for welding materials have to be kept dry and ventilated. Its temperature may not be lower than 5 and the relative humidity may not exceed 60%. The welding materials should be kept 300 mm (o
24、r over 300mm) away from the floor and walls and against damp.4.2.6 二氧化碳气体保护焊采用的二氧化碳气体纯度不应低于99.5%，含水量不应超过0.005%，使用前应预热和干燥，当瓶内气体压力低于0.98Mpa时，应停止使用。For CO2 protection welding, the purity of CO2 may not be lower than 99.5% and the water content may not exceed 0.005%. Pre-heat and dry it before use. When
25、 the in-bottle gas pressure is lower than 0.98Mpa, it may not be used.4.2.7 焊接材料应设专人负责保管，使用前应按产品说明书或下表的规定进行烘干和使用。The welding materials should be kept by the person specially assigned. They should be baked and used in accordance with the specifications or the following table.焊接材料烘干和使用 Drying and Usin
26、g of Welding Materials 种类Type烘干温度()Baking Temperature恒温时间(h)Time of Constant Temperature用前保温温度Holding Temperature before UseJ42735040012150J50735040012150A10215020012150A20215020012150A02215020012150A30215020012150烘干后的焊条,应保存在100150的恒温箱中,随用随取The baked welding rods should be kept in the constant tempe
27、rature chest of 100150 and be taken out only when necessary.4.3 储罐的焊接接头型式按照图纸要求。The types of welded joints of the storage tanks in accordance with the requirement of the drawings.4.4 焊接工艺方法说明Methods of Welding Technique4.4.1 跳焊：分为顺跳焊和逆跳焊，是一个从左至右或从右至左每焊一段长度，隔开相同的距离，再进行焊接。Leap welding: it is divided i
28、nto smooth leap welding and converse leap welding. Conduct welding on a section from left to right or from right to left, leap over the section of the same length and then continue welding on the next section.4.4.2 退焊：是一种使用率最高的焊接方法，可以有效地控制焊接变形，焊工无论采用退焊还是顺焊，都要进行焊接变形的控制。 Backward welding: this is the
29、welding method that is used most widely. It helps control welding deformation effectively. The welder has to control the welding deformation in both backward welding and smooth welding. 4.5 一般技术要求General Technical Requirements4.5.1 钢板边缘加工面应平滑，不得有夹渣、分层、裂纹及熔渣等缺陷。The processing side of steel plate shou
30、ld be smooth. It may not has such defections as slag inclusion, stratification, crack and slag.4.5.2 CO2 气体的使用Use of CO24.5.2.1 CO2 气体的纯度不应低于99.5%，含水量不应超过0.005%，使用前应预热和干燥，当瓶内气体压力低于0.98Mpa时，应停止使用。The purity of CO2 may not be lower than 99.5% and the water content may not exceed 0.005%. Pre-heat and d
31、ry it before use. When the in-bottle gas pressure is lower than 0.98Mpa, it may not be used.4.5.2.2 新充装气瓶倒置24小时，使用前，打开阀门，放去其中的积水，放水23次即可，每次放水时间间隔约30分钟。The newly filled gas cylinder should be placed upside down for 24 hours. Open the valve to discharge the water inside every 30 minutes for 23 times b
32、efore use. 4.5.2.3 使用前，先打开瓶口气阀，放掉瓶内上部纯度较低的气体，然后套接干燥器，进一步减少CO2 气体水分。Open the valve to discharge the low-purity gas on the top, and then connect it with the drier to further lessen the moisture of CO2.4.5.3 定位焊及工卡具的焊接，应由合格焊工担任，焊接工艺应与正式焊接相同。引弧和熄弧都应在坡口内或焊道上。每段定位焊缝的长度，普通碳素钢和低合金钢，不宜小于20mm。The tack welding
33、 and fixture welding should be conducted by the qualified welder. The welding procedure is same with that of the formal welding. The leading arc and extinguish arc should be on the groove or welding path. It should be 20mm or longer for the length of each tack welding line, plain carbon steel and lo
34、w- alloy steel.4.5.4 临时点焊只能由测试合格的焊工按照批准的焊接程序及规范参数进行。Temporarily spot weld can only be carried out by qualified welders according to parameter of welding procedure and criterion approved .4.5.5 点焊前应将点焊位置周边50mm的油、锈等污物清理至露出金属光泽。Before spot weld, filth such as oil and rust etc. within 50mm around spot w
35、eld point shall be cleared till give off metal luster.4.5.6 点焊所采用的焊接材料应与母材匹配,并与批准的WPS相同。Welding material adopted by spot weld shall accord with mother metal and the same as WPS approved.4.5.7 焊工点焊后应清除点焊的焊渣,检查点焊接头的外观质量,当发现有气孔、夹渣、裂纹等缺陷时应清除缺陷位置，重新点焊。Welders shall clear solidified slag by spot weld, che
36、ck the appearance quality of button weld, once find air hole, slag inclusion and crack, the defects shall be cleared immediately and spot weld again.4.5.8 当进行正式焊接时,焊缝与点焊位置的接点处应清除临时点焊,或者打磨掉临时点焊的起始点和结束点,以使点焊与焊缝成为一体。When begin weld in due form, temporary spot weld on junction between welding lines and
37、spot weld points shall be cleared or polish the initial point and finish point of spot weld ensure spot weld and welding line become one4.5.9 点焊的长度和点焊的层数应能保证连接件的强度,一般不应低于20mm。The length and layer of spot weld shall ensure the strength of connecting piece, generally, it shall not be less than 20mm.4.
38、5.10 应有足够的条件或措施保证点焊的环境条件。(如控制点焊的温度、湿度及防风、防雨措施等)。There must be adequate condition or measurement to ensure the environmental condition of spot weld. (such as the temperature and moisture of spot weld and wind & rain proof measurements etc.)4.5.11 焊接前要按设计和标准，规范要求检查预制构件的尺寸偏差，检查组装质量，焊接坡口角度、对口间隙、错边量应符合要求
39、。清除坡口及坡口两侧20mm范围内的熔渣、飞溅物、泥沙、铁锈、水及油污等并打磨好坡口,并应充分干燥。Before the welding work is conducted, check the dimension deviation of prefabrication parts and examine the assembly quality, the angle of welding groove and the joining clearance in accordance with the design and standard. The stagger sides should m
40、eet relevant requirements. Clear away the slag, splash, sands, rust, water and grease on the groove or on the section within 20mm from the groove, polish the groove and keep it dry. 4.5.12 焊接过程中必须制定防止焊接变形的具体措施，并予以执行。Set down and implement the specific measures against welding deformation during weld
41、ing process.4.5.13 焊接中应保证焊道始端和终端的质量。始端应采用后退起弧法，必要时可采用引弧板。终端应将弧坑填满。多层焊的层间接头应错开50mm以上。Ensure the quality of both ends of the welding path. The backward arc method may be used on the first section and the leading arc plate may be used when necessary. The arc pit should be filled on the end section. The
42、 inter-bedded joints should be staggered over 50mm for multiplayer.4.5.14 板厚大于或等于6mm的搭接角焊缝，应至少焊两遍。Conduct welding work twice at least on the joining welding lines with plate larger than or equal to 6mm in thickness.4.5.15 双面焊的对接接头在背面焊接前应清根。当用采用碳弧气刨时，清根后应修整刨槽，磨除渗碳层。For double-faced welding, the roots
43、 of butt joints should be cleared away before the work is conducted on the other side. When carbon arc plane is employed, the plane groove should be finished after the roots are cleared away.4.5.16 焊接后必须及时清除熔渣和飞溅物。The slag and splash should be cleared promptly after the welding work.4.5.17 焊后检查焊缝外观，
44、不得有熔渣、飞溅、裂纹、气孔、夹渣、弧坑等象现。Check the appearance of welding lines after the welding work. The following defects are unacceptable: slag, splash, crack, air vent, slag inclusion, arc pit.4.5.18 焊缝必须按设计和规范要求进行无损探伤，不合格焊口必须及时返修和重新探伤合格。焊缝无损检测由AA认可的第三方实施。从事油罐焊缝无损探伤的人员，必须具有国家有关部门颁发的并与其工作相适应的资格证书。NDE on the weld
45、ing lines should according to the design and specifications. The unacceptable welding lines have to be done over again until the NDE is accepted. The third party shall conduct the NDE on the welding lines. The NDE worker have to possess the appropriate qualification certificate issued by the departm
46、ent concerned. 4.5.19 在下列任何一种焊接环境,必须采取有效的防护措施,避免不利因素的影响,否则不得进行焊接:The effective safety measures have to be taken against the adverse factors in case of the following welding environments. Or, the welding work may not be conducted.(1)雨天或雪天；Rainy or snowy.(2)大气相对湿度超过90%。The relative humidity exceeds 90
47、%.（3）手工焊时，风速超过8m/s；气体保护焊时，风速超过2.2m/s。For manual welding, the wind speed exceeds 8m/s. For gas protection welding, the wind speed exceeds 2.2m/s.4.6 焊接标记Welding Mark4.6.1 应使用批准的不可擦除的颜料棒或不可擦除的颜料滚珠标记笔在焊缝旁边进行标记。Make signs beside the welding lines with the approved unerased paint club or paint ball pen.4.6.2 每个焊工应标记自己的焊接作业，如果有多个焊工同时作业于同一个接头（例如根焊工和其他的填充/密封焊工），所有焊工均应标记自己的 ID，并将根部焊工的 ID 标记在最前面。 Each welder should make mark on his welding work. If serveral we