电渣压力焊关键过程操作指导书.doc

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1、【精品文档】如有侵权，请联系网站删除，仅供学习与交流电渣压力焊关键过程操作指导书.精品文档.饮食广场关键过程操作指导书一、 工程概述本工程为饮食广场，由A、B、C、D、E五楼座组成，建筑面积38960平方米，框架结构。根据图纸设计要求框架柱竖向钢筋连接采用电渣压力焊。框架梁顶部通长钢筋采用闪光对焊连接。根据质量策划、质量计划及施工方案要求本工程确定电渣压力焊及闪光对焊工序为关键过程，并编写关键过程作业指导书用以指导施工。二、 编制依据1、 设计图纸2、 钢筋焊接及验收规程JGJ1896三、 人员要求：电渣压力焊和闪光对焊的施工操作人员要持证上岗，且上岗证在有效期范围之内。四、 施工机械要求：U

2、N1100型闪光对焊机4台，电渣压力焊接机8台。所用的机械设备由分公司机械科负责进场安装，验收后将由项目部机械管理人员派专人对设备使用保管负责。五、 施工材料要求：对焊所用钢筋原材必须有出厂合证及进场后的复试试验报告，合格后才能进行对焊，电渣压力焊所用的焊剂必须有出厂合格证明否则不能使用。六、 施工操作方法6.1、电渣压力焊6.1.1、焊接工艺：电渣压力焊的焊接工艺过程包括：引弧、电弧、电渣、压顶过程。6.1.1.1、引弧过程：通电后迅速将钢筋提起，使两端之间的距离为24引弧，当钢筋端头夹杂不导电物质或端头过于平滑造成引弧困难时，可多次把上钢筋移下于下钢筋短接后再提起，达到引弧目的。6.1.1

3、.2、电弧过程：靠电弧的高温作用，将钢筋端头的凸出部分不断烧化；同时将接口周围的焊剂充分熔化，形成一定厚度的渣池。6.1.1.3、电渣过程：渣池形成一定厚度后，将上钢筋缓缓插入渣池中，此时电弧熄灭，进入电渣过程6.1.1.4、挤压过程：在停止供电的瞬间，对钢筋施加挤压，把焊口部分熔化的金属、熔渣及氧化物等杂质全部挤出结合面。挤压力要小，对各种规格的钢筋仅为0.20.3KN。6.1.2焊接参数：电渣压力焊的焊接参数主要包括焊接电流、焊接电压、焊接时间。6.1.2.1、焊接电流：宜按钢筋端头面积取0.80.9A/。6.1.2.2、焊接电压：焊接电压在焊接过程中是变化的。当引弧后，进入电弧稳定燃烧时

4、，电压为40V45V。当钢筋与焊剂熔化，进入电渣过程时，电压2227V。如电压过高，易再度产生电弧现象，过低则易产生夹渣缺陷，焊接电压易受网络电压和操作因素的影响而波动，为了确保焊接质量，应使波动值控制在5V的范围内。6.1.2.3、焊接时间：是指电弧过程和电渣过程的延续时间，焊接时间长短根据钢筋直径确定。6.2、闪光对焊6.2.1、操作工艺：本工程中钢筋的闪光对焊采用闪光预热闪光焊。其过程包括一次闪光、预热、二次闪光及顶锻过程。6.2.1.1、一次闪光：即施焊时首先连续闪光，使钢筋端部闪平。6.2.1.2、预热：使两钢筋面交替地接触和分开，这时钢筋端面的间隙中发出连续的闪光，而形成预热过程。

5、6.2.1.3、二次闪光：伴随着预热过程，两钢筋面间隙中喷射出火花般熔化的金属微粒，接着徐徐移动钢筋使两端面仍保持轻微接触，形成连续闪光。6.2.1.4、顶锻过程：当闪光到预定的长度，使钢筋端头加热到将近熔点时，就以一定的压力迅速进行顶锻，先带电顶锻，再无电顶锻到一定长度，焊接接头即告完成。6.2.2、焊接参数：为了获得良好的对焊接头，应合理的选择焊接参数，焊接参数包括：调伸长度、闪光留量，闪光速度、顶锻留量、顶锻压力及变压器级次。6.2.2.1、调伸长度：调伸长度是指焊接前两钢筋端部从电极钳口伸出的长度。调伸长度的选择与钢筋品种和直径有关。应使接头能均匀加热，并使钢筋顶锻时不致发生弯曲。调伸

6、长度的取值，级钢筋为1.01.5，直径小的钢筋对焊时取大值。6.2.2.2、闪光留量与闪光速度：闪光留量是指闪光过程中，闪出的金属所消耗的钢筋长度。闪光留量的选择应使闪光过程结束时钢筋端部的热量均匀，并达到足够的温度。闪光预热闪光焊中闪光留量的取值：一次闪光为两端钢筋切断时刀口严重压伤的部分之和，二次闪光为810（直径大的钢筋取大值）。闪光速度由慢到快，开始时近于零，而后约1/，终止时达1.52.0/。6.2.2.3、预热留量与预热频率预热留量的选择：应使接头充分加热。预热留量的取值27(直径大的钢筋取大值)。预热频率取值：对级钢筋宜适中（12次/），以扩大接头加热范围，减少温度梯度。6.2.

7、2.4、顶锻留量、顶锻速度与顶锻压力顶锻留量是指在闪光结束，将钢筋顶锻压紧时因接头处挤出金属而缩短的钢筋长度。顶锻留量的选择，应使钢筋焊口完全密合并产生一定塑性变形，顶锻留量宜取46.5。级别或直径大的钢筋取大值。其中有电顶锻留量约占1/3，无电顶锻留量约占2/3，焊接时必须控制得当。顶锻速度应越快越好，特别是顶锻开始的0.1秒应将钢筋压缩23，使焊口迅速闭合不致氧化。而后断电并以6/的速度继续顶锻至结束。顶锻压力应足以将全部的熔化金属从接头内挤出而且还要使邻近接头处（约10）产生适当的塑性变形。6.2.2.5、变压器级数：变压器级数用以调节焊接电流大小。钢筋直径大其级数要高。焊接时如火花过大

8、并有强烈的声响。应将低变压器级数。当电压降低5%时，应提高变压器级数1级。七、 施工环境负温条件下焊接钢筋，应尽量安排在室内进行，如必须在室外焊接其环境温度不宜低于-20度。焊后未冷却的接头严禁碰到冰雪。风力超过3级时应有挡风措施。八、 焊接的缺陷及防止措施8.1、电渣压力焊缺陷及防止措施缺陷性质防治措施轴线偏移1、 钢筋的焊接端部力求挺直2、 正确的安装夹具和钢筋3、 及时修理或更换已变形的电极钳口4、 焊接操作过程中避免晃动接头弯折1、 钢筋的焊接端部力求挺直2、 正确的安装钢筋，并在焊接时始终扶持端正3、 焊毕，适当延长扶持上钢筋的时间4、 及时修理或更换已变形的电极或夹具结合不良1、

9、正确调整夹头的起始点，确保上钢筋下送到位2、 避免下钢筋伸出钳口的长度过短，确保熔池金属受到焊剂正常依托3、 防止在焊接时焊剂局部泄漏，避免熔池金属局部流失4、 避免顶压前过早断电，的效的排除夹渣焊包不匀1、 减少钢筋端面的不平整度2、 装焊剂时，力求钢筋四周均匀一致3、 焊剂回收使用时清除一切杂质4、 避免电弧电压过高，减少偏弧现象5、 防止焊剂局部泄漏，避免熔池金属局部流失过热（焊包薄而大）1、 合理选择焊接参数，避免采用大能量焊接法2、 减少焊接时间3、 缩短电渣过程气孔、夹渣1、 遵守使用焊剂的有关规定2、 焊接前对钢筋端部的锈斑、杂物清除干净3、 缩短电渣过程，使钢筋端面呈微凸状4、

10、 及时进行顶压过程8.2、闪光对焊缺陷及防止措施异常现象和缺陷的种类防止措施烧化过分剧烈并产生强烈的爆炸声1、 降低变压器的级数2、 减慢烧化速度闪光不稳定1、 清除电极底部和表面的氧化物2、 提高变压器的级数3、 加快烧化速度接头中有氧化膜、未焊透或夹渣1、 增加预热程度2、 加快临近顶锻时的烧化速度3、 确保带电顶锻过程4、 加快顶锻速度5、 增大顶锻压力接头中的缩孔1、 降低变压器级数2、 避免烧化过程过分剧烈3、 适当增大顶锻留量及顶锻压力焊缝金属过烧或热影响区过热1、 减少预热程度2、 加快烧化过程，缩短焊接时间3、 避免过多带电顶锻接头区域裂纹1、采取低频预热方法增加预热程度钢筋表

11、面微熔及烧伤1、 清除钢筋被夹紧部位的铁锈和油污2、 清除电极内表面的氧化物3、 改进电极槽口在，增大接触面积4、 夹紧钢筋接头弯折或轴线偏移1、 正确调整电极位置2、 修理电极钳口或更换已变形的电极3、 切除或矫直钢筋的弯头九、 质量检查质量检查分外观检查和力学性能试验。9.1、电渣压力焊接头9.1.1、外观检查电渣压力焊接头应逐个进行检查，检查结果应符合下列要求：（1）、四周焊包应均匀，凸出钢筋表面的高度应大于或等于4。（2）、钢筋与电极接触处，应无烧伤缺陷。（3）、接头处的弯折角不得大于4度。（4）、接头处的轴线偏移不得大于钢筋直径的0.1倍，且不得大于2。外观检查不合格的接头切除重焊。

12、9.1.2、力学性能试验应从每批接头中随机抽切3个试件做拉伸试验，且按下列规定抽取试件。每一楼层或施工区段中300个同级制钢筋接头做为一批，不足300个钢筋接头仍应做为一批。当初验结果有一个试件抗拉强度低于规定之值，应加倍取样复验。当仍有一个试件抗拉强度低于规定之值，应确认该批接头为不合格品。9.2、闪光对焊外观检查和力学性能试验应按规定抽取试件，批量划分。同一台班内，由同一焊工完成的300个同级别、同直径钢筋焊接接头应作为一批。当同一台班焊接的数量较少时，可在一周之内累计计算，若累计仍不足300个接头，应按一批计算。9.2.1、外观检查外观检查的接头数量，应从每批中抽取10%，且不得小于10

13、个。外观；检查结果应符合下列要求：（1）、接头处不得有横向裂纹（2）、与电极接触处的钢筋表面，级钢筋焊接时不得有明显的烧伤。负温闪光对焊时匀不得有烧伤。（3）、接头处的弯折角不得大于4度（4）、接头处的轴线偏移不得大于钢筋直径的0.1倍，且不大于2。外观检查结果中若有一个接头不符合要求时，应对全部接头进行检查找出不合格接头，切除热影响区后重新焊接。9.2.2、力学性能试验（1）、力学性能试验时应从每批接头中随机切取6个试件，其中3个试件做拉伸试验，3个试件做弯曲试验。（2）、当初试不合格时加倍取样复验。十、 监控内容1、 检查特殊工种持证上岗情况。2、 检查机械设备的运转情况是否良好。3、 检

14、查原材料和焊剂的合格证和复验报告。4、 检查操作者是否按作业指导书、技术交底及施工规范要求操作。5、 施工时的天气、环境温度是否符合操作条件。十一、监控方法由工长康秀河对关键过程监控内容进行连续监控，由刘红军填写关键过程监控记录1次/台班。记录要准确、完整、真实。关键过程作业指导书保定饮食广场编制：审核：（英文版 ） Two regulations promulgated for implementation is in the party in power for a long time and the rule of law conditions, the implementation o

15、f comprehensive strictly strategic plan, implementation in accordance with the rules and discipline to manage the party, strengthen inner-party supervision of major initiatives. The two regulations supporting each other, the adhere to a positive advocate, focusing on morality is of Party members and

16、 Party leading cadres can see, enough to get a high standard; around the party discipline, disciplinary ruler requirements, listed as negative list, focusing on vertical gauge, draw the party organizations and Party members do not touch the bottom line . Here, the main from four square face two part

17、y rules of interpretation: the first part introduces two party Revised regulations the necessity and the revision process; the second part is the interpretation of the two fundamental principles of the revision of laws and regulations in the party; the third part introduces two party regulations mod

18、ified the main changes and needs to grasp several key problems; the fourth part on how to grasp the implementation of the two regulations of the party. and revised the necessity and revised history of the CPC Central Committee the amendment to the Chinese Communist Party members and leading cadres h

19、onest politics several guidelines and column 1 by 2015 to strengthen party laws and regulations focus. Two party regulations revision work lasted a Years, pooling the wisdom of the whole party, ideological consensus, draw historical experience, respect for the wisdom of our predecessors, which refle

20、cts the unity of inheritance and innovation; follow the correct direction, grasp the limited goals, adhere to the partys leadership, to solve the masses of the people reflect a focus on the problem. The new revision of the and , reflects the partys 18 and the eighth session of the third, the spirit

21、of the fourth plenary session, reflecting the experience of studying and implementing the General Secretary Xi Jinping series of important speech, reflects the partys eighteen years comprehensive strictly practice. (a) revised two regulations of the party need of in based on revised, the promulgatio

22、n and implementation of January 2010, to strengthen the construction of the contingent of leading cadres play an important role. But with the party to manage the party strictly administering the deepening, has not been able to fully meet the actual needs. Content is too complicated, eight prohibitio

23、n, 52 are not allowed to hard to remember, and also difficult to put into practice; the second is concisely positive advocated by the lack of prohibited provisions excessive, no autonomy requirements; the third is banned terms and discipline law, both with the party discipline, disciplinary regulati

24、ons repeat and Criminal law and other laws and regulations repeat; the fourth is to clean the theme is not prominent, not for the existing problems, and is narrow, only needle of county-level leading cadres above. is in 1997 based on revision, in December 2003 the promulgation and implementation, to

25、 strengthen the construction of the party play very important role. Along with the development of the situation, which many provisions have been unable to fully meet the comprehensive strictly administering the practice needs. One is Ji law, more than half of the provisions and criminal law and othe

26、r countries laws and regulations Repetition; two is the political discipline regulations is not prominent, not specific, for violation of the party constitution, damage the authority of Party Constitution of misconduct lack necessary and serious responsibility to pursue; third is the main discipline

27、 for the leading cadres, does not cover all Party members. Based on the above situation, need to and the two is likely to be more relevant regulations first amendment. By revising, really put the authority of Party discipline, the seriousness in the party tree and call up the majority of Party membe

28、rs and cadres of the party constitution of party compasses party consciousness. (II) two party regulations revision process the Central Committee of the Communist Party of China attaches great importance to two regulations revision . Xi Jinping, general books recorded in the Fifth Plenary Session of

29、 the eighth session of the Central Commission for Discipline Inspection, on the revised regulations made clear instructions. According to the central deployment, the Central Commission for Discipline Inspection from 2014 under six months begin study two regulations revision. The Standing Committee o

30、f the Central Commission for Discipline Inspection 4 review revised. Comrade Wang Qishan 14 times held a special meeting to study two regulations revision, amendment clarifies the direction, major issues of principle, path and target, respectively held a forum will listen to part of the province (ar

31、ea) secretary of the Party committee, Secretary of the Discipline Inspection Commission, part of the central ministries and state organs Department The first party committee is mainly responsible for people, views of experts and scholars and grassroots party organizations and Party members. Approved

32、 by the Central Committee of the Communist Party of China, on 7 September 2015, the general office of the Central Committee of the Party issued a notice to solicit the provinces (autonomous regions, municipalities) Party, the central ministries and commissions, state ministries and commissions of th

33、e Party (party), the General Political Department of the military, every 3 people organization of Party of two regulations revision opinion. Central Commission for Discipline Inspection of extensive solicitation of opinions, careful study, attracting, formed a revised sent reviewers. In October 8 an

34、d October 12, Central Committee Political Bureau Standing Committee and the Political Bureau of the Central Committee After consideration of the two regulations revised draft. On October 18, the Central Committee of the Communist Party of China formally issued two regulations. Can say, two laws amen

35、dment concentrated the wisdom of the whole party, embodies the party. Second, and revision of the basic principles of two party regulations revision work and implement the partys eighteen, ten eight plenary, the spirit of the Fourth Plenary Session of the Eleventh Central Committee and General Secre

36、tary Xi Jinping important instructions on the revised and , highlighting the ruling party characteristics, serious discipline, the discipline quite in front of the law, based on the current, a long-term, advance as a whole, with Bu Xiuding independent and . Main principle is: first, adhere to the pa

37、rty constitution to follow. The constitution about discipline and self-discipline required specific, awaken the party constitution of party compasses party consciousness, maintaining the authority of the constitution. General Secretary Xi Jinping pointed out that no rules, no side round. Party const

38、itution is the fundamental law, the party must follow the general rules. In early 2015 held the eighth session of the Central Commission for Discipline Inspection Fifth Plenary Session of the 16th Central Committee, Xi Jinping again pointed out that constitution is the party must follow the general

39、rules, but also the general rules. the revision of the and is Method in adhere to the regulations established for the purpose of combining rule of virtue is to adhere to the party constitution as a fundamental to follow, the constitution authority set up, wake up the party constitution and party rul

40、es the sense of discipline, the party constitution about discipline and self-discipline specific requirements. 4 second is to adhere to in accordance with the regulations governing the party and the party. The Party of rule of virtue de, mainly refers to the partys ideals and beliefs, excellent trad

41、itional style. The revised the closely linked to the self-discipline, insisting on the positive initiative, for all members, highlight the vital few, emphasized self-discipline, focusing on the morality, and the majority of Party members and the ideological and moral standards. The revised Ji method

42、 separately, Ji, Ji Yan to Method, as a negative list, emphasizing the heteronomy, focusing on vertical gauge. Is this one high and one low, a positive reaction, the strict party discipline and practice results transformation for the integration of the whole party to observe moral and discipline req

43、uirements, for the majority of Party members and cadres provides benchmarking and ruler. Third, insist on to. In view of the problems existing in the party at the present stage, the main problems of Party members and cadres in the aspect of self-discipline and abide by the discipline to make clearly

44、 defined, especially the partys eighteen years strict political discipline and political rules, organization and discipline and to implement the central eight provisions of the spirit against the four winds and other requirements into Disciplinary provisions. Not one pace reachs the designated posit

45、ion, focusing on in line with reality, pragmatic and effective. After the revision of major changes, major changes in the and modified and needs to grasp several key problems (a) adhere to according to regulations governing the party and party with morals in combination, for at the present stage, th

46、e leadership of the party members and cadres and Party members in existing main problems of self-discipline, put forward principles, requirements and specifications, showing Communists noble moral pursuit, reflected at all times and in all over the world ethics from high from low 5 common requirements. One is closely linked to the self-discipline, removal and no direct relation to the provisions of . the second is adhere to a positive advocate, eight prohibition 52 are not allowed to about the content of the negative list moved int