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1、本资料仅限于申辉焊接论坛发布、使用，禁止在其它网站发布PROJECT FOR CARBON STEEL PIPINGSUBCONTRACT No.:Document No:Document Title: Document Title:焊接控制手册Issued by:This document is the property of 23rd Co. It must not be used, reproduced, transmitted or disclosed without the prior written permission of 23rd Co.A:IdenticalB:Modifi
2、edC: NewNo. of pages of Attachments (if any) are as follows :Attachment No:0CFC05.04, 2004NEWRev.StatusDateOriginatorChecked ByApproved ByModificationObservation目录/CONTENT1. 目的 Purpose2. 编写依据 Compiling basis3. 焊接工程师职责 Responsibility of welding engineer4. 焊接质量检查员职责 Responsibility of quality inspector
3、5. 焊接工艺（PQR、WPS）welding procedure6. 电焊工管理 Welder management7. 焊接消耗品控制 Welding consumable control8. 焊接追踪程式计划Weld tracking plan9. 附录 Attachment1）焊接工艺指导书（WPS）Welding Procedure Specification2）Acceptance criteria for welds焊缝验收准则3）合格焊工登记表Registration form for accepted welder4）焊条日发放记录表Record form for daily
4、 issuing rods5）焊丝日发放记录表Record form for daily issuing wires1、目的 Purpose为了确保CSPC南海石化项目管道焊接工程质量，特编制此焊接控制手册。We establish this welding control manual so as to assure welding project quality for piping of CSPC Nanhai Petrochemicals Project.2、编制依据BasisCSPC 南海石化项目文件：CSPC Nanhai Petrochemicals documents:1) P
5、R8710 0000 0025 Welding Program Procedure 焊接计划2) PR8710 0000 0026 Welder Training And Qualification Procedure焊工培训和资格评定3) PR8710 0000 0038 Welding Control Procedure焊接控制程序4) DEP 30.10.60.18-CSPC Welding of metals5) GN8710 3000 1002电焊工考试与管理规则(附件十二)GN8710 3000 1002electric welder examination and managem
6、ent regulation(attachment twelve) 美国机械工程师协会标准：American Society of Mechanical Engineer Codes:ASME B31.1、 ASME B31.3、 ASME IX 国内标准：national standard GBJ5023698、GB50235 973、现场焊接工程师职责 responsibility of field welding engineer3.1. 负责准备、发布、保存被业主批准的焊接程序、标准、规范及焊工数据库、程序 资格认定测试、WPS以及PQR认定记录。Responsible for pre
7、paring, issuing, keeping the welding procedure, standard, specification coupled with welder database, procedure qualification test, WPS and PQR recognizance record, all of which mentioned above are authorized by owner.3.2. 保存用于合同项下与永久性工程有关的压力管道每个焊接作业的焊接跟踪系统(数据库)。Preserving welding track systerm for
8、each welding operation of pressure piping correlative to permanent project under contract.3.3. 负责编制现场所有焊接资料，随机抽查现场所有焊接活动及无损检测活动。Responsible for editing all welding data on site and random sampling site welding as well as NDE activity.3.4. 负责项目竣工时将所有与焊接相关的文件和档案提交资料室。Responsible for submitting all doc
9、uments and files correlative to welding to data room after the completion of this project.4、现场焊接质量检查员Welding quality inspector on site4.1. 每日填写、保存现场所有焊接活动记录。Filling in and keeping the records for field welding activity every day.4.2. 根据要求提交每周焊接报告，报告内容应包含以下：Submitting weekly welding reports inclusive
10、 as per requirements. The report should include:a. 各焊工完成的焊接工作包含各种管线等级对焊、承插焊每周及累记工作量(以英寸表示)。The welding work that have been completed by every welder inclusive of weekly and accumulated working quantities for various pipelines, butt weld and socket weld.(inch).b. 返修数量包含焊工编号缺陷类型和每周及累计返修率。The repairing
11、 quantities inclusive of welder No.defect type and weekly and accumulated repairing rate.c. 待返修数o Quantities to be repairedd. 已完成 NDE 数量。NDE quantities that have been completed5、焊接工艺 welding procedure5.1.焊接方法 welding approach管道直径 diameter of Piping接头类型 type of joint厚度范围 thickness焊接方法 welding approac
12、hW2SWSMAWBWGTAWN2BWtW6mmGTAWBWt6mmGTAW+SMAWSWSMAW5.2.焊接工艺评定（PQR）PQR的编制原则应符合国标4708-2000及ASME IX卷规定，对我公司己有适合标 准要求和与业主图纸要求的成熟工艺，不再重新评定。PQR should be edited in principle of international standard and stipulated as per ASME IX. For the procedure as applied to requirements of standard and owner as well as
13、 the drawing in our company, we shall not reassess.NoJointTypeSizeEase metalWelding locationWelding methodHeat treat.Evaluation. CodeRemark1EW 21.3x2.77A106GrE 5GTGTAWASME JE4708-2000To be done2EW 168x6.02A106GrE5GTGTAW+SMAWASME JE4708-2000To be done3EW 219x20.62A106GrE5GTGTAW+SMAWPWHTASME、JE4708-92
14、Report No Y95-0494EW 60.3x3.91A335Cr-P115GTGTAWPWHTASME、JE4708-92Y95-0295EW 114x6.02A335Cr-P115GTGTAW+SMAWPWHTASME、JE4708-92Y95-0276EW 168x10.97A335Cr-P115GTGTAW+SMAWPWHTASME、JE4708-92Y95-0287EW 21.3x7.47A335Cr-P225GTGTAWPWHTASME、JE4708-92Y95-040EW 48.3x5.08A335Cr-P225GTGTAW+SMAWPWHTASME、JE4708-92Y9
15、5-0428EW 114.3x15.3A335Cr-P225GTGTAW+SMAWPWHTASME、JE4708-92Y95-0449EW 168x25.4A335Cr-P225GTGTAW+SMAWPWHTASME、JE4708-92Y95-04810EW 325x12.47A335Cr-P225GTGTAW+SMAWPWHTASME、JE4708-92Y95-0475.3, 焊接工艺指导书（WPS）WPS的编制原则是参照合格的PQR执行WPS格式参见附录1WPS shall be edited in reference to PQR. WPS format See Attashment 1
16、.5.4, 焊工评定 welder qualification对于我公司进场的焊工，需是通过取得国家劳动局认可的合格证件的焊工，并 通过现场资格认证测试后,才能进场施工，从事相应焊接位置的焊接工作。Our welders cannot be mobilized to site involving in the welding work on properly position unless they obtain the acceptable certificate as recognized by labour bureau and pass field qualification test
17、5.5, 焊接准备 welding preparation依据批准的承包商通用焊接标准（GWS）进行焊接准备。Initiating welding preparation as per GWS authorized by contractor.5.6, 施焊工序 flow procedure for welding5.6.1 先决条件检查 pre-condition inspection5.6.1.1 母材和焊材的查核，要求如下:requirements for base materials and filler metal are as follows:焊材生产厂家要经BSF审核资质；Wel
18、ding material manufacturers qualification must he examine by BSF.母材和焊材必须具有相应的标识代号；Base material and filler metal must be provided with marking No. as appropriate.母材和焊材必须具有相应的材质证明书；并根据材质证明书检查炉批号、规 格、表面质量或包装等项目。Welding material and base material must be qualified with correlative quality certificate b
19、ased on which inspecting batch No, Specification, surface quality or wrapping and the like items.5.6.1.2焊接工艺指导书及焊工资格：WPS and welder qualification焊接工艺指导书被批准，焊工通过资格考试WPS is authorized and welder pass the examintation.5.6.1.3焊接及热处理设备(必须通过标定合格的设备)。Welding equipment and heat treatment equipment (must be
20、marked conformance)5.6.1.4 坡口及清洁度 Groove and cleanness对接接头的坡口准备应应符合批准的WPS，并按照WPS准备一个合适的坡口，以 确保正确焊透。Groove preparation of joints should be in conformance with WPS AS approved and properly groove must be prepared in accordance with the WPS so as to assure correct penetration.焊接坡口应无污物、铁锈、锈皮、润滑油、泥士、油漆以及
21、任何可能的局部凹 凸不平，清理范围应在焊口两侧内、外管表面至少20mm。The welding groove should be free of filth, rust, lubricant, soil, paint and any possible accidented. The scope of cleaning must be within at least 20mm on the surface inside and outside the pipe of two sides of groove.5.6.1.5 焊接热处理人员资格 Welding heat treatment pers
22、onnel qualification该工程中的所有焊接热处理人员必须有相关的工作经验，通过相关的资格 培训，并取得相应的资格。In this project, welding heat treatment personnel shall have the relevant working experiences, and pass the relevant trainings and obtain corresponding qualification.焊接热处理人员必须按照焊接工艺规程相关要求及热处理工艺规程进行工作。Welding heat treatment personnel sha
23、ll perform the work according to welding procedure specification requirement and heat treatment process regulation5.6.2 若需要，需装配氩气室 If required, Assembling Argon room如果焊接需要内部保护气体，保护气体纯度应符合经批准的WPS要求。预制时， 可制作氩气室保护。保护气体排气孔应位于顶部。进气孔可位于中部或底部。如图Internal gas backing of welds, when required, shall be in acco
24、rdance with the WPS. When prefabricated, the argon gas backing may be made. Vents for purge gas should be located at the top. The inlet may be centered or at the bottom. SketchPrefabricated weld5.6.3 组对 fit up5.6.3.1组对时工具要求：碳素钢所使用的手工工具(砂轮、钢丝刷等)不得用于奥氏 体钢。不锈钢丝刷只能用于不锈钢或镍合金。Tools requirements while fitt
25、ing up:Manual tools (grinding wheel, steel wire brush) used for carbon steel but not austenitic steel. Stainless steel brush is only used for stainless steel or nickel alloy.5.6.3.2对于碳钢，允许自动氧切割，在进行手工氧气切割之后，应使用砂轮机去除氧 化物2mm，并在组对前进行外观检查。The carbon is permitted auto-oxygen 2mm cutting. After performing
26、manual oxygen cutting, use grinding machine to demolish oxid and initiated visual inspection prior to assemble.5.6.3.3不锈钢坡口加工一般采用机加工的方法，若采用等离子切割坡口时，要用砂轮 机将被切割面打磨掉2mm以上。Stainless stell groove adopt cold machining commonly,if plasma to incise groove that need to polish on the surface which be incised
27、over 2 mm with grinding wheel.5.6.3.4耐热型低合金钢和高合金钢易采用冷加工方法。若采用热加工方法，对影响焊 接质量的表面层，应用冷加工方法去除。Refractory low alloy steel and high-alloy steel ease in cold machining .If heat machining,it should wipe off the surface layer which effects the welding quality with cold machining.5.6.3.5壁厚相同的管子、管件组对时，应使内壁齐平，其
28、错边量最大不应超过1.6mm。While fitting-up pipe and pipe material with the same thickness, its max misalignment should not exceed 1.6mm.5.6.3.6组对过程中，焊件应放置稳固，防止焊接时发生变形，点焊时应与正式焊的工艺 要求相同，点固焊的长度为6 12mm,高为2 4mm，至少3处以上。点固焊的焊缝不 得有裂纹等缺陷，焊接过程中，点固焊的两端宜磨成缓坡形或完全清除，以使焊点与 焊缝熔为一体。Weldment should be placed steady in the proce
29、ss of assembling so as to prevent distortion while welding. Tack welding must conform to formal welding requirements with length of 6-12mm and height of 2-4mm, at least 3 positions.the weld line should not have crack and the like defects and both sides should be polished slope or fully cleaned out d
30、uring welding so that the complete fusion between tack weld and weld line.5.6.3.7采用临时垫块或临时点焊或其他合适的方式正确装配以便焊接。在进行点固焊 接时，临时垫块应与母材相匹配。9本资料仅限于申辉焊接论坛发布、使用，禁止在其它网站发布Properly fitting up with temporary block or tack welding or other appropriate manners so as to weld. The temporary block should be matched wi
31、th base material.5.6.3.8临时点焊只能由合格的焊工按照批准的焊接程序规范参数进行。Tack welds shall only be made by qualified welders using the parameters of an approved WPS.5.6.3.9不得将临时垫块宜接从母材上敲掉。可以用任何适当的方法去除临时垫块，去 除后应对母材进行打磨。如果采用热切割方式取下附件，应至少留3mm进行打磨去 除，并对打磨区进行外观缺陷目视检查。发现的所有缺陷均应通过再次打磨去除，必 要时进行补焊。重新焊接应按照经批准的合格焊接程序进行。Temporary bl
32、ocks shall not be knocked off base material. The block may be removed by any suitable means, followed by polishing on the base material. When thermal cutting is used to remove accessories, at least 3mm shall be left for finish removal by grinding and the ground area shall be visually examinated for
33、defects. Any defects found shall be removed by additional grinding and rewelded, if necessary. Rewelding shall be performed with a qualified WPS.5.6.3.10在打底焊之前，应仔细地检查坡口的清洁度后，再进行底焊。Seriously inspecting the cleanness of groove prior to bottom welding.5.6.4 若需要预热If required, preheating5.6.4.1当需要预热时，应检查
34、焊前预热温度是否达到WPS的要求.We should inspect the preheat temperature whether or not achieve the requirement of WPS when need to preheat,5.6.4.2预热温度应采用测温笔、热电偶高温计或其它合适的方法进行检查，以保证在 焊前达到规定的温度并在焊接过程中保持这一温度，指示温度的材料和技术不应对 母材有不良影响。Preheat temperature should be inspected with thermoscope pen or thermocouple pyrometer
35、or other method ,which ensure achieving the stipulate temperature before welding and must keep this temperature in 10本资料仅限于申辉焊接论坛发布、使用，禁止在其它网站发布the progress of welding . The material and technology of indication temperature should not blight the base material.5.6.4.3局部预热时，预热区域应伸出焊缝每侧至少25mm。Preheat a
36、rea should spread welding line out at least 25mm every side when part preheat.5.6.5焊接：焊缝经由取得国家认可资质并经过技能测试合格的焊工施焊，具体工艺参 照“ WPS ”焊接工艺指导书。Welding: Welding must be made by the welder who acquired national qualification and pass skill test. The details about procedure should refer to “WPS” .5.6.5.1焊接位置只能
37、在批准的焊接程序规范指定的位置进行焊接。Welding shall be performed only in the positions specified in the approved WPS.5.6.5.2施焊过程中应控制层间温度不超过规定的范围。当焊件需要预热时，焊件在整 个焊接过程中应不低于预热温度。The process of welding should control the interpass temperature not to excess the range of provsion.It must low in preheat temperature all the w
38、elding process when weld material need to preheat .5.6.5.3每条焊缝应尽可能一次焊接完。若焊接中断，在恢复焊接前应进行WPS中规定的 预热。Exert every effort to accomplish each welding line one time.It should preheat basis WPS qulifacation before welding if welding interrupt .5.6.5.4对P-No4、P-No5A的合金钢焊缝中间热处理应在焊后立即进行，若焊后立即进 行热处理则可不做中间热处理。Wel
39、d of P-No4、P-No5A alloy steel should intermediate heat treatment immediately after welding ,it cannot to intermediate heat treatment if heat treatment immediately after welding. P-No4、P-No5A的合金钢焊缝在焊接完成后不能立刻进行PWHT，焊缝从焊接温度 开始冷却前先进行中间热处理。厚度介于10mm-30mm，中间热处理将按如下执 行。If final PWHT is not carried out immed
40、iately after completion of welding, an intermediate heat treatment shall be performed prior to allowing the weld to cool from welding temperature.For thickness between 10 and 30 mm, intermediate heat treatment shall be performed as follows.Plate Thickness(mm)150C(hr)200C(hr)250C(hr)300C(hr)10-206321
41、.520-3010753 厚度超过30mm，焊缝在冷却到环境温度前先按600620 C进行中间热处理，保 温时间1hr/25mm以实际厚度为准。For thickness over 30mm,an intermediate heat treatment shall be performed at 600-620C for 1hr/25mm of nominal thickness prior to cooling to ambient temperature.5.6.6 焊后检验 post weld inspection5.6.6.1焊工焊接过程和焊口完成之后都应对自己所焊的焊缝进行自检，消除
42、层间缺陷 及清理防碍检查的渣皮，飞溅物，接受焊接检查员的外观检查。During Welding and post welding line, the welders should self-inspect welding crack and eliminate defects among layers and clean spatters together with the visual inspection of welding inspector.5.6.6.2焊缝外观检查应按照ASME B31.3，表K341.3.2规定的焊缝验收准则(附录 2)。焊缝外表面在允许高度以及与母材连接方面都
43、应是合格的。角焊缝的尺寸应如 有关图纸所示的那样。假如是承插接头，则不能熔融承口的边缘。Welding visual inspection shall conform to welding acceptance rules as specified in K341.3.2 of ASME B31.3 ( Attashment 2). Weld exterior within the allowed height as well as the aspect of connecting with base material must be accepted. The dimension of fi
44、llet welding shall conform to drawings. It is ot allowed to fuse the edge of socket if socket joints are used.5.6.6.3 焊缝完成之后，焊接检查员和施工班组应在探伤前在距焊缝边缘50mm处及时的标明焊缝编号和焊工代号，并由焊接检查员核对焊接位置，做好工作记录。Following the completion of welding, welding inspector and construcion team shall timely mark weld No. and welder
45、 No. On the points that any from the edge of welds with 50mm,prior to radiographic test, then the inspector shall check welding position and do well the records.5.6.7 焊后热处理 Post-weld heat treatment (PWHT)5.6.7.1不同的管道级别持有不同的PWHT温度，同ASME B31.3规定范围一致。Pipe classes having a stated range of temperature in
46、 the PWHT column shall be heat treated in accordance with ASME B31.3 at the stated range.管道级别为P-No 1的碳钢管道，焊缝厚度19mm，PWHT温度为593-649C，2.4 分/mm。P-Number 1 carbon steel Pipe Classes annotated with PWHT” shall be heat treated when the weld thickness 19 at 593-649C for 2.4 minutes/mm.所有的P-No4的低合金钢管道(1.25Cr
47、-0.5Mo)热处理温度704-746C,2.4 分/mm。All P-Number 4 low alloy steel (1.25Cr-0.5Mo) shall be heat treated at 704-746C for 2.4 minutes/mm.所有的P-No5A的低合金钢管道(2.25Cr-1Mo)热处理温度704-760C , 2.4 分/mm。All P-Number 5A low alloy steel (2.25Cr-1Mo) shall be heat treated at 704-760C for 2.4 minutes/mm.5.6.7.2提供焊后热处理操作的时间一温度图(焊后热处理图)Time-