大型油罐焊接程序 WELDING PROCEDURE.doc
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1、 16 大型油罐焊接程序 WELDING PROCEDURE Page1 Table of Contents 1. PURPOSE2 2. SCOPE.2 3. REFERENCES.2 4.WELDING PROCESS FLOWCHART.2 5.REQUIREMENTS3 5.1 Preparation prior to welding3 5.1.1 Selection of welding method 3 5.1.2 Management of welding consumable.3 5.1.3 Welding procedure qualification.4 5.1.4 wel
2、der qualification 4 5.1.5 welding equipments4 5.1.6 Clean-up prior to Welding4 5.2 Control of welding process5 5.2.1 Weather conditions for welding5 5.2.2 Tack welding.5 5.2.3 Back gouging5 5.2.4 Attachments welding 5 5.2.5 Welding order of tanks .6 5.2.6 Welding of bottom plate .6 5.2.7 Welding of
3、tank shells 7 5.2.8 Welding of roof of tank 8 5.2.9 Product test plates.8 5.2.10 Marking of Welds 焊接标记.8 5.3 Inspection of welding seam .8 5.3.1 Visual inspection.8 5.3.2 NDT9 5.4 Welding seam repairing 10 6. WELDING DOCUMENTS AND RECORDERS11 .ATTACHMENT12 Page2 1. PURPOSE This project is to constru
4、ct 2 butadiene tanks, (size:1660010000).The procedure provides some welding process and welding requirements, to ensure welding quality of butadiene tanks to meet requirements of contract and applied specification/standard to satisfy the owner. 目的:本工程是建造两台储罐。本程序为确保油罐的焊接施工质量符合合同、 适用规范和标 准的要求,使业主满意,特制
5、订焊接工艺和焊接要求。 2. SCOPE This procedure is applicable to the tank welding of 00 00 Petrochemical Project 2 butadiene tanks. 范围:本施工程序适用于中海壳牌石油化工有限公司 2 台 xx 罐的焊接施工。 3. REFERENCES 3.1 “Vertical cylindrical steel welded oil tank” GBJ128-90 3.2 “welding evaluation for steel pressure vessel ” JB47082000 3.3 “
6、mechanical property tests of product welded test coupons for steel pressure vessels” JB47442000 3.4“Design and Construction of Large,Welded,LowPressure Page3 storage Tanks” API-620 3.5 “Code of welding and Brazing Evaluate” SECTION IX ASME code 3.6 PMC Relevant Welding Procedures 00-0025 00-0038 3.7
7、“BUTADIENE STORAGE TANKS, 002 baking time is 1 hour ; constant temperature is 100150; and the baking frequency is not over 2 times. 指定专人管理焊条,包括烘干、发放、回收,并作好记录。现场焊接工 程师必须严格监控。焊条使用前应拆封按照制造商的说明书进行烘干, 烘干温度是 350400,时间 1 小时;保温温度 100150;烘干次数不 得超过 2 次。 The Welder shall keep the electrodes in the portable rod
8、 ovens . During welding, electrode shall be taken out one by one. 焊工应将焊条放在便携式焊条筒内,焊接时一根一根取出焊条。 5.1.3 Welding procedure qualification In order to weld butadiene tanks, according to “mechanical property tests of product welded test coupons for steel pressure Page6 vessels”(JB4708-2000), we shall quali
9、fy the following welding procedure items on site: AWS A516 Gr60 =8mm SMAW vertical double-face welding; AWS A516 Gr60 =15mm SMAW vertical double-face welding. The test plate shall be carried out tensile test, transverse tensile test, and Cv-impact test(-46). 焊接工艺评定 针对 xx 罐的焊接,我们将在现场按照 JB4708钢制压力容器焊接
10、工艺评 定做以下焊接工艺评定: AWS A516 Gr60 =8mm 手工电弧焊 立焊 双面焊 AWS A516 Gr60 =15mm 手工电弧焊 立焊 双面焊 焊接工艺评定试板需进行拉伸试验、弯曲试验、低温冲击试验(-46)。 5.1.4 welder qualification All welders to participate the project must be qualified according to “welder training and qualification procedure”(XXCNS0011). Details of welder qualificatio
11、n see “welder training and qualification procedure” (XXCNS0011). 焊工资格认证 所有参加本项目焊接的焊工必须按照焊工培训和资格认证程序 (XXCNS0011)的要求进行考试,详细要求见焊工培训和资格认证 程序 (XXCNS0011) 。 5.1.5 welding equipments The welding equipments must possess sufficient power for welding Page7 work. Its characteristic shall meet requirement of co
12、nstruction. Each welding machine shall be provided with suitable cables and attachments (holders, earth clamps, etc) that are in good safe working order, any found to be unsafe shall be removed. XX prepare to put into use of welding equipments see “CEP” of butadiene tanks(XXCNS0001). 焊接设施 焊接设备对于所承担的
13、工作必须具有足够的功率,性能能够满足施工现 场的需要。每台焊接机器应具备状态良好的合适的电缆及附件(保持器、 接地夹等) ,应停止使用发现的任何不安全的机器。 准备投用的焊机参见 xx 罐施工执行计划 (XXCNS0001) 。 5.1.6 Clean-up prior to Welding Base material within range of groove and both sides (20mm each) shall be cleared up prior to welding. All surface dirt, such as rust, paint, grease and w
14、ater etc, must be cleared up to show metal luster. 焊前清理 焊接之前应对焊缝坡口及坡口两侧 25mm 范围内的母材进行清理,清除 表面的锈、油漆、油脂、 水等污物,直至露出金属光泽。 5.2 Control of welding process 焊接过程控制 5.2.1 Weather conditions for welding Page8 Under any kind of following welding environment, welding work shall not be allowed to perform unless
15、effective protection measures are taken: a) Rain b) Wind speed8m/s (for manual arc welding) c) Ambient humidity90% 焊接气象条件 下列任一情况下,如果没有有效的防护措施,不得进行焊接工作: a)下雨; b)风速8m/s(手工电弧焊); c)空气相对湿度90%。 5.2.2 Tack welding Length of tack welding is not less than 50mm, and space between welding spots is not less tha
16、n 200mm. Qualified welders using the parameters of an approved WPS shall only make tack welds. Tack welds shall either be removed completely, or have their start and stop ends feather ground in order to include the tack(s) into the finished weld. Tack welds should be inspected by the welder for crac
17、ks prior to inclusion in the final weld. Weld filler metals used for tack welding must be the same as the intended WPS. 罐组对时点焊长度不小于 50mm,间距不小于 200mm。 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。应完全清除 点焊,或者打磨掉点焊的起始点和结束点,以使焊点与焊缝成为一体。 Page9 正式焊接之前,焊工应检查是否有裂缝。点焊采用的焊材必须与焊接工 艺指导书相同。 5.2.3 Back gouging Flame back-gouging sh
18、all not be used, the back-gouging and fabrication of back grooves use grinder or arc air-gouging. Residual carbon deposits produced by arc air-gouging shall be removed from the groove by grinding. Before applying weld metal from the second side, the prepared surface shall be examined by dye penetran
19、t inspection. 清根 不能用火焰割,背面坡口的清根可用打磨或碳弧气刨。碳弧气刨留下的 渗碳层应该磨除。背面焊接前,坡口表面应做渗透检查。 5.2.4 Attachments welding 附件焊接 5.2.4.1 Temporary Attachments Weld filler metals used for attachments(lifting ear, etc.)welding must be the same as the intended WPS of the tanks. If attachments need be removed, they shall not
20、be knocked off base material. Attachments may be removed by any suitable means, followed by grinding with the base material. When thermal cutting is used to remove attachments, at least 1/8 inch (3mm) shall be left for finish removal by grinding and the ground area shall be visually examined for def
21、ects. Any defects founded shall be removed by additional grinding and Page10 repaired, if necessary. 临时附件 临时附件(吊耳、卡具等)在罐板上焊接时采用的焊材必须与罐的焊接 工艺指导书相同。 当去除附件时,不得将附件从母材上敲掉。去除附件之后应对母材进行 打磨。如果采用热切割方式取下附件,应至少留下 1/8 英寸 (3mm) 进 行打磨抛光去除,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。 5.2.4.2 Attachments of tanks At
22、tachments of tanks include stairsway, platform, reinforce ring, manhole, nozzles, etc. Welding of such attachments should be in accordance with the requirements of the welding seam dimension which is specified by the design drawings. Welding consumable should be the same as the intended WPS of the t
23、anks. 罐附件 罐附件包括梯子、平台、加强圈、人孔、管口等。这些附件的焊接,应 符合设计图纸对焊缝尺寸的要求,焊材应与罐本体焊接工艺指导书上的 相同。 5.2.5 Welding order of tanks According to the relevant codes and standards, our construction experience, and eructing order, we determine the welding order as the following: Bottom plate annular plate(outer 300mm) the 8th
24、, 9th course vertical seams horizontal seam between the 8th and 9th course roof plate the 7th course vertical seams horizontal seam between the 7th and 8th course the 6th course vertical seams horizontal seam between the 6th and 7th course the 5th course vertical seams horizontal seam between the 5t
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