熔盐储罐焊接施工方案修改

1、1.工程概况.Project Summary.2编制依据2 Compilati on Basis3施工准备3 Con structi on Preparation4 焊前准备4 Weld Preparation5施工工序5 Con structi on process6熔盐罐底板组对焊接6 Assembly weld ing for tank bottom plate7熔盐储罐壁板的焊接7 Weldi ng of tank shell8拱顶的焊接8 Weld ing of vault9焊缝的修补9 Repair weld10焊接检验10 Weld ing in specti on11质量保证措

2、施11Quality assura nee measures12 HSE保证措施12 HSE Assura nee Measures13工机具及人力资源13 Machi nes & Tools, and Huma n Resources1.工程概况1.Project Summary本工程为2台20000m3拱顶冷、热熔盐储罐新建工程，工程所在地位于青海省德令哈市 西出口太阳能发电基地内，工程内容包括储罐罐主体制作、安装、防腐、及相关检测。This work is for two sets of 20000m3vault hot melt salt storage tank newproject

3、, the project is located in solar energy base of west exit of Delingha City, Qinghai province, and the project contents include fabrication,installation,anti-corrosion,and releva nt in spect ion of the main body of the storage tank.储罐结构形式为拱顶固定顶，共由五带壁板组成，壁板材质为Sa-516 Gr.70 N，壁板厚度从下到上依次为 42mm 34mm 25mm

4、 16mm 10mmThe storage tank structure is fixed arch roof which is constituted with five shell plates. The material of shell plate is Sa-516 Gr.70 N, the thickness of shell plate from up to dow n in seque nee is 42mm, 34mm, 25mm, 16mm and 10mm respectively.2 编制依据2 Compilation Basis2.1中广核德令哈50MW光热项目热传储

5、热系统施工图2.1 Construction Plan of CGN-Delingha 50MWSolar Thermal Power Generation Project Heat Transmission and Heat Accumulation System2.2 合同、招标文件；2.2 Contract, bidding document;2.3 安全技术操作规程2.4 GB50128 2014立式圆筒形钢制焊接储罐施工及验收规范2.4 GB50128-2014 Vertical Cylindrical Steel Storage Tank Welding Construction

6、and Acceptance Specification2.5 SH/T3530-2011 石油化工立式圆筒形钢制储罐施工工艺标准2.5 SH/T3530-2011 Technical Standard for Construction Vertical Cylindrical Steel Storage Tanks for Petrochemical Industry2.6 GB50341-2003 立式圆筒形钢制焊接油罐设计规范2.6 GB50341-2003 Code for Design of Vertical Cylindrical Welded Steel Oil Tanks2.7

7、 GB/T709-2006 热轧钢板和钢带的尺寸、外形、重量及其允许偏差2.7 GB/T709-2006 Dimension, Shape, Weight and Tolerances for Hot-rolled Steel Plates and Sheets2.8 NB/T47014-2011 承压设备焊接工艺评定2.8 NB/T47014-2011 Welding procedure qualification for pressure equipment2.9 NB/T47015-2011 压力容器焊接规程2.9 NB/T47015-2011 Welding specification

8、 for Pressure Vessels2.10 GB/T985-1998 气焊、手工电弧焊及气体保护焊焊缝坡口基本形式与尺寸2.10 GB/T985-1998 Basic forms and sizes of weld grooves for gas welding manual arc welding and gas-Shielded arc weldind2.11 GB/T986-1998 埋弧焊焊缝坡口的基本形式与尺寸2.11 GB/T986-1998 Basic forms and sizes of weld grooves for submerged arc welding2.1

9、2 JB/T4730-2005 承压设备无损检测2.12 JB/T4730-2005 Nondestructive Testing of Pressure Equipments3 施工准备3 Construction Preparation3.1 焊工考试3.1 Welder Examination3.1.1 所有参加熔盐罐制作安装工程的焊工必须经过严格的审核和正规的岗前培训，持 证上岗，对从事埋弧焊、气体保护焊和手工焊的焊工，应按GB50236-2011现场设备、工艺管道焊接工程施工规范焊工考核的有关规定进行考试。3.1.1 All welders who will take partici

10、pationin the manufacture and installationof the hot melting salt tank must receive strict reviewing and regulated pre-jobtraining and obtain certificates before being appointed the post. The welders who take participation in the submerged welding, gas shielded welding and manual welding should take

11、examination as per relevant regulations for assessment of welders in Field Equipment, GB50236-2011 Process Pipeline Welding Construction Specification.3.1.2对于首次施焊SA-516 Gr.70 N钢板的焊工，必须考试合格，才允许进行相应的焊 接工作。3.1.2 The welder who first welds SA-516 Gr.70 N steel plate must take the examination and then be

12、 appointed to conduct the welding work after examination qualification.3.1.3 根据现场情况，在正式开工前，完成焊工考试情况。按焊工实际焊接类型分别进 行考试。考试合格后，方可进行焊接操作。3.1.3 According to field situation, the welder examination should be completed before formal starting of the construction. The examination should be prepared inline wit

13、h the actual welding type respectively which will be performed by the welder. The examination qualified welder will be awarded with welder qualification certificate and will be appointed the post in line with certificate. No welding job for welder who failed to be awarded with welder qualification c

14、ertificate.3.1.4 焊接工作进行前，焊接技术员要对所有焊工进行焊接技术交底，让焊工熟知焊接 工艺方案，熟练掌握所焊部位的材质种类和所采用的工艺方法，如坡口形式、焊材选用、焊 接电压电流调节、焊接速度控制等，让焊工了解焊接应力与焊接缺陷的危害与预防措施。3.1.4 Before welding, the welding technician should deliver technical details disclosure to all welders to make each welder be familiar with the welding technology pla

15、n, to perfectly master the materials classification and applicable technology for the welding parts, such as groove shape, welding materials selection, regulationofwelding voltage and current, and welding speed control, in order to makethe welders understand the hazards and prevention measures of we

16、lding stress and welding defects.3.2 焊接设备3.2 Welding device直流电焊机、CO2气体保护焊焊机、埋弧自动平（角）焊机等。焊接设备的电流表、电 压表、等仪表、仪器以及规范参数调节装置应定期进行检验。上述表、计装置失灵时，不得 进行焊接。手工电弧焊、氩弧焊焊机必须集中放置在离焊接区较近的焊机棚内；自动焊根据 现场需要进行放置，放置焊接设备的场地必须保持通风良好、干燥、维修方便。Welding equipment: DC welder, CO2gas shielded welding machine, automatic submerged a

17、rc flat fillet welder, etc. Ammeter, voltmeter, and other specification parameter adjusting devices shall be inspected periodically. Whenthe aforesaid meter and metering device fail to function, welding shall not be performed. SMAW and GTAW welder must be collectively placed in the weld machine shed

18、, near by the weld zone, the automatic weld machine to be placed according to the site needs. The weld machines shed must be kept well ventilated, dry and easy maintaining.3.3 焊接材料Welding materials: 焊接材料应具有产品质量证明文件，符合现行国家标准的规定，且实物与证明书上的批 号相符，外观检查时，焊条的药皮不得有受潮、脱落或明显的裂纹；焊丝在使用前应清除其 表面的油污、锈蚀等；埋弧自动焊丝、焊剂必须

19、放在干燥处妥善保管；低氢型焊材需按照批 次、规格不同，分别取样送有资质试验室进行熔敷金属的扩散氢含量检测，扩散氢含量以不 超过4mg/100g为合格。Welding materials shall have certificate of qualification and shall meet the stipulations of the current national standard, and lot number on the material package shall conform to the certificate; Electrode shall be free of m

20、oisture, falling or apparent crack during visual inspection; Welding wire shall be free of oil stain, rust stain and so on prior to usage; Submerged automatic arc welding wire and flux shall keep in a dry place properly;焊接材料入库前检查其装箱单，出厂质量证明书等文件，检查焊材包装等情况及核对标 识后方可入库。焊材入库后应根据焊材种类、型号、批号分类存放，存放焊材的库房应干 燥

21、、退风，库内温度应大于50C，相对湿度不大于60%焊材应放在焊材架上，离开地面和 墙壁的距离不小于300mm应安放湿度计并做好记录。Before receiving welding materials, it is required to check its packing list, leave-factory quality certificate and other documents, welding material packages, and identifications. When the welding material is received, it shall be st

22、ored as per its category, type, and batch number respectively, and the welding material storage room shall be dry, ventilated, room temperature shall be larger than 50C,relative humidity shall not be larger than 60%; welding materials shall be put on the welding material support, its distance to the

23、 ground and wall shall not be less than 300mm, and humidity meter shall be installed and its reading shall be well recorded.焊接材料设专人保管，掌握焊材库的温度、湿度状况及焊材库存量、出库量，并必须设 去湿剂。Welding materials shall be kept be designated person, temperature, humidity, inventory, distribution amount of the welding material s

24、torage room shall be mastered, and the de-wetting agent shall be used.焊条和焊剂烘干设专职烘干员，并按厂家说明书要求进行烘烤，如无规定按下表要求烘 烤。在使及过程中保持干燥，焊条烘干数量要有计划，根据工程的进展情况，适量的进行烘 干。烘干时，要经常打开通风孔并打开风扇，驱除潮气，焊条、焊剂放进或取出时，干燥箱 内温度不得低于200C ;烘干合格后的焊条放入恒温箱内。焊工取焊条时，必须携带焊条 筒，随用随领。同一焊条筒内不准放入两种不同规格的焊条，以免用错。当湿度为 80%-90% 时，使用时间不超过 2 小时。湿度小于 80

25、%时，使用时间不超过 4 小时，超过这些时间，应 按规定重新烘干，焊条再烘干的次数，一般不超过 2次。烘干焊条要使用远红外线式焊条烘 干箱和保温箱，箱内不得烘干除焊条、焊剂以外的物品，干湿温度计要定期校验。焊条烘干 员应及时做好焊条烘干记录、焊材发放记录、焊材库温湿度记录，记录时写全 焊材的使用部位、材料名称、牌号、批号等内容。对于回收的焊条，应分类存放，重新烘 干，不得与未使用的焊条混放。The designated person shall be arranged to ne responsible for drying electrodeand flux, and it shall be

26、 dried as per the instruction of the manufacturer, if no stipulation is made, below table shall be followed. During usage process, it is required to keep dry, the electrode shall be dried as per the scheduled quantity, and drying operation shall be properly madeas per the project progress. During dr

27、ying process, vent shall be opened and fan shall be used frequently to remove moisture; when electrode and flux are used, temperature in the dryer shall not be less than 200C ; After it is dried thoroughly, the electrode shall be put into thermostat. When the welding operator takes out the electrode

28、, quiver must be carried for placing the electrode. The same quiver shall not be placed with electrode of different specification so as to avoid misapplication. Whenthe humidity is 80%-90%,usage time shall not be more than two hours. When the humidity is less than 80%, the usage time shall not be mo

29、re than four hours, otherwise, it shall be dried again, but the drying times for the electrode shall not be more twice in gen eral. It is required to use far-i nfrared electrode drying ove n and in cubator to dry the electrode, beside electrode and weld ing flux, no other article is allowed to be dr

30、ied in the ove n, and dry and wet bulb thermometer shall be calibrated periodically. The electrode drying resp on sible pers on shall make Electrode Bak ing Record, Electrode Issue Record, and Temperature and Humidity Record of Weldi ng Material Storage. Applicati on positi on, ven dor n ame, brand

31、n o., and furn ace nu mber of the weldi ng material shall be recorded clearly. The recovered electrode shall be stored as per its classification and dried again, and it is forbidden to put it with the unused electrode together.药皮受潮、脱落或有明显裂纹的焊条不得使用，焊丝在使用前应清除表面的油污、锈蚀 等。If the coat ing is moisture, dro

32、pped, or sig nifica nt crack exists, theelectrodeis not allowed to use; prior to application of welding wire, grease, rust, and other defects shall be removed from its surface.4焊前准备4 Weld Preparation4.1坡口形式4.1 Groove Type项目间隙形式角度备注边缘板对接内端 1214mm外端810mm加垫板50中幅板对接及收缩缝6mm加垫板40大角缝2mm/内侧45外侧50罐壁环焊缝间隙21 m

33、m/内侧45外侧45罐壁纵焊缝3mm/50 -604.2熔盐罐各部位焊接方法4.2Weldi ng various parts of molte n salt tanks序号No.焊接部位Weldi ng parts焊接方法Weldi ng method所用焊材Weldi ngcon sumables1熔盐罐底板Molte n salt tank bottom气保焊+埋弧自动焊GMAW+SAWER50-6+H10 Mn22熔盐罐壁板立缝气电立焊AT-YJEG50AMolten salt tank wallsta nding seamEGW3熔盐罐壁板环缝（外侧）Molten salt tank

34、 wall ring seam熔盐罐壁板环缝（内侧）Molten salt tank wall ring seam埋弧自动焊SAW手工电弧焊SMAWH10 Mn2J5074熔盐罐大角焊缝Bighorn weld molten salttank焊条电弧焊+埋弧自 动焊GTAW+SAWJ507+H10 Mn25熔盐罐拱顶板Molten salt tank topplate手工电弧焊GTAWJ5074.3焊接注意事项4.3 Weldi ng atte nation4.3.1U nless otherwise no ted in the desig n draw ing, other fillet w

35、elds weld joi nt height shall be equal to the thi nner part of the two welded parts, and continu ous weld ing is required.4.3.2Welders who en gaged in the storage tank weld ing must pass the exam in ati on of the labor departme nt, and the weld ing work shall be performed by the welder with corresp

36、onding project and positi on.4.3.3Tack-welding shall be performed by the qualified welder, and the welding process requireme nts shall be ide ntical to formal weldi ng requireme nts. Run-on tab and run-off tab shall not be applied in pare nt material or the completed weld pass, prior to formal weldi

37、ng, it isrequired to trim and grind both ends of the tack weldinto slow slope so as to en sure the joint quality, and the tack weld len gth shall not be less tha n 50mm.4.3.4Prior to assembling weld, bevel surface and 20mnof both sides shall be free of sediment, rust, water, and grease, it shall be

38、fully dried, and it is required to have the metallic luster.4.3.5It is required to ensure starting and finishing end of each weld pass are qualified, the starting end adopts backward arc striking method, the finishing endshall have the crater filled fully, and joint of multilayer welding shall be st

39、aggered.所有角接及T型接头焊缝，至少焊两遍完成，接头错开，圆滑过渡；板厚大于或等于 6mm勺搭接角焊缝，至少焊两遍。4.3.6AII corner joi nt and T joi nt welds shall be welded at least twice, joi ntsshall be staggered and roun ded off; if the plate thick ness is larger tha n or equalto 6mm lapped fillet weld, it shall be welded twice at least.4.3.7lf one

40、 of followingwelding condition occurs, effective preventive measuresshall be take n, otherwise, it is forbidde n to execute weld ing.a 手工电弧焊时风速大于 8m/s；b. 气体保护焊时风速大于2m/s；c 大气相对湿度大于85%d.雨、雪、大雾环境。a. Whe n manual arc weldi ng is performed, wind speed is larger tha n8m/s;b. Whe n gas shielded weldi ng is

41、 made, wind speed is larger tha n2m/s;c. Relative humidity of atmosphere is larger tha n85%;d. Ra in, snow, and fog occur.4.3.8If the above phe nomena occur, followi ng measures shall be take ncorrespondingly: set up wind proofing and rain proofing shed, heat the initial welding pass within 100mm,an

42、d keep the welding pass dry; the aforesaid measures must satisfy this requirement; otherwise, execution of welding is not allowed. 5施工工序5 Con structi on process基础验收组装、焊接其余四带vi壁板环焊缝、立焊缝p-1检测 一ScribeMount edge plateAssemble300|mm焊接纵缝 伸缩缝、龟甲缝 Layng搏 nter plate 铺设中幅丨焊接中幅焊接边缘板外侧 组装第五带壁板Weld centerplate -

43、中幅板真空试验“Fit-up and weld other four shellpate -In spect熔盐罐底板组对焊接接weld aiAssemblykwelding fdr tarbgbotwm plateand weld tank Assemble and weldWeld edge plate outsideWeld30CmmFit-up the 5th with罐底由中幅板和边缘板组成，罐底板焊缝均采用对接焊。基础验收合格后 , 确定方位画出中心线，得出中点、画出垫板、边缘板安装位置线，其中边缘板安装铺设按设计直径和基 础坡度长度外加收缩余量来确定半径。边缘板之间铺设间隙外侧为

44、8-10mm内侧为12-14mm。Tank bottom is composed of center plate and edge plate, the tank bottom plates are all butt welded, before laying the bottom plates, its lower surface should be painted with anti-corrosion coatings, leaving 50mm range of the edge. After foundation inspection & acceptance, the positi

45、on shall be determined to draw the center line, so as to find the midpoint, draw the mounting position lines of backing board and edge plate, wherein the radius of edge plate mounting and laying is determined as the design diameter and foundation slope length plus shrinkage allowance. The laying gap

46、 of edge plates is 6mm of outside and 8mm of inside.6.1 罐底边缘板焊接6.1 Weld tank bottom plate6.1.1Manual welding is applied for the butt welding of curved edge plates. First, the outside 300mmweld joint shall be carried out, with penetration inspection after back ing weldi ng. Start ing from the sec ond

47、 layer, each layer shall shift 5070mm,after welding is completed, the upper part shall be grinded flat. To control the angular distortion caused by welding, the end bevel shall be lifted 6 8mm up with clamp.6.1.2边缘板剩余对接焊缝的焊接，焊工应对称分布每隔600mm隔缝跳焊600mm,焊缝表面应光滑平整，焊接应加防变形板。6.1.2For the welding of edge pla

48、tes butt weld seam, the welder should do the skip sequence welding of 600mm in symmetrical distribution of 600mm.Weld surface should be smooth and anti-deformation plate should be added.Anti-deformation plate6.2 中幅板焊接6.2 Center plate welding6.2.1中幅板的焊接，采用CO2气体保护焊打底，埋弧自动焊盖面焊接成形。6.2.1 The welding of c

49、enter plate uses CO2 gas shielded welding for backing,with submerged automatic arc welding and cosmetic welding. 初层焊道采用分段退焊法施焊。6.2.2 The plate in the bottom plate is welded according to the order of the initial length and the long post, and the primary bead is welded by subsection back welding metho

50、d.6.2.3 When laying the center plates, it should be done according to the layout diagram from the center to the edges, with backing plate and one of two adjacent bottom plates spot welded first, the bottom plate and backing plate should be tightly against each other, with the gap not greater than 1m

51、m.61 mm之间。底板与垫板之间的点焊应按焊接技术措施规定的次序严格执行。6.2.4 When fitting up the center plates, the gap should be kept between 4-6mm. Spot-welding between the base plate and backing plate should be carried out according to the sequence provided in welding technical specifications strictly.6.2.5 罐底板中幅板焊接时，按下图顺序进行： 按照

52、上图所示焊接顺序和方向进行分段倒退跳焊，同一组内的焊缝同时焊接，分段长度要一致，焊接层数相同，焊接电流和焊接速度一致，层与层之间的焊接接头要错开，另外中 幅板之间丁字口区域200mm预留不焊，待长、短缝自动焊完成后用手工焊接完成。6.2.6 罐底板焊接时，须采取以下防变形措施：6.2.6 When doing the tank bottom plate welding, the following anti-deformation measures should be taken:Whencarrying out short seamwelding, back panel (with leng

53、th not less than 600mm and width not less than 150mm) shall be set at 150mm from the edges at both ends of the weld seam.0号槽钢固定于焊缝两侧，离焊缝 200mn并卡紧。When carrying out long seam welding, batter board is used to fix the22 channel on both sides of the weld, 200mm from the weld, and clamped firmly.6.3 边缘板剩

54、余对接缝的焊接6.3 The welding of edge plate remaining butt seams 边缘板剩余的对接缝焊接应在大角焊缝焊接完毕后，收缩缝(中幅板与边缘板的搭接焊 缝)焊接之前进行，采用手工电弧焊进行焊接。焊接时由多名焊工对称均匀分布，隔一条缝 焊一条，焊接方向由外向内，初层焊可采用分段跳焊法。焊接前将垫板与 2 块边缘板进行点 固，间隙小于1mm未焊接的焊缝不得将2块边缘板都与底板点焊。焊接时应采用背杠与卡 具进行加固。The remaining butt sea m welding of edge plate shall be carried out afte

55、r the full fillet weld is completed, before the welding of contraction joints (the lap weldsof center plates and edge plates), using manual arc welding. A number of welders shall be symmetrical evenly distributed, separated by a weld seam, with the welding direction from outside to inside, and the p

56、rimary layer welding can adopt the method of segmented wandering sequence . Before welding, the backing plate and two edge plates shall be tack welded, with the gap less than 1mm,the two edge plates and bottom plate of non-welded seam shall not be spot welded. Fixture and back panel should be used f

57、or reinforcement in welding.6.4 收缩缝(龟甲缝)的焊接6.4 Welding of contraction weld (tortoise-shell seam) 收缩缝为整个底板的最后一条焊缝，收缩缝的焊接采用埋弧自动焊机焊接，焊前应将边 缘板与中幅板之间的卡具松开或磨开定位焊点，焊工应沿圆周均匀分布，分段跳焊Contraction joint is the last weld of the whole base plate. The welding of contraction joint uses automatic submerged fillet arc welding machine, the fixture or the tacked spot between edge plate and center plate shall be loosened or removed before welding and the welding operator shall be evenly distributed circumferentially to carry out segmented skip weldin