管道焊接施工程序Pipeline Welding Procedure

1、管道焊接施工程序pipeline welding procedurecontent1. scope.12. purpose.13. references.14. welding process flowchart.15. requirements.26. welding documents and records.6attachmentuseful forms.71. scope 范围this procedure includes the requirements for the construction and quality control of the pipeline welding.

2、 it is applicable to assess the qualification of welders who perform the welding of feedstock storage tanks pipeline of xx.本程序包括对管道焊接的施工要求和质量控制。适用于xx石化原料油罐工程的焊接工作。the material of pipe is carbon steel, including a106 gr b and 20#.管的材质为碳钢 a106 gr b 和 20# 钢等。2. purpose 目的the procedure provides some wel

3、ding process and welding requirements, to ensure welding quality of pipe to meet requirements of contract and applied specification/standard to satisfy the owner.本程序为确保管线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，特制订焊接工艺和焊接要求。3. references 参考3.1 “code for construction and acceptance of field equipment, industrial

4、 pipe welding engineering” gb50236-98现场设备、工业管道焊接工程施工及验收规范 gb50236-983.2 “welding evaluation for steel pressure vessel” jb47082000钢制压力容器焊接工艺评定 jb470820003.3 “welding and brazing qualifications” asme ix焊接和钎焊评定 asme 第ix卷3.4 “requirement for pipeline construction in chemical plant and oil refinery” asme

5、31.3石油化工厂管道施工要求 asme31.33.5 pmc relevant welding procedures pmc 相关的焊接文件:xx25 “welding program” 焊接计划;xx38 “welding control” 焊接控制。4. welding process flowchart 焊接工艺流程 review drawing 审查图纸 pqr 工艺评定 work out wps 制定wps welder qualification焊工考核 welding preparation 焊接准备 fitting/tack welding组对/点焊welding 焊接 vi

6、sual inspection 目测检查 pwht 焊后热处理 ndt (repair)final acceptance 最终验收。if any weld is not acceptable, step , , , shall be followed again.如果焊缝发现缺陷，重复步骤, , , 。5. requirements 要求5.1 preparation prior to welding 焊前准备5.1.1 welding method selection 焊接方法选择it shall adopt gtaw to welding of root pass and smaw to

7、welding of filling and capping pass forpipeline with a diameter more than 2”.直径大于2”的管用钨极氩弧焊打底，手工电弧焊填充、盖面。it shall adopt gtaw to welding of root and capping pass for pipeline with a diameter less than 2”.直径小于2”的管用钨极氩弧焊打底，盖面。5.1.2 management of welding consumable 焊材管理· type of welding consumable

8、shall be accordance with the following chart：焊材型号选用按下表：· certification is to be checked prior to use. 材使用前检查质量证明书。· at-site all welding consumables for permanent works are to be stored in a controlledlockable store (rod store). all weld consumables must remain in their manufacturerspackagi

9、ng until required for the work.现场所有用于永久性工程的焊材应存放于受控制的、可上锁的库房（带锁库房-焊材库）内。所有焊接消耗品在使用之前，必须存储于制造商的原始包装内。· special person must be arranged to manage welding consumables ,including baking,storage, issue , return ，he must do a record. and site welding engineer must monitor and review consumable strict

10、ly. prior to use, all electrodes shall be newly unpackaged or re-dried according to the manufacturer's instructions, and the baking frequency is not over2 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，烘干次数不得超过2 次。· the welder shall keep the welding rods in the portable

11、 rod ovens that could be heated by electricity. if the rod ovens could not be heated, the electrodes collected per time should be used in 4 hours. during welding, welding rod shall be taken out one by one.焊工应将焊条放在可电加热的便携式焊条筒内，如果焊条筒不能加热，则每次领取的焊条应在4 小时内用完。焊接时一根一根取出焊条。· welding consumables should

12、also meet the relevant requirements of “welding control”5.1.3 pqr and wpspqr and wps will be prepared according to the relevant standard and procedures, and shall be submitted to pmc/jianli for review in time.pqr 和wps 应根据相应的规范和程序要求进行编制，并要及时报送pmc/jianli 审核。5.1.4 welder qualification 焊工资格认证all welders

13、 to participate the project must be qualified according to “welder qualificationprocedure”(-ben-cns-0009). details of welder qualification see “welder training andqualification procedure” (-xx-cns-0009).所有参加本项目焊接的焊工必须按照焊工资格程序(-xx-cns-0009)的要求进行考试，详细要求见焊工培训和资格认证程序(-xx-cns-0009)。5.1.5 welding equipmen

14、ts 焊接设施the welding equipments must possess sufficient power for welding work. its characteristic shall meet requirement of construction. 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 unsaf

15、e shall be removed.焊接设备对于所承担的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。xx prepare to put into use of welding equipments see “cep” of feedstock storage tanks.准备投用的焊机参见原料油罐项目施工执行计划。5.1.6 clean-up prior to welding 焊前清理base material within range of groove and both sides

16、 (20mm each) shall be cleared up prior to welding. all surface dirt, such as rust, paint, grease and water etc, must be cleared up to show metal luster.焊接之前应对焊缝坡口及坡口两侧20mm 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 welding process control 焊接过程控制5.2.1 welding weather conditions 焊接气象条件under any kind of

17、 following welding environment, welding work shall not be allowed to performunless effective protection measures are taken: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：· rain 下雨· wind speed8m/s (for smaw)， wind speed2m/s (for gtaw)风速8m/s（手工电弧焊）；风速2m/s（钨极氩弧焊）· ambient humidity90%空气相对湿度90%。5.2.2 tack w

18、elding 点焊length and quantity of tack welding shall be accordance with the following chart:点焊长度和数量应参考下表：tack weld shall be made by qualified welders using the qualified parameters. weld fillermetals used for tack welding must be the same as the intended wps.点焊由合格的焊工按照批准的焊接程序规范参数进行。点焊采用的焊材必须与焊接工艺指导书相同

19、。5.2.3 other requirement 其它要求· purity of ar gas shall not less than 99.99%. 氩气的纯度不低于 99.99%。· arc shall be only stricken in welding area. when using low hydrogen electrode, weldersshall apply short arc welding. 引弧只能在焊接区内进行，当用低氢焊条时应采用短弧焊。· it shall not intermit the welding of root pass

20、 unless it needs to replace the electrode orpermits welders to take their place again.除非更换焊条或允许焊工换位置，否则打底焊道不得中断。· apply maximum distance to separate circular butt welds and the distance between them isnot less than 1.5 times of pipe diameter. 焊缝间距不小于1.5 倍的管径。· welders shall conduct visual

21、inspection to the former welds. all the defects such as slag,crack and porosities shall be removed and repaired before next pass welding.焊工应对前一层焊缝进行外观检查，焊渣、裂纹、气孔等缺陷在下一层焊接前应打磨去除。5.3 welding seam inspection 焊缝检查5.3.1 visual inspection 目视检查all welds shall be visually inspected. a weld shall be acceptab

22、le by inspection if examinationshows the following:所有的焊缝应进行目视检查，一条焊缝如果符合下列要求，则认为合格：· the surface of welding seam and haz has no crater cracks or other surface cracks,porosity, welding spatters, slags, abrupt ridges, and valleys;焊缝表面及热影响区没有弧坑裂纹或其它表面裂纹、气孔、飞溅、焊渣、焊瘤和凹陷；· the edges of the welds

23、 shall merge smoothly with the surface of the plate without a sharpangle. there shall be a maximum permissible undercutting of 0.5mmfor butt joints;焊缝边缘应平滑过渡到钢板表面，无尖角。对接焊缝的最大咬边允许深度0.5mm ；· the thickness of the reinforcement shall not exceed 3mm: 焊缝余高不超过3mm5.3.2 ndt 无损检测acceptance standard is ac

24、cording to jb4730-94 “non-destructive testing of pressure vessels”, atsame time, asme code should be accordance.无损检测标准按jb4730-94，同时符合asme 标准。proportion, acceptance criterion of ndt shall be accordance with the design drawing.无损检测的比例、合格级别符合设计图纸的规定。5.4 welding seam repairing 焊缝返修· the defects, ex

25、isted axxer the surface grinding, shall be fully eliminated through mechanicalgrinding or arc air gouging.对于通过表面打磨还不能消除的所有缺陷，焊接前应用机械研磨或刨槽直到完全消除为止。· all the repair work needs to be done by the qualified welder using the wps approved bypmc/jianli.应由合格的焊工采用经pmc/jianli 批准的焊接工艺规范，进行所有的返修工作· all repaired welds shall be inspected by x-ray examination and the films shall be puttogether with original films as the repair evidence.返修的焊缝用射线检查，底片与原来的底片放在一起。·