2022年焊工培训与考核程序

1、Welder Training and Qualification Procedure焊工培训与考核程序PROJECT PROCEDURE: PR-8710-8100-0026项目程序: PR-8710-8100-0026REV版次DATE 日期REASON FOR ISSUE 修订因素BY 编制Chkd 审核QA 审查APPR批准A16 Sep Issue for ReviewB07 Oct Issue for Approval0029 Oct Issue for Use0115Nov.Issue for UseContent目 录 TOC h z t 样式1,1 1. Purpose 目的

2、 42. Scope 范畴 4 3. Definition 定义 4 4. References 有关文献 5 5. Responsibility 职责 6 6. Procedure 程序 7 7. Record 记录 13 8. Attachments 附录 14 版次Ver.章节号Section No.重要修改内容Description of main changes01All“SEPCO1and SEPCO2 “is changed to “SEPCO1/2”.将程序中SEPCO1和SEPCO2改为SEPCO1/23Definition of SEPCO is added.增长了对SEP

3、CO的定义4GB code and HB code references are added.增长了国标、行标等参照原则5增长了SEPCO1/2项目经理的职责Project manager resiponsebility is added.将”进行任何焊工测试之前至少24小时告知BSF”改为进行任何焊工测试之前至少48小时告知BSF“Notifying BSF a minimum of 24 hours in advance of any welder tests” is change to “Notifying BSF a minimum of 48 hours in advance of

4、any welder tests”.5.3Adding content of responsebilities about leader,welding engineer and NDE engineer in weld examination team.增长了焊工考试小组中领队、焊接工程师和NDE工程师的职责。6.4.4Relevant details about weld testing are added.增长了焊缝检查的有关内容8Appendix D ,Eand Appendix F are added.增长了附录D、附录E和附录F。1 Purpose 目的This procedure

5、 regulate the welder training and test management in CSPC Nanhai Petrochemicals Project, ensure every welder in the project qualified in accordance with applicable standard and fulfill project welding work requirement, and ensure qualified welder in welding work.规范南海石化项目SEPCO的焊工培训与考核管理，使参与项目施工的焊工根据合

6、用的原则获得相应资格证书，满足项目焊接施工的需要，保证合格的焊工从事相应的焊接工作。2. Scope 范畴The procedure applied SEPCO welder train and test work in Steam&Power Project.本程序合用于汽电联产项目SEPCO的焊工培训和考核工作。3. Definition 定义3.1 SEPCO 山东电力基本建设总公司 Shandong Electric Power Construction Corporation3.2 SEPCO1/2 山东电力建设一、二公司 SEPCO No.1/2 Construction Comp

7、any .3.3Weld Control Manual(WCM) 焊接控制手册（WCM）The WCM is the compilation of welding procedures, Weld heat treatment, non-destructive examination, positive material identification procedures, and Form 167 (or Equivalent) Welding and NDE Matrix issued by SEPCO for project use to fulfill the requirements

8、 of the CSPC Nanhai Steam&Power Project.WCM 汇编了由 SEPCO发布的焊接程序、焊接热解决程序、无损检测程序，材料光谱分析程序以及焊接和无损检测一览表 167（或类似表格），将 WCM 应用于项目中以贯彻 CSPC 南海汽电联产项目的规定。4. References 参照资料4.1 PR-8710-8100-0025 焊接程序Welding Program4.2 PR-8710-8100-0038 焊接控制 Welding Control4.3 ASME Standard Welding and Brazing Quanlification ASME

9、 原则第卷焊接和钎焊评估4.4 AWS D 1.1 Steel Construction Welding Regulation AWS D 1.1 钢构造焊接规范4.5 WI-8710-8100-0003C 焊接材料控制 Welding Material Control 4.6 PR-8710-8100-0213 NDE管理程序NDE Management Procedure4.7 PR-8710-8100-0215 焊接热解决程序Welding Heat Treatmeant Procedure 4.8 WI-8710-8100-0022 WCM 文献General Welding Stan

10、dards (GWS) 通用焊接原则 (GWS)4.9 ASME Section I Power Boilers. ASME 第一卷 动力锅炉4.10 ASME Section VIII Pressure Vessels. ASME 第八卷 压力容器4.11 ASME Section V Non-destructive Examination . ASME第五卷 无损检测 ASME 第一节 第一卷 动力锅炉ASME 第八节 第八卷 压力容器ASME 第五节 第五卷 无损检测4.12 DL5007-92 The Code Of Erection and Acceptance for Power

11、Plant Constraction Welding Section 电力建设施工及验收技术规范（焊接篇）4.13 DL/T822- The Code of The Welding Teat Treatment for Power Plant火力发电厂焊接热解决技术规程4.14 ASME B31.1 动力管道ASME B31.5 制冷管道GB3323-87 GB3323-87 钢熔化焊对接接头射线照相和质量分级 5. Responsibilities 职责5.1SEPCO Construction Manager SEPCO 施工经理SEPCO construction manager is

12、responsible for implementing the welder testing program by sub-contractors on site. SEPCO 施工经理负责贯彻分包商现场进行焊工考试筹划。5.2 Project manager of SEPCO1/2 SEPCO一/二公司项目经理Responsible for supvising and reviewing welder testing and qualification.SEPCO1/2项目经理负责监督与审核焊工考试和资格评估。5.3Welder Examination Team 焊工考核小组5.3.1 L

13、eader领队：Reviewing welder qualification,PQR and WPS. Organizing weider examination.审查焊工资格，审核工艺评估报告和焊接工艺规程，组织进行焊工考试。5.3.2 Welding engineer 焊接工程师：Constituting welder examination plan.Organizing examination at site.Be responsible for discipline of examination room.Transacting welder card.Establishing an

14、d managering welder archives.制定焊工考试筹划，组织现场考试，负责考场纪律，办理焊工证，建立管理焊工档案。5.3.3 NDE engineer NDE工程师：Responsible for testing examination ing out testing report.负责考试试件的检查，出具检查报告。5.4SEPCO Field Welding Engineer SEPCO现场焊接工程师Notifying BSF a minimum of 48 hours in advance of any welder tests, giving the location

15、 and number of welders to be tested, including the applicable WPS.在进行任何焊工测试之前至少 48 小时告知BSF，阐明测试地点、要测试的焊工人数及合用的 WPS。Responsible for issuing the required welder certification in a timely manner, prior to the welder(s) commencing work on permanent facilities.负责焊工在永久设施上开始作业之前，及时颁发必需的焊工证书。5.5CMD welding

16、engineer from SEPCO1/2一、二公司施工部焊接工程师Entire responsible for all the welder training and test including welding equipment preparation、welding workpiece preparation、theory and technical training guiding、testing workpiece machined、check examine、training result review and so on, and put up welder training

17、 record.全面负责所有焊工的培训和考核工作，涉及焊接设备准备、焊件准备、理论和技能培训指引、试件加工、检查实验、培训成果评估等，并建立焊工培训档案。5.6 Welding engineer from construction (or Erection) team 施工队或工程处焊接工程师Responsible for cooperating welder training and test management including selfs welder training plan、welding material preparation、steel structure welder

18、training and high pressure welder training commission and so on。各专业工程处负责配合做好焊工培训和考核管理工作，涉及编制本单位焊工培训筹划、准备焊接材料、钢构造焊工的培训及高压焊工的培训委托等。6. Procedure 程序6.1General 总则6.1.1 SEPCO1/2 have contractual responsibility for welder training programs. When a contractor deems that his welders have been properly traine

19、d for their intended work on the CSPC Nanhai Petrochemicals Project and have passed the tests given by the appropriate Chinese Labor Bureau, each welder and/or welding operator shall pass a welder qualification test conducted on site at the contractors test facility before being permitted to perform

20、 any welding on site. 根据合同规定，SEPCO1/2应负责执行焊工培训筹划。如果承包商觉得焊工已经得到了 CSPC 南海石化项目有关作业的合适培训，且已经通过中国劳动局举办的有关考试，则在容许焊工现场作业之前，每个焊工和/或焊接操作员必须通过在承包商测试设施上现场举办的焊工资格认定测试。6.1.2 After successful testing, welders will be required to attend a training class given by SEPCO to explain the basic project welding requireme

21、nts.测试通过后，规定焊工参与SEPCO为阐明项目焊接基本规定举办的培训班。6.1.3SEPCO1/2 welders are subject to performance review at all times by the BSF LFWE or FWE. Whenever deemed appropriate or necessary due to unacceptable repair rates, a welder may be asked to re-perform qualification testing by BSF in the contractors welder te

22、sting facility at the contractors expense.SEPCO1/2焊工将随时接受 BSF LFWE 或 FWE 的体现评审。无论何时，由于不能接受的返修率而觉得合适或必要时，也许规定焊工重新进行 BSF 在承包商焊工测试设施上规定的资格认定测试，测试费用由承包商承当。6.1.4 Qualification testing of SEPCO1/2 welders will be conducted under the supervision of the SEPCO welding engineer. Each Contractor shall ensure t

23、hat each welder is properly trained and qualified for performance of welding on the designated CSPC Nanhai Petrochemicals contract.SEPCO1/2焊工的资格认定测试由 SEPCO焊接工程师监督执行。各承包商应保证每个焊工接受合适培训，并能胜任在指定的 CSPC 南海石化合同项下的焊接工作。6.2 Welder Training Work Progress焊工培训工作流程6.2.1 SEPCO1/2 shall provide a list(s) of welder

24、 candidates to perform welding training on the CSPC Nanhai project.SEPCO1/2应提供接受 CSPC 南海项目焊接培训的焊工名单。6.2.2SEPCO1/2 shall provide their welder candidates with classroom training and practical shop demonstrations of the welding processes as they deem necessary. SEPCO1/2 are responsible to ensure that e

25、ach welder has been tested by the appropriate Chinese Labor Bureau.SEPCO1/2应根据需要，为报考焊工提供课堂培训，并实际演示该项目的焊接措施。SEPCO1/2应保证每个焊工均已通过中国劳动局举办的有关考试。6.2.3Welding Engineer Department review every engineer departments training plan and the welders qualification, and write site welder training plan and welder li

26、st about the training which will be approved by SEPCO1/2 project chief engineer.焊接工程处审核各工程处的焊工培训筹划和参与培训的焊工的资质，编制工地焊工培训筹划和参与培训的焊工名单，报一、二公司项目总工批准。6.2.4In accordance with the approved training plan and the welder list, SEPCO1/2 arrange the training including theory train and technical train.按照批准的焊工培训筹划

27、和参与培训的焊工名单，由SEPCO1/2统一安排培训，涉及理论培训和技能培训。6.3Welder Testing Facility 焊工测试设备6.3.1SEPCO1/2 shall provide an appropriate welding testing facility at-site. The facility shall be suitable for testing welders to international Code standards, together with adequate fume extraction, and a separate screened tes

28、t booth for each welder.SEPCO1/2应提供合适的现场焊接测试设施。设施应适合于对焊工进行符合国际法规原则的测试，并可充足排烟，每个焊工应有独立的遮蔽测试间。6.3.2The test facility shall be provided with safe and calibrated welding equipment for each of the intended welding processes, all welding equipment shall be maintained in good working order at all times. Un

29、safe, uncalibrated, damaged, and/or unusable welding equipment shall be removed from the test facility.对每种拟测试的焊接措施，测试设备均应安全可靠且已通过校准，所有焊接设备应始终保持良好的工作状态。不安全的、未经校准的、损坏的和/或不能使用的焊接设备应停止使用。6.3.3Each welding machine shall be provided with suitable cables and attachments (holders, earth clamps, etc) that ar

30、e in good safe working order, any found to be unsafe should be removed.每台焊接机器应具有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。6.3.4Test facilities shall have suitable baking and holding ovens for the welding filler metal used. As a minimum filler metal shall be treated in accordance with the manufacturer

31、s recommendations.测试设施应具有合适的供焊接填充金属使用的烘焙炉与保持炉。至少应根据制造商的建议措施解决填充金属。6.3.5All welders shall be provided with suitable and safe hand tools (grinders, brushes, etc), and personnel protective equipment (PPE) for performing welding operations.应向所有焊工提供进行焊接作业所需的合适的安全手动工具（磨光机、刷子等）以及个人安全保护器材 (PPE)。6.4Welder Qu

32、alification Work Progress 焊工资格认定流程6.4.1When a contractor deems that his welder candidate(s) have demonstrated the ability during training to perform sound welds and/or have passed the appropriate Chinese Labor Bureau tests, SEPCO1/2 welding engineer should submit concerned welders training and test

33、documents which include but not is limited to:如果SEPCO1/2觉得其焊工候选人在培训期间体现出了优秀的焊接能力和/或已通过中国劳动局的有关测试，SEPCO1/2焊接工程师需向SEPCO提交焊工培训及考核有关资料。这些资料涉及但不限于：a) Concerned testified documents about welders qualification and approved examination on Chinese Labor Bureau;焊工焊接作业资格及通过中国劳动局测试有关的证明材料； b) WPS、PQR about the

34、welder qualifying test;焊接测试有关的WPS、PQR；c) Concerned testified documents about the site conditions according to examination requirements including: site equipment adjusting record、welding rod and material testify documents、store and withdrawal record; 现场符合测试规定的有关阐明。涉及：现场设备校准记录、焊条及焊材证明文献、存储及领用记录； d) Th

35、e appropriate control forms shall be in approved specification with the project WCM that is issued in accordance with SEPCO procedure PR-8710-8100-0025,Welding Program. 根据SEPCO 的PR-8710-8100-0025焊接程序发布的WCM中应有合适的控制表格。6.4.2SEPCO shall notify BSF a minimum of 48 hours in advance of any welder tests, gi

36、ving the location and number of welders to be tested, including the applicable WPS.SEPCO应在进行任何焊工测试之前至少 48小时告知 BSF，阐明测试地点、要测试的焊工人数及合用的 WPS。6.4.3SEPCO1/2 shall test each welder employed on the CSPC Nanhai Steam&Power Project in accordance with an approved Project Procedure/Specification.SEPCO1/2应按照批准的

37、项目程序/规范测试 CSPC 南海汽电联产项目所用的每个焊工。6.4.4 SEPCO weld engineers; in together with counterparts from BSF, will take overall reviews, including document, materials, and work piece, weld spot appearance. Non-destructive test, after the appearance inspection of welded work piece has been proved to be qualifie

38、d, shall be applied.SEPCO焊接工程师和BSF代表对焊接文献、焊接材料、试件细节、焊缝外观进行检查。焊缝外观合格后，才干进行无损检查；Non-destructive test shall be done in the selections of MT, PT, UT and RT etc. and non-destructive test must be implemented by those who are qualified through professional skill training and examination.无损检查采用磁粉、着色、超声波、射线等

39、措施，且必须由通过专业培训考核且获得相应措施合格证的人员来完毕。6.4.5A welder is allowed a maximum of two attempts at a welding qualification. If a welder is considered acceptable for re-testing he/she shall undergo a further agreed training period prior to a re-test. Following re-training the welder is only allowed one re-test, i

40、f the welder falls this re-test he/she shall not be allowed to work on the NanHai project.一种焊工最多只容许尝试进行两次焊接资格认定。如果觉得某位焊工可进行再次测试，在再次测试之前，这位焊工应参与通过协商的进一步培训。再次培训之后，仅容许焊工进行一次再次测试，如果该焊工仍不能通过测试，则应严禁其在南海项目中工作。6.4.6When the welder successfully passes the appropriate qualification test, he/she is required to

41、 attend a training class for explain the welding general work requirements of the CSPC Nanhai Petrochemicals Project.焊工成功通过有关资格认定测试后，规定其参与阐明 CSPC 南海石化项目通用焊接作业规定举办的培训班。6.4.7Following successful qualification, SEPCO shall issue each welder a personal ID Card, which shall bear a recent photograph of th

42、e welder and the welders unique ID number, together with the list of the relevant approved qualifications on the reverse (second) side. The welder shall carry this ID Card at all times when working on the CSPC Nanhai Petrochemicals Project. SEPCO shall have a different numbering system from other co

43、ntractors, and the unique welder identification number given to each welder shall not be re-issued to any other welder during the life of the CSPC NanHai project.资格认定合格之后，SEPCO应采用不同于其她承包商的编号系统，在整个 CSPC 南海项目期间，向每个焊工发放的唯一焊工辨认号不得再向其她任何焊工发放。6.4.8The welder ID card No. used by SEPCO is numbered as: SEPCO

44、-W。The first group is SEPCO1/2; the second group is welders project ID Number; the third group is serial number, W is abbreviation of word Welder.SEPCO 使用的焊工个人辨认号编号为：SEPCO-W。第一组为SEPCO1/2；第二组为焊工的出入证号；第三组为流水号，W为Welder的缩写。6.4.9Prior to the commencement of any work on site, all welders, welding operator

45、s and/or tack welders shall be qualified to the applicable approved Contractor welder qualification standards. These standards for welding qualification shall be included in the project WCM. On process piping the first two production butt welds for each newly qualified welder shall be radiographed.所

46、有焊工、焊接操作员和/或点焊工在现场开始任何作业之前，应具有批准的有关的承包商焊工资格认定原则资格。焊接资格认定的这些原则应囊括在项目 WCM 内。对于程序管道系统，每个刚刚获得资格认定的焊工焊接的头两个对接焊缝应采用射线照相进行检查。7. Record 记录7.1 SEPCO1/2 shall maintain test record lists on a daily basis for all welder qualifications, weekly qualification maintenance logs, welders weld reject records and any o

47、ther records associated with the testing and qualification of welders,and shall issue all welder qualification certificates for SEPCO approval.SEPCO1/2应每日保存所有焊工资格认定测试记录清单、每周资格认定维护记录、焊工的焊接不合格记录以及与焊工测试和资格认定有关的任何其她记录，并发放通过SEPCO批准的所有合格焊工资格认定证书。 During the welder training, the teacher should fill in weld

48、er 焊工培训过程中，焊接教练要填写焊工操作技能培训登记表； Fill in welder technical evaluation sheet after completing qualification examination;焊工完毕资格认定测试后，要填写焊工技能评估表； Welding teacher should keep the newest welder qualification record including rejects rates.焊接教练应保持最新的焊工资格认定记录，涉及不合格率； SEPCO welder engineer should submit copy o

49、f welder qualification record weekly.SEPCO焊接工程师每周向BSF提交焊工资格认定记录的副本。8. Attachments 附录8.1Attachment AWelder operation technical training record 附录A 焊工操作技能培训登记表 8.2 Attachment BWelder technical evaluation sheet 附录B 焊工技能评估表8.3 Attachment CFlow chart附录C流程图8.4 Attachment D List of Welder Examination Team

50、Members附录D 焊工考核小构成员名单8.5 Attachment E WPS for welder training and skill appraisal 附录E 焊工考试用WPS8.6 Attachment F Qualified Welder List附录F 合格焊工名单 Attachment A附录AWelder operation technical training record sheet焊工操作技能培训登记表Name姓 名Welder No.焊工代号Regulation规 格Material材 料Welding technical焊接工艺WeldIing rod焊 条Po

51、sition试件位置Welding Procedure焊接程序WeldIing wire焊 丝Connection Style接头型式Date日 期Workpiece No.试件编号Technical Condition工艺状况Result成果Appearance Quality外观质量Result成果Internal Quality内部质量Result成果Score得分Training Charge:Training Coach:培训负责人： 培训教练：Attachment B附表B: Attached Form B:焊工技能评估表Welder Skill Appraisal Sheet项目

52、编码Project Code: 项目名称 Project Name: 日期Date: 焊工姓名Welder Name: 证号Certificate No: 钢印号Steel Stamp No：考试类型Test Category：焊接工艺措施Weld Process: 使用的WPS: 母材Material Base Metal: 厚度Thickness: 手工或半自动变素/每种措施 Manual or Semi-Automatic Welding Processes实际值 Measured Value评估范畴Evaluated Scope衬垫pad(金属、焊缝金属等metal)(填fill in

53、“是yes”或or“否no”)ASME P-No. to P-No.P-No. FORMDROPDOWN FORMTEXT P-No. FORMDROPDOWN FORMTEXT to P-No. FORMDROPDOWN FORMTEXT FORMCHECKBOX 板plate FORMCHECKBOX 管 pipe (若是管,填直径write down diameter for pipe material)填充金属metal to pack: ; 类别category填充金属metal to packF-No.(工艺process #1/工艺process #2)熔化性嵌条molten p

54、acking rod (GTAW) (填fill in“是yes”或or“否no”)#1工艺焊缝熔敷厚度 molten weld thickness in #1 process#2工艺焊缝熔敷厚度molten weld thickness in #2 process焊接位置 welding location焊接方向(上坡焊/下坡焊) welding orientation (upward/downward)背面保护气(填“是”或“否”) back protective weld (yes or no)熔化极气体保护焊过渡形式 transit disposal in weld with pola

55、rized liquefied gas protection钨极气体保护焊电流类型/极性 current type in weld with tungsten gas protection /polarity其他成果other result 类型type接受回绝不合用inapplicable 位置外观检查: appearance inspection FORMCHECKBOX FORMCHECKBOX FORMCHECKBOX 射线检查成果: RT inspection FORMCHECKBOX FORMCHECKBOX FORMCHECKBOX 焊接实验执行人Welding Test Und

56、ertaker : 实验室实验编号Laboratory No:兹证明本报告记载对的，且测试试样是根据ASME规范第IX卷的规定进行准备、焊接和实验的。This is to certify that this report is recorded without false. Welding test samples are prepared, tested in accordance with requirement in ASME Specification Volume9 现场焊接工程师: 日期Date: Attachment C Flow chart附录C流程图Issue welder ID card颁发焊工个人辨认卡Welder Enter焊工进场Theory Train理论培训Theory Test Pass理论考试合格BSF profession witness the test at site联系BSF专家现场资格认定测试见证Join the training class clarifying proj