(设备管理)船舶舱室设备底座焊接工艺规范

1、船舶舱室设备底座焊接工艺规范WELDINGPROCEDURESPECIFICATIONFOREQUIPMENTBASEOFHULLCABIN范围Scope本规范规定了船舶舱室重要设备底座焊接与普通设备底座焊接施工前的准备、人员、工艺要求、工艺过程、检验。Thespecificationrulestherequirementsofforeweldingtopreparation,personnel,technrequirements,technologyprocess,examination;whichareforbaseofimportantequipmentsandcommonequipme

2、ntsofhullcabin.本规范适用于各类船舶舱室设备底座的焊接。Thespecificationapplytotheweldingforequipmentbaseofdiversifiedhullcabin.规范引用文件船舶建造质量检验ReferringtodocumentWQUALITYINSPECTIONOFSHIPBUILDING三焊接前准备PreparationofforeweldingCJ422钛钙型药皮碳钢焊条参数(CJ422parametersforCsteelelectrodeofTiandCacovering)表3.1-1(form)试验项目（丁$土project）5s

3、(Mpa)5b(Mpa)55(%)AKV(-20)J三330三420三22三47X射线探伤(Radiographicinspection):II级(Gradetwo)焊条直径（MM）Diameter2.53.245焊接电流(A)Current601101201501602102202703.2CJ507低氢钠药皮碳钢焊条参数(CJ422parametersforCsteelelectrodeoflowhydrogenNacovering)表3.2-1(form)试验项目（丁$土project）5s(Mpa)5b(Mpa)55(%)AKV(-20)J(-30)三400三490三22三47三27X

4、射线探伤(Radiographicinspection)II级(Gradetwo)焊条直径(MM)Diameter2.53.2455.8焊接电流(A)Current60110120150160210220270210260焊前施工人员应先了解被焊工件的施工要求及作业环境、钢材牌号等级、据此按材料的选配原则确定焊条焊丝牌号、规格及极性。Weldershouldknowabouttheweldingrequirements,environment,brandandgrandofsteelbeforewelding.Accordingtothat,todecidethebrand,sizeofele

5、ctrodeandwireandpolarityontheprincipleofchoosingmaterial.定位焊Tackwelding定位焊用的焊条牌号应与正式焊缝的焊条牌号相同。Electrodebrandfortackweldingshallbeuniformwithnormalwelds.定位焊高度不得超过正式焊缝的高度，焊后的熔渣应立即去除。Theheightoftackweldingdontexceednormalwelds,eliminatingpostweldslagatonce.由于CO2定位焊容易产生焊接缺陷，定位焊缝不宜过短，一般强度钢为（3040）mm,高强度钢为

6、50mm，焊缝厚为（34）mm。ThelengthoftackweldsshallbelongerbecauseofmakingdefectseasilywithCO2gas-shieldedarcwelding.Commonstrengthsteel（3040）mm,highstrengthsteel50mm,thicknessofwelds（34）mm.所要焊接的设备底座已经按照装配要求定位好，并且打磨焊前认可才能进入焊接阶段。Equipmentbasetobeweldedmustbefittedonrequirementslikeandgrinded,beforeitwelded.对于船

7、舶重大设备如主机、发电机、中间轴承、锚绞车、舵机及主甲板设备吊艇、舷梯等基座应选用CJ507低氢钠型药皮碳钢焊条或CO2气体保护焊。Forthegrandshipequipmentweldingofbaseofmainengine,generator,intermediatebearing,windlass,steeringgear,anddavit,accommodationladderwhichisonthemaindeck;shouldchooseCJ507lowhydrogenNacoatingCsteelelectrodeorCO2gas-shieldedarcwelding.其他普

8、通设备基座可选用普通的CJ422钛钙型药皮碳钢焊条。MaychoosecommonCJ422CsteelelectrodeofTiandCacoveringforothercommonequipmentbase.焊接材料Weldingconsumable焊丝：WeldingwireCO2焊丝可选用直径为（01.2）mm的实芯焊丝或药芯焊丝，并须经船级社认可。并有规则地盘绕在焊丝盘或焊丝筒内。Diameter1.2mmflux-coredwirewillbeusedforCO2gas-shieldedarcweldingandneedbeapprovedbySociety.CO2气体：CO2ga

9、s使用的液体二氧化碳其质量应符合国家标准GB6052-85工业液体二氧化碳中规定的I类或H类一级标准ThequalityofliquidCO2usedshallaccordwithgradeoneoftypeIorIIruledbynationalstandardGB6052-85WIndustryliquidCO2三CO2气瓶压力低于1MPa时不能使用。Dontuseitagainwhencylinderpressureisbelow1Mpa.焊接设备WeldingequipmentCO2气体保护焊焊接设备应采用设备制造厂生产的专用设备，并应定期进行严格的检测与维修。ForCO2gas-sh

10、ieldedarcweldingusethespecialequipmentthatneedbeexaminedandmaintainedcarefullyeverytime.CO2焊接电源必须具备必要的电流容量及适合于焊接的电气特性，并应有可靠的外壳安全接地。WeldingpowersourceforCO2gas-shieldedarcweldingmusthavenecessarycurrentvolumeandelectriccharacteristicsuitableforwelding.Itmusthavereliablesafegroundingforcrust.送丝机构的控制装置

11、，必须具备与焊接电源输出特性相应的控制机能，必须能均匀地调节焊接电流或电弧电压。Controllingdeviceofwirefeedermusthavecorrespondingcontrollingfunctionaswiththeinputcharacteristicofweldingpowersource,rugulatecurrentandvoltageuniformly.焊枪必须具备必要的电流容量及耐用性能，而且还要有良好的操作性能，必须能稳定地送丝，焊枪的外壳必须有良好的绝缘性能。Weldinggunmusthavecurrentvolumeandcanbeusedforalon

12、gtime,convenientoperationtowelder,feedingwiresteadily.Crustofweldinggunmusthavebetterinsulatedproperty.人员PersonnelCO2保护焊的焊工必须经过专门培训和考试，并按船级社合格证所规定之类别从事产品焊接。手工电弧焊焊接的焊工持证方能上岗。WelderforCO2gas-shieldedarcweldingwhomustbespeciallytrainedandexaminedcanbepermittedtoworkonitemsruledincertificateissuedbySoci

13、ety.Welderforcoveredelectrodemanualarcweldingcantworkunlesswithcertificate.工艺要求Technologyrequirement根据图纸的要求或者焊工根据焊接规范中焊件的厚度等确定设备底座的焊脚尺寸、焊接顺序、方式等。Accordingtodrawingrequirementsorthicknessofweldmentwhichisinweldingspecification,sizeofweldingtoe,weldingsequence,weldingmeansetcwhichareforequipmentbasewi

14、llbedecided.焊接规范中对焊接电流与电弧电压的匹配要求较高，因此在施焊过程中，若焊接电流发现变化，应及时调整电弧电压，使之处于最佳状态。Inthecourseofweldingprocess,adjustvoltageintimetomakethembest,ifweldingcurrentchanged.wedoso,becausethereishigherrequirementstocurrentandvoltage.设备底座上船安装前应作好防绣漆，底座吊运上船后应妥善放置，并尽快安装，不宜随意乱丢，以防遗失、损坏。Antirustcoatingshouldbewell-done

15、onthegroundforequipmentbasetobeinstalled,itshallbeputingoodorderonthehull,installitasquicklyaspossible,avoidlosing,destruction.查看底座所装区域的甲板或围壁是否平整(一般待火工校正后安装)。Checktheplaceofdeckorhousewallswherethebaseshallbeinstalledwhetheritisflat(installitafterbeingproofreadedbyfire)凡有甲板敷料的舱室其底座要在敷料施工前定位装焊结束。Base

16、ofthecabinwithdeckcoveringshouldbefittedandweldedcompletelybeforecovering.底座切割后应清除氧化铁及毛刺等，其焊缝空隙不超过3mm,空隙长度不得超过全长勺10%。Toeliminate-andinclusionafterthebasewascut,theweldsgapshouldntexceed3mm,thelengthofgapshouldntexceed10percentofall.底座高度应符合图纸要求，甲板上的底座高度允许公差5mm，围壁上的底座高度允许公差2mm。Heightofbaseshouldaccord

17、withrequirementofthedrawing,thepermittedtoleranceforheightofbaseonthedeckis5mm,thepermittedtoleranceforheightofhousewallsis2mm.坐标位置正确，常规底座允许公差W5mm。Correctcoordinateposition,thepermittedtoleranceforcommonbasei云5mm.底座面水平，四角不平度1米长度内W2mm。Basesideshouldbeplane,planenessamongfourangles:W2mmintherangeofone

18、meter.底座结构方向符合图纸要求，其底脚最低处必要时须开流水孔。Directionofbasestructureshouldaccordwithdrawingrequirements.Makingaholewhichwillbetodischargewaterifthereisaneedatthelowestplaceofbottomtoe.Technologyprocess安装程序Installingprocedure划线一底座就位水平面校正一对角线校正一划出底脚切割线一切割底座多余部位T去除毛刺一第二次就位一校对水平面、对角线一底座焊装Drawingline-Baseprimaryfi

19、xing-Proofreadlevel-Proofreaddiagonal-Drawcuttinglineofbottomtoe-Cuttingsuperfluouspartsofbase-Removinginclusions-Formalfixing-ProofreadlevelanddiagonalWeldingofbase手工电弧焊Coveredelectrodemanualarcwelding应按焊接材料保管要求，焊条经过焙烘、保温后保存。每次领出碱性焊条使用不能超过4小时，高强度钢用焊条须用保温筒加热保温。Electrodeneedbeheatedandkeptwarm,before

20、preserved.Allthethingsshouldbedoneaccordingtostoragerequirementsofweldingconsumable.Alkalineelectrodetakenoutshouldbeusedupwithin4hours,electrodeforhighstrengthsteelneedtobekeptwarmwithkeepingwarmbox.施焊规范和要求，应严格遵照有关工艺文件的规定，不得随意更改。Weldingspecificationandrequirementruledbytechnologicaldocumentcouldntr

21、ejiggeroptionally,itshouldbecarriedoutstrictly.薄板焊接，焊前应采取一定的预防变形的工艺措施。Beforewelding,technologymeasuresofpreventingdeformationshouldbetakenforslightplate.应根据板厚和施焊工艺位置来决定其直径，第1、2道打底焊缝最好采用“3.2、4焊条，打底焊缝不宜过薄。Accordingtoplatethicknessandweldingpositiontochooseelectrodediameter,03.2,04arethebestchoiceforth

22、efirstandthesecondrunofbottomweld,bottomweldsshouldbefilledmore.采用多层焊时，每层焊道的始末端应交错(3050)mm。Formultilayerwelding,thereisa30-50mmdistanceofstartandendbetweenrunweldedandtheruntobewelded.多层焊时，必须清除前一道焊缝的焊渣和金属飞溅，修补结束后才可施焊下一层。Mustremovetheslagandspatterofthelastlayerandrepairit,andthentoweldnextlayer.对高强度

23、、高拘束管节点采用手工电弧多层焊时，应考虑在焊缝的最表面一层，施以小直径低线能量的退火焊道以提高抗低周疲劳强度。Annealingrunthatimproveresistingfatiguestrengthwillbeoperatedonthetoplayerofweldswithlowdiameterlowenergyinput,whenweldbuttjointofpipesforhighstrengthandlimitwithCoveredelectrodemanualarcwelding.焊缝末端收口处应填满弧坑，以防止产生弧坑裂纹。Endcratershouldbefilledful

24、lyinordertopreventproducingcratercracking.在去除临时焊缝、定位焊缝、缺陷、焊疤和清根时，均不得损伤母材。Dontdestroybasemetal,whenremovetemporarywelds,tackwelds,defects,overlapsandgouging.CO2气体保护焊CO2gas-shieldedarcwelding在焊接部位清除水份，铁锈，氧化皮，油污等杂物。Removingwater,rust,oxidation,oilandotherinclusions.检验确认焊机及其附属设备以及供气系统都能正常工作。Checkingweld

25、ingmachineanditssubsidiaryequipment,thesystemofsupplygas,whethertheycandowell.在更换焊机的主要部件后必须检验并确认焊机能在使用的焊接条件下正常工作。Mustcheckandconfirmthatweldingmachinecanworknormallyontheconditionofwelding,aftermajorcomponentwillbechanged.喷嘴必须经常清理，导电嘴亦须经常更换。在焊接过程中要避免焊枪软管过渡弯曲。Nozzlemustbecleaned,contactnozzlemustofte

26、nchangedtoo.Wireconduitshouldavoidbeingbent.由于风对气体的保护效果危害较大，室外焊接施工时在风速超过2m/sec环境下使用时，应采取相应的防风措施。Takecorrespondingprotectivemeasure,ifwindspeedexceeds2m/secoutsidewhenwelding.6.3.6焊缝的起端和终端容易出现缺陷，因此施工时必须特别注意。Paymuchattentiontothestartandendofwelds,wheredefectscomeintobeingeasily.焊前按工艺规范要求调节焊接规范，达到要求后，

27、开始焊接。Atfirst,regulateweldingspecificationbytherequirementsofweldingprocedure,andthentoweld.CO2气体保护焊操作要领OperationitemsforCO2gas-shieldedarcwelding.焊接中，焊枪角度后仰1520，焊丝伸出长度为（1015）mm。Theangleofgunis1520backwards,dryextensionofwireis1015mm.当采用横向摆动运条方法时，摆动幅度稍大于根部间隙或前一层焊缝两趾端，并略作停顿，以保证根部及两趾间熔透。Whentaketransve

28、rseswingmovingwire,thewidthofswingrangeislittlebiggerthangapofrootorthewidthoflayer,stoppingalittletimethere,inordertomakesurethepenetrationofrootandedges.中途熄弧时，必须用砂轮将弧坑打磨成圆滑过渡，再引弧继续焊接。当焊缝与定位焊相接时，必须将定位焊去除，然后再引弧焊接。Ifyouwanttocontinuetoweldfromthepositionwhereyoustopwelding,mustgrindthecratermakingitp

29、liable.Whenweldsmeettackwelds,removetackweldsandthentoignite.安全卫生Safetyandprotecting焊接操作者必须使用面罩、安全帽、皮手套等遮光保护用具，防止灼伤和烫伤。Topreventburning,weldermustuseprotectivethings,suchas:veil,cap,leathernglovesetc.工作中，应注意周围环境是否有易燃易爆物品，以防止飞溅引起的火灾事故。Spattercouldcausefire,sohavetocheckwhethertherearesomethingthatwillbeburningandexplodingeas