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WELDREGISTRATIONANDWELD焊接记录和焊接检验MECHANICALCOMPLETION机械完Project项目 Sanofi（Hangzhou）PW Projectnumber项目号:Protocolno文件号SAN-T0057-MC-Version版本:Status状态:ForapprovalDate日期17-Apr-APPROVALOFTHE文件的批准Preparedby起草人EnsystaQualityEngineer质量工程师Initials拼音缩写 Date日期 :EnsystaSiteManager现场经理Initials拼音缩写 Date日期 Signature签字EnsystaProjectManager项目经理Initials拼音缩写 Date日期 Signature签字Sanofi(Hangzhou)ProjectManager赛诺菲（杭州）项目经理：Initials拼音缩写 Date日期 Signature签字Distribution传阅Byapproval:filloutthedateandsignattheceINDEX索 WELDREGISTRATIONANDWELDINSPECTION焊接记录和焊缝检 Responsibilities职 METHOD方 Pre-qualificationofwelders焊工的资 Tacking点 StorageWeldinspections焊接检 Acceptancecriteria接受标 Weldingcertification焊接 Rengoraddingwelds重焊或增加焊点 Workdirectives工作指 TESTSHEETS测试 WELDREGISTRATIONANDWELDINSPECTION缝检OBJECTIVE目The‘weldregistrationandweldinspection’protocolsetsoutthemethodtobefollowedinordertoensurethetraceabilityandqualityofweldingworkcarriedout.RESPONSIBILITIES职责TheweldregistrationandweldinspectioniscarriedoutundertheresponsibilityoftheQualityEngineerandtheweldinginspector.Itisthewelder’sresponsibilitytoentertheweldingregistrationintheweldinglogandtosurethattheweldinglogiscorrect.ThisisalsocheckedonadailybasisbythequalityEndoscopicweldingregistrationsareperformedbytheoperatorsoftheboroscopes.Theweldinginspectorchecks,approvesorrejectsthewelds.PREREQUISITES前提TheusedweldingprocedurespecificationsWPSTheirrespectiveprocedurequalificationrecordsPQR()ThewelderhasauniquewelderID-No.焊工有唯一的号Thewelderhascarriedoutandpassedrelevantweldingtests焊工参加并通告相关焊接考METHOD方Pre-qualificationofwelders焊工的资Everyweldermustbecertifiedinaccordancewiththe’srequirement.每一个焊工必须通告业Materialhandlingandpreparation材料处理和准MaterialscanonlybecutwithGFcuttingmachinesandnocuttingdisksshallbe材料只能用GF切割机切割，任何绞磨片不允许使Ascuttingmediaonly“SawbladelubricantGFLUB”willbeTakeawayburrsbymeansofscraper用刮刀刮去毛Degreaseallweldingendsoveratleast40mmbeforeweldingwithacetoneor用或在焊接端至少脱脂Afterdegreasingdryupendswithcleannon-wovenfabricWhenspoolshavetobemodifiedorexistingpipesneedtobecutcutscanbeperformedusingahandsaw.当焊口需要修改或者现有管道要被切掉时，要用锯条锯掉。Nomarkswillbemadeontheinsideortheoutsideofthepipes.Weldnumberswillnotbeetchedormarkedpermanentlyonthetube.Weldsareidentifiedbytheuniquenumberonthecorrespondingisometricdrawing.Gases气Allweldingmustbedoneprotectedbyproperinertgasesinthetube.所有焊接必须在合适的惰性Shieldinggas99.99pureARGONor5H2+95ARGONgasshallbeusedascoolinggasonthetorch.99.999%的氩或者5%的氢气加95%的氩气可作为焊把的冷却气体。Controleachbottleforthe“99.99%Argon”mark.每个氩的气瓶上要有标识Laminargasflowthroughgaslense.通体流量器使气体平稳Backinggas.99.999%pureARGONgasshallbeusedasbackinggas要用99.999%的氩作为管道内保护气Controleachbottleforthe“Highpurity99.999%Argonmark.每个氩的气瓶上要有标识ThebackinggasareamustbemadeasnarrowaspossiblebymeansofbackingPreflow:tomakesurethattheoxygenlevelisacceptableWhenwehavelongpiperunsonbothsidesoftheweldwewillusedissolvingpurgingpapertolimitthevolumethatneedstobepurged.Thispaperissolubleinwater.Backingduringwelding:Postflow:atleast120seconds(temperaturebelow200°CTacking点TackweldingtobeperformedwithoutaddingfillermaterialPipesandfittingsmustbealignedtohavetheleastpossibleTackingonlywhenbackinggasflowTackpointsmayshownooverthicknessandmaynotappearontheinsideofthetubes.Aftertack-weldingalignmentmustbechecked,andnotacceptabledeviationsmustbeadjustedbeforewelding.Welding焊Onlycertifiedweldersareallowedtoproducewelds.Theweldersmustbecertifiedtocorrespondingweldingprocedure.只有被的焊工允许焊接。焊工必须要对相应的焊接规程进行AllweldingmustbedoneconformtotheapprovedproceduresstatedAsaruleonlyorbitalweldingmaybeapplied.Handweldsareonlyallowedincaseofobstructionsfororbitalwelding,andafterwrittenapprovalbythe.只有在自动焊无法进行的时候才可以手工焊接，这也需要业主的批准。Demandsforauthorizationwillbeaddressedtothesitesupervisor.DemandscanbedonebytheENSYSTAProjectEngineerortheENSYSTAsiteWeldingmustbeperformedwithoutaddingfillermaterial.焊接时不可填加焊丝Eachweldhasauniqueweldingnumberindicatedontheisometricdrawing.Immediayaftertheexecutionoftheweld,theinformationaboutthisweldisfilledinintotheweldinglog(seechapter2.6.4).StorageSpecialattentionmustbepaidtotheneatnessofthepi,internallyandAllpipesandprefabricatedspoolsmustbecappedoffatallEndprotectionmayonlyberemovedduringprefabricationorsite-AttheendofthedayorworkinaspecificareaallopenendsmustbeclosedWorkshopsandstorageareasmustbekeptcleanandofallcarbonsticfoilprotectiononpipesmaynotberemovedduringWeldinspections焊接检Followingweldinspectionswillbeexecuted将执行以下焊接检验VisualweldinspectionAllinspectionresultsmustberecordedintheweldingloginthedesignatedVisualweldinspectionThevisualweldinspectioniscarriedoutbythesitesupervisor外观检查由现场主管执行Duringvisualinspectiontheoutsideoftheweldwillbeinspected.FollowingASMEBPE2009guidelines100%oftheweldsshouldbevisualinspected.Tobeabletocarryoutdirectandpreciseinspection,theeyemustbepositionedapproximay600mmfromthesurfacetobeexaminedandatanangleofnotlessthan30°.约于Theminimumluminousintensityrequiredis350lx,500lxis mended.Theinspectionsmustbeperformedindaylightorartificiallight.要在Area检测Aweldischeckedfor焊口的检验包含Nosaggingseeconcaveweld没有下陷（见没有凹面Appearancesmoothnessflatevenweld)外观，平滑（平，平滑焊接Discoloration.Strawyellowispermitted;clearlyvisiblebluediscolorationisnotaccepted.Seebelowpicture(1-2areacceptable,3needpicklingandpassivation,restneedredothewelds).Thisappliesonlytotheinternalpipeinspection.Theabsenceofbackinggasontheoutsideofthepipeduringcoolingafterweldingincreasesthepossibilityofbluediscoloration,butthisonlyhasanegativeaestheticeffect.颜色。轻微的草黄色可以接受，清晰的蓝色不可接受。见下图（12级可接受，3需要酸洗和钝化，4级以上需要重焊）这适用于焊缝内部检查。在焊接完毕开始冷却时，如果管道不充内保护气，将增加颜色变重的可能性，这只对奥氏体不锈钢有影响。TheacceptancecriteriaarelisteddownintableMJ-3“Acceptancecriteriaforweldsontube”ASMEBPETheboroscopeinspectionsarecarriedoutbytheweldinspector.内窥镜检查由焊接检验员Duringboroscopicinspectiontheinsideoftheweldwillbeinspected.FollowingASMEBPE2009guidelinesandtherequirementsatleast10%oftheweldsshouldbeinspectedwhere在内窥镜检查时，焊缝的内表面将被检查。按照ASMEBPE2009和业主的要求，至10%的焊缝做内TheacceptancecriteriaarelisteddownintableMJ-3“Acceptancecriteriaforweldsontube”ASMEBPEBoroscopicinspectionsresultmustbeedoncolorEachsystemwillhaveitsownDVD(ormorethanoneiftheDVDisfull).ForeachisometricdrawingweprepareonefolderontheDVD.Inthisfoldereachweldhasitsownfile.InthiswayitisveryeasytotracebackeachweldontheDVD.每个系统将有该DVD（一张或多张）DVD里，我们为每一张轴测图建一个文件夹。在此文件夹里，每一个焊点都有自己的文件。这样，我们就容易追溯DVD里每一个焊点。Rejectioncodes代号ThefollowingrejectioncodeswillbeusedduringtheinspectionoftheCode1Con内23Cracks裂4Lackoffusion56Arcstrikes打789Weldbeamuneven焊缝不规Other其Fulltraceabilityofmaterialheatnumber材料热处理号全Theheatnumbersofpi,fittingsandvalveswillbefilledinbythewelderonaseparatepaperattachedtotheisometricdrawing.WewillforeseeatestsheetonwhichweindicatefollowingNumberindicatingtheitemItemtype部件类HeatnumberThematerialscorrespondingtotheseheatnumbersareattachedtothematerialtestsheetandtheweldinglog.Beforethematerials,wealsoprepareanoverviewlistofallmaterialstolistallthesandgivethemauniqueID.Fortheinstruments,wedon’ttheheatnumbersintheweldinglog,andwecantracethematerialinthereceivinginspectionation.InthiswaywecanguaranteefulltraceabilityfromtheiteminthefieldtothematerialReferenceweldsanddailysamplewelds参考焊样和每日Atthebeginningoftheprojectandbeforethestartoftheworkonsite,referenceweldsaremadeforeachdiameterforapprovalbythe’srepresentative.在每个项目开始时现场施工之Thesereferenceweldsundergothesameinspectionsasarrangedforinstallationweldsoftheworksite.参考焊样和现场安装时的焊接执行相同的检验。Thereferenceweldsmustbekeptasareferenceforinspectionofallweldscarriedout.Eachtestweldmustbemarkedwith:‘Referenceweld”参考焊”“Date焊接日Thereferenceweldsarealsofilledintheweldinglogonaseparateweldinglogsheetforreferenceweldsanddailysample.Everyday,beforethewelderstartsweldingacertaindiameterhemakesasampleweldforthatdiameter.Whenthediameterofthetubechangeshefirstmakesasampleweldbeforehestartsexecutingtheinstallationwelds.Thesedailysampleweldsundergothesameinspectionasallotherwelds这些每日焊接试样和其他Everyday,beforeandafterinstallation,thedailysampleweldsmustbekeptseparayandsubmitto’srepresentativeforapproval.Ifthedoesn’tinspecttheweldseveryday,weassumethattrustusandwecandecidebyourselves.Whentheprojectiscompleted,allthesampleweldswillbehandedovertothe.Eachdailysampleweldmustbemarkedwith:每一个日焊样必须”Thedailysampleweldsarealsofilledintheweldinglogonaseparateweldinglogsheetforreferenceweldsanddailysample.Externalwelds外部焊Toensuretheweldingquality,wealsochecktheweldsontheexteriorofthepi.Theseweldscanbedonetoconnectthesupportorconnectthepipetotheceiling/wallte,insulationthimble,etc…Externalweldsaremanualwelds.Fortheseweldsitisimportantthereisgoodpenetration,goodfusionandtobeprovedfirmenough.However,theexternalviewisalsotobeconsideredtomaketheweldsneatandtidy.Ifpossible,polishingshouldbeusedforthesewelds.Theweldinginspectordoesavisualcheckofthesewelds.Iftheinteriorofthepipeisnotvisuallyaccessible,theendoscopecanbeusedtodoanonlineinspection.Forthespecificmanualwelding,ifit’saweldthatneedstobearacertaingreat,wewillmakeadrawingandtheweldinspectiontotracethewelding.Thedrawingisalsosubmittedtotheforinformation,whentheprojectisfinished,wehandoverthedrawingtothe.温套管等的。外部焊接是手工焊。对于这些焊接，最重要的是好的，好的熔合以及焊缝的见识牢固。当ACCEPTANCECRITERIA接受标AllweldersmusthavevalidweldingsaccordingtoASMESectionIXorequal,issuedbyanaccreditedinstitution.所有焊工都要有符合机械工程或对等的机构颁发的焊接Theweldersmustprovethattheyarequalifiedtoperformwiththeappliedweldingprocedures(Performaweldingtest).TheweldersmustkeepaweldinglogonallweldingsexecutedonstainlesssteelpiUntreatedweldsinstainlesssteelincontactwiththeproductmustbewithoutweldingdefects–asdefinedinASMEBPE,MJ-6.Discolorationexceeding“lightstraw”or“lightblue”mustnotexistintheheattreatedzone.和产品接触的未处理的不锈钢焊缝必须如ASMEBPE上规定的一样没有焊接缺陷。在热影响区，颜色不AllweldsmustcomplywiththeacceptancecriteriaaslistedintableMJ-3“Acceptancecriteriaforweldsontube”intheASMEBPE2009.所有焊缝必ASMEBPE2009的表MJ-3上列出的管道焊缝接受Incaseoferrors,repairandre-inspectionmustbeperformedaccordingtotheprocedureapprovedbythe.REPORTING报Ensystadrawsuptestsheetsonthebasisofthisprotocol.我们根据这份方案起草测试页Thetestsheetsconsistofthefollowing这些测试页包含以下Coversheetwiththeapprovaloftheandthefinalacceptanceoftheexecutionofthetest带文件批准和最终执行结果接受的封面SummarysheetwithasummaryofalltestsexecutedWeldinglogsands焊接记录Thetestsheetsaresubmittedtotheforapproval.Thesheetscompletedduringthecheckortestisacopyoftheapprovedoriginal.Duringexecutionofthecheckonthebasisoftheprotocol,thesheetsarefilledinmanually.Thespecifictestverifications,suchasboroscopicoftheweldshavetobeenclosed.Allreportshavetobekeptinthefolderspersystem,includingthenon-conformityreport.Iftheinspectionsareperformedtothesatisfactionofallpartiesconcerned,thecoversheetissignedoffforapprovalbythequalityengineerofEnsystaandthe’snelinvolvedinthetest. Weldingprocedurespecifications(WPS)forSS不锈钢焊接工艺指Theweldingproceduresweusedhavetobeenclosedwiththetestsheetsmentionedin2.6.AdesignatedsectionisforthisWPSinthetest附在Usually,thepipewhatweselectedissamethicknessandstandard,atypicalWPSandPQRissuitforallsizepipes.TypicalWPSofAutomaticweldingWithoutjoiningmaterial不加丝WPSWPSPQR号ØWall壁TorchTypicalWPSofManualweldingWithoutjoiningmaterial不加丝WPSWPSPQR号ØWall壁TorchWeldingcertificationThewelders’shavetobeenclosedwiththeMCreport.EnsystawillprovideAWSweldingfortheWelders.Referencewelds参考焊Wherereferenceweldsarerequired,suchreferenceweldshavetobelistedpersysteminaseparatelogbookandfinallyenteredintheMCreport.Weldinglog焊接记Onepageofthelogsheetmustcorrespondtoeachpageofaweldisometricdrawing.Thesecorrespondingpageshavetobekepttogetherandformthereport.Theweldisometricsandcorrespondinglogsheetsareclassified:persystemperlinenumberThefollowinginformationistobeenteredintheweldinglogforallwelds所有焊点的焊接记录要包Weldnumber焊点Weldnumberaccordingtotheweldisometric根据轴测图的焊PipediameterPipesize管子FWSW现场焊/预制FWmarkinginthecaseofafieldweld现场焊SWmarkinginthecaseofashopweld预制间Welder’sinitials焊工缩Initialsofthewelder.焊工缩Weldingdate焊接Date(e.g.2010.06.08)onwhichtheweldiscarried焊接日期例如201068WeldingequipmentWeldingmachinenumber焊机Weldingprocedure焊接工艺指导书Weindicatetheweldingprocedurespecification我们写出焊接工艺指导书Torchgasbottlenumber外保护气瓶NumberoftheArgonbottleonthetorch焊把处氩气瓶号Torchgasflow外保护Flowoftorchgas(L/min)氩气气流（升/分钟Backinggasbottlen°内保护NumberoftheArgonbottleforthebacking管道内氩气气瓶Backinggasflow内保护Flowofbackinggas(L/min)内保护气流量（升/分钟O2concentrationlevel氧气浓度等Howmuchoxygeninsidethepipe管道里有多少氧Visualinspection:Compliant外观视觉检 符合（是/否Result:compliantyes/no)oftheexternalvisualinspectionareentered焊点的外观检查是否符合Visualinspection:Rejection外观检查：代Iftheweldwasnotcompliant,therejectioncodewillbefilledinhere.IftheweldiscompliantthiscellwillbekeptN/A.如果焊缝不符合，填上不符合代号 如果符合，该列填写Endoscopicinspection:Compliant内窥镜合（是/否Result:compliant?(yes/no)oftheendoscopicinspectionare填写内窥镜检查的结果是否符合（是/否Endoscopicinspection:Rejection内窥镜检查：代Iftheweldwasnotcompliant,therejectioncodewillbefilledinhere.IftheweldiscompliantthiscellwillbekeptN/A.如果焊缝不符合，填上不符合代号 如果符合，该列填写Weldinginspector:Sign焊接检验员：签Theldinginspctrsignsofhrefrheinspcinshedidnhselds.Wldinginspcrisrspnsiblefrndscpicinspcin.焊接检验员在此对他做过检查的焊缝签字，检验员对内窥镜检Weldinginspector:焊接检验员：日Dateonwhichtheinspectionoftheweldoccurred焊接检验Registrationiscarriedoutasfollows记录工作进行如下Theweldercompletescolumn1uptoandincludingcolumn12焊工完成填112Thesitesupervisorfillinthecolumns13and14现场主管完1314Theweldinginspectorcompletescolumns15to18;1518AlineisdeletedifaweldceasestobevalidforthefollowingTheweldisnolongerrequiredintheinstallation该焊点不再需Theweldisgrounddownandredonebecauseofrejectionoftheweld;该焊缝被而切了Theweldisgrounddownandredonebecauseofchangestotheinstallation.该焊缝由于安Re-ngoraddingwelds重焊或增加焊点Wheneverweldsareredoneasaresultofadjustmentsorerrors,thecorrespondingregistrationintheweldinglogmustbere-enteredbythewelderonanewlineintheweldinglog.Thenewweldisgiventhesamenumberplusaletterofthealphabet(A,B,C,etc.).Example:weld1isredoneand es:1A.Iftheweldisredoneagain,it es:1B,andsoAdaptationtofieldweldsmustalsobenoted.现场的焊点调整也要做Weldsthatareaddedaregivenanewnumberfollowingonfromthehighestnumberoftheweldisometric.Theaddedweldisnotgiventhenumberoftheweldnolongervalid.Inthecaseofrejectedwelds,thereasonforrejectionistobeincludedintheNon-conformitylistandanon-conformityreportmustbegenerated. Weldsummaryreport焊接总结报Foreachsystemwewillprepareanoverviewofhowmanyweldsareexecutedforthatsystem,howmanyweldsareinspected,visuallyandbyendoscope,howmanyweldsareinspectedbythethirdpartyinspectorandhowmanyweldswererejected. ENCLOSURES附WORKDIRECTIVES工作指NotapplicableTESTSHEETS测试 Coversheet封 Summaryreport总结报 PQR&WPS焊接工艺评定报告和工艺指导 ReferencesampleWeldinglogsheet参考焊样焊 DailysampleWeldinglogsheet每日焊接记 Weldinglogsheet焊接记 Heatnumbertraceability热处理号追 Non-conformitylist不符合GLOSSARY术Fieldweld(FW)Weconsiderthatweldsdoneonsiteas‘fieldwelds’.Because‘fieldwelds’oftenhavetobecarriedoutindifficultcircumstances,specialattentionispaidtosuchweldsduringinspection.现场焊接（FW）我们认为该类焊点是在施工现场完成的焊接。由于现场焊接经常在环境状况恶劣条件下进Shopweld(SW)Weconsiderthatweldsdoneintheworkshopas‘shopwelds’.Whennningweldingwork,‘shopwelds’haspreferenceover‘fieldwelds’becauseintheworkshopwecancreatetheidealsituationtoguaranteethequalityoftheweld.预制焊接（SW）我们认为该类焊点是在焊接预制车间完成的。在计划焊接工作时，预制焊优先于现场焊接，因为在车间里我们能创造一个理想的环境以保证焊接质量。Compliant符合：Eachstageofatestorinspectionisanactionthatproducesaresult.Theanticipatedresultandacceptancecriteriaarereportedforeachstage/action.Iftheactualresultmeetstheacceptancecriteria,suchtestorinspectionstageisconsideredcompliant.Fault错误 Errorordeficiencyinanywork.任何工作中的错误或缺陷Comment评述:ObservationorcriticismthatdoesnotinfluencePass/ Thefinalresultofatestor LogNo.: Eachiteminthefaultandcomment