焊工培训与考核程序

WelderTrainingandQualificationProcedure焊工培训与考评程序PROJECTPROCEDURE:PR-8710-8100-0026项目程序:PR-8710-8100-0026REV版次DATE日期REASONFORISSUE修订原因BY编制Chk’d审核QA审查APPR同意A16SepIssueforReviewB07OctIssueforApproval0029OctIssueforUse0115Nov.IssueforUseContent目录TOC\h\z\t"样式1,1"1. Purpose目标 42. Scope范围 43. Definition定义 44. References相关文件 55. Responsibility职责 66. Procedure程序 77. Record统计 138. Attachments附录 14版次Ver.章节号SectionNo.主要修改内容Descriptionofmainchanges01All“SEPCO1andSEPCO2“ischangedto“SEPCO1/2”.将程序中SEPCO1和SEPCO2改为SEPCO1/23DefinitionofSEPCOisadded.增加了对SEPCO定义4GBcodeandHBcodereferencesareadded.增加了国家标准、行标等参考标准5增加了SEPCO1/2项目经理职责Projectmanagerresiponsebilityisadded.将”进行任何焊工测试之前最少二十四小时通知BSF”改为进行任何焊工测试之前最少48小时通知BSF“NotifyingBSFaminimumof24hoursinadvanceofanyweldertests”ischangeto“NotifyingBSFaminimumof48hoursinadvanceofanyweldertests”.5.3Addingcontentofresponsebilitiesaboutleader,weldingengineerandNDEengineerinweldexaminationteam.增加了焊工考试小组中领队、焊接工程师和NDE工程师职责。6.4.4Relevantdetailsaboutweldtestingareadded.增加了焊缝检验相关内容8AppendixD,EandAppendixFareadded.增加了附录D、附录E和附录F。1．Purpose目标ThisprocedureregulatetheweldertrainingandtestmanagementinCSPCNanhaiPetrochemicalsProject,ensureeverywelderintheprojectqualifiedinaccordancewithapplicablestandardandfulfillprojectweldingworkrequirement,andensurequalifiedwelderinweldingwork.规范南海石化项目SEPCO焊工培训与考评管理，使参加项目施工焊工依照适用标准取得对应资格证书，满足项目焊接施工需要，确保合格焊工从事对应焊接工作。2.Scope范围TheprocedureappliedSEPCOweldertrainandtestworkinSteam&PowerProject.本程序适适用于汽电联产项目SEPCO焊工培训和考评工作。3.Definition定义3.1SEPCO山东电力基本建设总企业ShandongElectricPowerConstructionCorporation3.2SEPCO1/2 山东电力建设一、二企业SEPCONo.1/2ConstructionCompany.3.3 WeldControlManual(WCM)焊接控制手册（WCM）TheWCMisthecompilationofweldingprocedures,Weldheattreatment,non-destructiveexamination,positivematerialidentificationprocedures,andForm167(orEquivalent)WeldingandNDEMatrixissuedbySEPCOforprojectusetofulfilltherequirementsoftheCSPCNanhaiSteam&PowerProject.WCM汇编了由SEPCO公布焊接程序、焊接热处理程序、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应用于项目中以落实CSPC南海汽电联产项目标要求。4.References参考资料4.1PR-8710-8100-0025焊接程序WeldingProgram4.2PR-8710-8100-0038焊接控制WeldingControl4.3ASMEStandardⅨWeldingandBrazingQuanlificationASME标准第Ⅸ卷焊接和钎焊评定4.4AWSD1.1SteelConstructionWeldingRegulationAWSD1.1钢结构焊接规范4.5WI-8710-8100-0003C焊接材料控制WeldingMaterialControl4.6PR-8710-8100-0213NDE管理程序NDEManagementProcedure4.7PR-8710-8100-0215焊接热处理程序WeldingHeatTreatmeantProcedure4.8WI-8710-8100-0022WCM文件GeneralWeldingStandards(GWS)通用焊接标准(GWS)4.9ASMESectionI[PowerBoilers].ASME第一卷[动力锅炉]4.10ASMESectionVIII[PressureVessels].ASME第八卷[压力容器]4.11ASMESectionV[Non-destructiveExamination].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]4.12DL5007-92TheCodeOfErectionandAcceptanceforPowerPlantConstractionWeldingSection电力建设施工及验收技术规范（焊接篇）4.13DL/T822-TheCodeofTheWeldingTeatTreatmentforPowerPlant火力发电厂焊接热处理技术规程4.14ASMEB31.1[动力管道]ASMEB31.5[制冷管道]GB3323-87<Radiogramandqualitygradeofbutt-jointforsteelfusion-weiding>GB3323-87《钢熔化焊对接接头射线摄影和质量分级》5.Responsibilities职责5.1 SEPCOConstructionManagerSEPCO施工经理SEPCOconstructionmanagerisresponsibleforimplementingtheweldertestingprogrambysub-contractorsonsite. SEPCO施工经理负责落实分包商现场进行焊工考试计划。5.2ProjectmanagerofSEPCO1/2SEPCO一/二企业项目经理Responsibleforsupvisingandreviewingweldertestingandqualification.SEPCO1/2项目经理负责监督与审核焊工考试和资格评定。5.3 WelderExaminationTeam焊工考评小组5.3.1Leader领队：Reviewingwelderqualification,PQRandWPS.Organizingweiderexamination.审查焊工资格，审核工艺评定汇报和焊接工艺规程，组织进行焊工考试。5.3.2Weldingengineer焊接工程师：Constitutingwelderexaminationplan.Organizingexaminationatsite.Beresponsiblefordisciplineofexaminationroom.Transactingweldercard.Establishingandmanageringwelderarchives.制订焊工考试计划，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。5.3.3NDEengineerNDE工程师：Responsiblefortestingexaminationingouttestingreport.负责考试试件检验，出具检验汇报。5.4 SEPCOFieldWeldingEngineerSEPCO现场焊接工程师NotifyingBSFaminimumof48hoursinadvanceofanyweldertests,givingthelocationandnumberofwelderstobetested,includingtheapplicableWPS.在进行任何焊工测试之前最少48小时通知BSF，说明测试地点、要测试焊工人数及适用WPS。Responsibleforissuingtherequiredweldercertificationinatimelymanner,priortothewelder(s)commencingworkonpermanentfacilities.负责焊工在永久设施上开始作业之前，及时颁发必需焊工证书。5.5 CMDweldingengineerfromSEPCO1/2 一、二企业施工部焊接工程师Entireresponsibleforalltheweldertrainingandtestincludingweldingequipmentpreparation、weldingworkpiecepreparation、theoryandtechnicaltrainingguiding、testingworkpiecemachined、checkexamine、trainingresultreviewandsoon,andputupweldertrainingrecord.全方面负责全部焊工培训和考评工作，包含焊接设备准备、焊件准备、理论和技能培训指导、试件加工、检验试验、培训结果评定等，并建立焊工培训档案。5.6Weldingengineerfromconstruction(orErection)team施工队或工程处焊接工程师Responsibleforcooperatingweldertrainingandtestmanagementincludingself’sweldertrainingplan、weldingmaterialpreparation、steelstructureweldertrainingandhighpressureweldertrainingcommissionandsoon。各专业工程处负责配合做好焊工培训和考评管理工作，包含编制本单位焊工培训计划、准备焊接材料、钢结构焊工培训及高压焊工培训委托等。6.Procedure程序6.1 General总则6.1.1SEPCO1/2havecontractualresponsibilityforweldertrainingprograms.WhenacontractordeemsthathisweldershavebeenproperlytrainedfortheirintendedworkontheCSPCNanhaiPetrochemicalsProjectandhavepassedthetestsgivenbytheappropriateChineseLaborBureau,eachwelderand/orweldingoperatorshallpassawelderqualificationtestconductedonsiteatthecontractorstestfacilitybeforebeingpermittedtoperformanyweldingonsite.依照协议要求，SEPCO1/2应负责执行焊工培训计划。假如承包商认为焊工已经得到了CSPC南海石化项目关于作业适当培训，且已经经过中国劳动局举行相关考试，则在允许焊工现场作业之前，每个焊工和/或焊接操作员必须经过在承包商测试设施上现场举行焊工资格认定测试。6.1.2Aftersuccessfultesting,welderswillberequiredtoattendatrainingclassgivenbySEPCOtoexplainthebasicprojectweldingrequirements.测试经过后，要求焊工参加SEPCO为说明项目焊接基本要求举行培训班。6.1.3 SEPCO1/2weldersaresubjecttoperformancereviewatalltimesbytheBSFLFWEorFWE.Wheneverdeemedappropriateornecessaryduetounacceptablerepairrates,aweldermaybeaskedtore-performqualificationtestingbyBSFinthecontractorsweldertestingfacilityatthecontractorsexpense.SEPCO1/2焊工将随时接收BSFLFWE或FWE表现评审。不论何时，因为不能接收返修率而认为适宜或必要时，可能要求焊工重新进行BSF在承包商焊工测试设施上要求资格认定测试，测试费用由承包商负担。6.1.4QualificationtestingofSEPCO1/2welderswillbeconductedunderthesupervisionoftheSEPCOweldingengineer.EachContractorshallensurethateachwelderisproperlytrainedandqualifiedforperformanceofweldingonthedesignatedCSPCNanhaiPetrochemicalscontract.SEPCO1/2焊工资格认定测试由SEPCO焊接工程师监督执行。各承包商应确保每个焊工接收适当培训，并能胜任在指定CSPC南海石化协议项下焊接工作。6.2WelderTrainingWorkProgress焊工培训工作流程6.2.1SEPCO1/2shallprovidealist(s)ofweldercandidatestoperformweldingtrainingontheCSPCNanhaiproject. SEPCO1/2应提供接收CSPC南海项目焊接培训焊工名单。6.2.2 SEPCO1/2shallprovidetheirweldercandidateswithclassroomtrainingandpracticalshopdemonstrationsoftheweldingprocessesastheydeemnecessary.SEPCO1/2areresponsibletoensurethateachwelderhasbeentestedbytheappropriateChineseLaborBureau.SEPCO1/2应依照需要，为报考焊工提供课堂培训，并实际演示该项目标焊接方法。SEPCO1/2应确保每个焊工均已经过中国劳动局举行相关考试。6.2.3 WeldingEngineerDepartmentrevieweveryengineerdepartment’strainingplanandthewelders’qualification,andwritesiteweldertrainingplanandwelderlistaboutthetrainingwhichwillbeapprovedbySEPCO1/2projectchiefengineer. 焊接工程处审核各工程处焊工培训计划和参加培训焊工资质，编制工地焊工培训计划和参加培训焊工名单，报一、二企业项目总工同意。6.2.4 Inaccordancewiththeapprovedtrainingplanandthewelderlist,SEPCO1/2arrangethetrainingincludingtheorytrainandtechnicaltrain.按照同意焊工培训计划和参加培训焊工名单，由SEPCO1/2统一安排培训，包含理论培训和技能培训。6.3 WelderTestingFacility焊工测试设备6.3.1 SEPCO1/2shallprovideanappropriateweldingtestingfacilityat-site.ThefacilityshallbesuitablefortestingwelderstointernationalCodestandards,togetherwithadequatefumeextraction,andaseparatescreenedtestboothforeachwelder.SEPCO1/2应提供适当现场焊接测试设施。设施应适合于对焊工进行符合国际法规标准测试，并可充分排烟，每个焊工应有独立遮蔽测试间。6.3.2 Thetestfacilityshallbeprovidedwithsafeandcalibratedweldingequipmentforeachoftheintendedweldingprocesses,allweldingequipmentshallbemaintainedingoodworkingorderatalltimes.Unsafe,uncalibrated,damaged,and/orunusableweldingequipmentshallberemovedfromthetestfacility.对每种拟测试焊接方法，测试设备均应安全可靠且已经过校准，全部焊接设备应一直保持良好工作状态。不安全、未经校准、损坏和/或不能使用焊接设备应停顿使用。6.3.3 Eachweldingmachineshallbeprovidedwithsuitablecablesandattachments(holders,earthclamps,etc)thatareingoodsafeworkingorder,anyfoundtobeunsafeshouldberemoved.每台焊接机器应具备状态良好适宜电缆及附件（保持器、接地夹等），应停顿使用发觉任何不安全机器。6.3.4 Testfacilitiesshallhavesuitablebakingandholdingovensfortheweldingfillermetalused.Asaminimumfillermetalshallbetreatedinaccordancewiththemanufacturersrecommendations. 测试设施应具备适当供焊接填充金属使用烘焙炉与保持炉。最少应依照制造商提议方法处理填充金属。6.3.5 Allweldersshallbeprovidedwithsuitableandsafehandtools(grinders,brushes,etc),andpersonnelprotectiveequipment(PPE)forperformingweldingoperations. 应向全部焊工提供进行焊接作业所需适宜安全手开工具（磨光机、刷子等）以及个人安全保护器材(PPE)。6.4 WelderQualificationWorkProgress焊工资格认定流程6.4.1 Whenacontractordeemsthathisweldercandidate(s)havedemonstratedtheabilityduringtrainingtoperformsoundweldsand/orhavepassedtheappropriateChineseLaborBureautests,SEPCO1/2weldingengineershouldsubmitconcernedwelders’trainingandtestdocumentswhichincludebutnotislimitedto: 假如SEPCO1/2认为其焊工候选人在培训期间表现出了优异焊接能力和/或已经过中国劳动局相关测试，SEPCO1/2焊接工程师需向SEPCO提交焊工培训及考评相关资料。这些资料包含但不限于： a)Concernedtestifieddocumentsaboutwelder’squalificationandapprovedexaminationonChineseLaborBureau; 焊工焊接作业资格及经过中国劳动局测试相关证实材料； b)WPS、PQRaboutthewelderqualifyingtest; 焊接测试相关WPS、PQR； c)Concernedtestifieddocumentsaboutthesiteconditionsaccordingtoexaminationrequirementsincluding:siteequipmentadjustingrecord、weldingrodandmaterialtestifydocuments、storeandwithdrawalrecord; 现场符合测试要求相关说明。包含：现场设备校准统计、焊条及焊材证实文件、存放及领用统计；d)TheappropriatecontrolformsshallbeinapprovedspecificationwiththeprojectWCMthatisissuedinaccordancewithSEPCOprocedurePR-8710-8100-0025,WeldingProgram.依照SEPCOPR-8710-8100-0025焊接程序公布WCM中应有适宜控制表格。6.4.2 SEPCOshallnotifyBSFaminimumof48hoursinadvanceofanyweldertests,givingthelocationandnumberofwelderstobetested,includingtheapplicableWPS. SEPCO应在进行任何焊工测试之前最少48小时通知BSF，说明测试地点、要测试焊工人数及适用WPS。6.4.3 SEPCO1/2shalltesteachwelderemployedontheCSPCNanhaiSteam&PowerProjectinaccordancewithanapprovedProjectProcedure/Specification. SEPCO1/2应按照同意项目程序/规范测试CSPC南海汽电联产项目所用每个焊工。6.4.4SEPCOweldengineers;intogetherwithcounterpartsfromBSF,willtakeoverallreviews,includingdocument,materials,andworkpiece,weldspotappearance.Non-destructivetest,aftertheappearanceinspectionofweldedworkpiecehasbeenprovedtobequalified,shallbeapplied.SEPCO焊接工程师和BSF代表对焊接文件、焊接材料、试件细节、焊缝外观进行检验。焊缝外观合格后，才能进行无损检验；Non-destructivetestshallbedoneintheselectionsofMT,PT,UTandRTetc.andnon-destructivetestmustbeimplementedbythosewhoarequalifiedthroughprofessionalskilltrainingandexamination.无损检验采取磁粉、着色、超声波、射线等方法，且必须由经过专业培训考评且取得对应方法合格证人员来完成。6.4.5 Awelderisallowedamaximumoftwoattemptsataweldingqualification.Ifawelderisconsideredacceptableforre-testinghe/sheshallundergoafurtheragreedtrainingperiodpriortoare-test.Followingre-trainingthewelderisonlyallowedonere-test,ifthewelderfallsthisre-testhe/sheshallnotbeallowedtoworkontheNanHaiproject. 一个焊工最多只允许尝试进行两次焊接资格认定。假如认为某位焊工可进行再次测试，在再次测试之前，这位焊工应参加经过协商深入培训。再次培训之后，仅允许焊工进行一次再次测试，假如该焊工仍不能经过测试，则应禁止其在南海项目中工作。6.4.6 Whentheweldersuccessfullypassestheappropriatequalificationtest,he/sheisrequiredtoattendatrainingclassforexplaintheweldinggeneralworkrequirementsoftheCSPCNanhaiPetrochemicalsProject. 焊工成功经过相关资格认定测试后，要求其参加说明CSPC南海石化项目通用焊接作业要求举行培训班。6.4.7 Followingsuccessfulqualification,SEPCOshallissueeachwelderapersonalIDCard,whichshallbeararecentphotographofthewelderandtheweldersuniqueIDnumber,togetherwiththelistoftherelevantapprovedqualificationsonthereverse(second)side.TheweldershallcarrythisIDCardatalltimeswhenworkingontheCSPCNanhaiPetrochemicalsProject.SEPCOshallhaveadifferentnumberingsystemfromothercontractors,andtheuniquewelderidentificationnumbergiventoeachweldershallnotbere-issuedtoanyotherwelderduringthelifeoftheCSPCNanHaiproject. 资格认定合格之后，SEPCO应采取不一样于其余承包商编号系统，在整个CSPC南海项目期间，向每个焊工发放唯一焊工识别号不得再向其余任何焊工发放。6.4.8 ThewelderIDcardNo.usedbySEPCOisnumberedas:SEPCO--W。ThefirstgroupisSEPCO1/2;thesecondgroupiswelder’sprojectIDNumber;thethirdgroupisserialnumber,WisabbreviationofwordWelder. SEPCO使用焊工个人识别号编号为：SEPCO--W。第一组为SEPCO1/2；第二组为焊工出入证号；第三组为流水号，W为Welder缩写。6.4.9 Priortothecommencementofanyworkonsite,allwelders,weldingoperatorsand/ortackweldersshallbequalifiedtotheapplicableapprovedContractorwelderqualificationstandards.ThesestandardsforweldingqualificationshallbeincludedintheprojectWCM.Onprocesspipingthefirsttwoproductionbuttweldsforeachnewlyqualifiedweldershallberadiographed. 全部焊工、焊接操作员和/或点焊工在现场开始任何作业之前，应具备同意相关承包商焊工资格认定标准资格。焊接资格认定这些标准应囊括在项目WCM内。对于程序管道系统，每个刚才取得资格认定焊工焊接头两个对接焊缝应采取射线摄影进行检验。7.Record统计7.1 SEPCO1/2shallmaintaintestrecordlistsonadailybasisforallwelderqualifications,weeklyqualificationmaintenancelogs,welder’sweldrejectrecordsandanyotherrecordsassociatedwiththetestingandqualificationofwelders,andshallissueallwelderqualificationcertificatesforSEPCOapproval.SEPCO1/2应每日保留全部焊工资格认定测试统计清单、每七天资格认定维护统计、焊工焊接不合格统计以及与焊工测试和资格认定相关任何其余统计，并发放经过SEPCO同意全部合格焊工资格认定证书。Duringtheweldertraining,theteachershouldfillinwelder焊工培训过程中，焊接教练要填写焊工操作技能培训统计表；Fillinweldertechnicalevaluationsheetaftercompletingqualificationexamination;焊工完成资格认定测试后，要填写焊工技能评定表；Weldingteachershouldkeepthenewestwelderqualificationrecordincludingrejectsrates.焊接教练应保持最新焊工资格认定统计，包含不合格率；SEPCOwelderengineershouldsubmitcopyofwelderqualificationrecordweekly.SEPCO焊接工程师每七天向BSF提交焊工资格认定统计副本。8. Attachments附录8.1 AttachmentA Welderoperationtechnicaltrainingrecord附录A焊工操作技能培训统计表8.2AttachmentB Weldertechnicalevaluationsheet附录B焊工技能评定表8.3AttachmentC Flowchart 附录C 流程图8.4AttachmentDListofWelderExaminationTeamMembers附录D焊工考评小组组员名单8.5AttachmentE WPSforweldertrainingandskillappraisal附录E焊工考试用WPS8.6AttachmentFQualifiedWelderList附录F合格焊工名单AttachmentA附录A Welderoperationtechnicaltrainingrecordsheet焊工操作技能培训统计表Name姓名WelderNo.焊工代号Regulation规格Material材料Weldingtechnical焊接工艺WeldIingrod焊条Position试件位置WeldingProcedure焊接程序WeldIingwire焊丝ConnectionStyle接头型式Date日期WorkpieceNo.试件编号TechnicalCondition工艺情况Result结果AppearanceQuality外观质量Result结果InternalQuality内部质量Result结果Score得分TrainingCharge: TrainingCoach:培训责任人： 培训教练：AttachmentB附表B: AttachedFormB: 焊工技能评定表WelderSkillAppraisalSheet项目编码ProjectCode:项目名称ProjectName:日期Date:焊工姓名WelderName:证号CertificateNo:钢印号SteelStampNo：考试类型TestCategory：焊接工艺方法WeldProcess:使用WPS:母材MaterialBaseMetal:厚度Thickness:手工或半自动变素/每种方法ManualorSemi-AutomaticWeldingProcesses实际值MeasuredValue评定范围EvaluatedScope衬垫pad(金属、焊缝金属等metal)(填fillin“是yes”或or“否no”)ASMEP-No.toP-No.P-No.FORMDROPDOWNFORMTEXTP-No.FORMDROPDOWNFORMTEXTtoP-No.FORMDROPDOWNFORMTEXTFORMCHECKBOX板plateFORMCHECKBOX管pipe(若是管,填直径writedowndiameterforpipematerial)填充金属metaltopack:;类别category填充金属metaltopackF-No.(工艺process#1/工艺process#2)熔化性嵌条moltenpackingrod(GTAW)(填fillin“是yes”或or“否no”)#1工艺焊缝熔敷厚度moltenweldthicknessin#1process#2工艺焊缝熔敷厚度moltenweldthicknessin#2process焊接位置weldinglocation焊接方向(上坡焊/下坡焊)weldingorientation(upward/downward)反面保护气(填“是”或“否”)backprotectiveweld(yesorno)熔化极气体保护焊过渡形式transitdisposalinweldwithpolarizedliquefiedgasprotection钨极气体保护焊电流类型/极性currenttypeinweldwithtungstengasprotection/polarity其它结果otherresult类型type接收拒绝不适用inapplicable位置外观检验:appearanceinspectionFORMCHECKBOXFORMCHECKBOXFORMCHECKBOX射线检验结果:RTinspectionFORMCHECKBOXFORMCHECKBOXFORMCHECKBOX焊接试验执行人WeldingTestUndertaker:试验室试验编号LaboratoryNo:兹证实本汇报记载正确，且测试试样是依照ASME规范第IX卷要求进行准备、焊接和试验。Thisistocertifythatthisreportisrecordedwithoutfalse.Weldingtestsamplesareprepared,testedinaccordancewithrequirementinASMESpecificationVolume9现场焊接工程师:日期Date: AttachmentCFlowchart附录C 流程图IssuewelderIDcard颁发焊工个人识别卡WelderEnter焊工进场TheoryTrain理论培训TheoryTestPass理论考试合格BSFprofessionwitnessthetestatsite联络BSF教授现场资格认定测试见证Jointhetrainingclassclarifyingprojectweldingrequirements参加说明项目焊接要求培训班SiteTechnicalQualificationTest现场技能资格认定测试Contractor