新编塔架焊接工艺规程.docx

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NO: 3MW-01～2-T

焊 接 工 艺 规 程

产品名称 SL3000项目塔架
产品编号 3MW-01～2-T
图 号 T6010002

编 制 年 月 日

审 核 年 月 日

青岛海洋热电化工设备有限公司

NO: 3MW-01～2-T

Welding Procedure Specification

Product Name: Tower of SL3000 Project
Product No. 3MW-01～2-T
Drawing No. T6010002

Prepared by Wang Peng August 5th ,

Reviewed by year month day

Qingdao Haiyang Thermoelectrical Chemical Equipment Co., Ltd.

焊接工艺规程目录

序 号
名 称
页 数
备 注
1
接头编号表
8

2
焊接材料汇总表
2

3
接头焊接工艺卡
58

4
焊缝返修工艺要求
2

5
技术要求
2

6

7

编制: 年 月 日 审核: 年 月 日

Welding Procedure Specification Contents

No.
Description
Pages
Remark
1
Joint No. Sheet
4

2
Welding Consumables Summary
1

3
Joint Welding Procedure Card
29

4
Weld Repair Technology Requirement
1

5
Technical Requirement
1

6

7

Prepared by: Wang Peng August 5th , Reviewed by: year month day

接 头 编 号 表

接头编号示意图

编制: 年 月 日 审核: 年 月 日

Joint No. Sheet

Joint No. sketch :

Prepared by: Wang Peng August 5th , Reviewed by: year month day

接 头 编 号 表
焊 接 工 艺 规 程
接头编号
接头焊接
工艺卡编号
无损检测要求
注:1、 内件焊接用焊接材料按焊接材料汇总表, 焊角高度按图纸要求。
2、 无损检测要求如下:
(1)所有焊缝必须进行100%的VT检查,按照EN ISO 5817 B级执行。
(2)超声波检验, 按照JB4730- 标准I级要求执行。
塔筒纵向焊缝、 环向焊缝、 塔筒法兰和筒体过渡处的环向焊缝、 门框和焊接筒体之间过渡处的连续焊缝都必须进行100%UT检查。
( 3) 塔架法兰和筒节的T型焊缝接头处根据JB4730- 均布片射探; 筒节与筒节处的T型焊缝接头按照100%数量进行布片射探, 每个T型布片2张, 胶片长度为300mm, 级别为Ⅱ级。
( 4) 塔筒法兰和筒体之间环向焊缝、 门框和筒体之间连续焊缝须进行100%MT检查,结果符合JB4730- .4Ⅰ级合格; 附件连接板焊接焊缝总数的20% 进行100%PT检查, 结果符合JB4730- .5Ⅰ级合格。
3、 经射线或超声检测的焊接接头, 如有不允许的缺陷, 应在缺陷清除后进行补焊, 并对该部位采用原检测方法重新检查直至合格。进行局部探伤的焊接接头, 发现有不允许的缺陷时, 应在该缺陷两端的延伸部位增加检查长度, 增加的长度为该焊接接头长度的10%, 且不小于250mm。若仍有不允许缺陷时, 则对该焊缝做100%检测。
4、 焊缝需要返修时, 其返修工艺应符合焊接工艺要求。焊缝同一部位的返修次数不应超过两次, 如超过两次, 返修前应经用户单位技术总负责人批准, 返修次数, 返修部位和返修情况应如实记入质量证明资料。
5、 仅产品编号为3MW-01-T代产品试板, 其余以批代台。

A1( 带试板) A2
HJ-01
见注2
A3( 带试板)
HJ-02
见注2
A4( 带试板)
HJ-03
见注2
A5( 带试板)
HJ-04
见注2
A6( 带试板)
HJ-05
见注2
A7( 带试板)
HJ-06
见注2
A8( 带试板)
HJ-07
见注2
A9( 带试板)
HJ-08
见注2
A10( 带试板)
HJ-09
见注2
A11( 带试板) A12
HJ-10
见注2
A13( 带试板)
HJ-11
见注2
A14( 带试板)
HJ-12
见注2
A15( 带试板) A16
HJ-13
见注2
A17( 带试板)
HJ-14
见注2
A18( 带试板)
HJ-15
见注2
A19( 带试板)
HJ-16
见注2
A20( 带试板)
HJ-17
见注2
A21( 带试板) A22
HJ-18
见注2
A23( 带试板) A24 A25
HJ-19
见注2
A26( 带试板) A27
HJ-20
见注2
A28( 带试板) A29 A30
HJ-21

编制: 年 月 日 审核: 年 月 日

Joint No. Sheet
Welding Procedure Specification
Joint No.
Joint Welding Procedure Card No.
NDT Requirement
Note: 1.The welding consumables for internals welding as per Welding Consumables Summary, the fillet weld height as per drawing requirement.
2、 NDT requirements are as follows::
(1) All welds must be performed 100% VT, as per EN ISO 5817 B Class.
(2) UT as per JB4730- I Class.
Perform 100% UT to LW and CW of towers 、 CW of transition between tower flange and tube、 continuous weld on transition between doorframe and welding tube.
( 3) Perform NDT to T weld joint of flange and tube as perJB4730- ; Perform test on 100% quantity of T weld joint between tubes, arrange 2 films for each T type, with length 300mm, II class.
( 4) Perform 100% MT to CW between flange and tube、 continuous weld between doorframe and tube, result complying with JB4730- .4 I Class is acceptable. Perform 20% PT to 20% amount of welds of attachments connection plate, result complying with JB4730- .5 I Class is acceptable.
3、 For the welding joint tested with RT or UT, if there is defect, perform welding repair after clearing the defect, and re-test the part with original method until accepted. For the welding joint tested partly, if there is defect, add length of the extended part of the two ends of defect, the added length should be 10% of the welding joint length, and not less than 250mm. if there is still defect, perform 100% test to the welding joint.
4、 The repair technology should comply with the welding technology requirement when weld needs repair. The same part on weld should not exceed twice repair, if exceeds, it should be approved by the technology general responsible person of user before repair. The repair times、 repair position and repair situation should be recorded in quality certificate.
5、 Only the product No. 3MW-01-T shall have test plate, others in lot in place of set.
A1( with template) A2
HJ-01
see
see Note 2.
A3( with template)
HJ-02
see Note 2.
A4( with template)
HJ-03
see Note 2.
A5( with template)
HJ-04
see Note 2.
A6( with template)
HJ-05
see Note 2.
A7( with template)
HJ-06
see Note 2.
A8( with template)
HJ-07
see Note 2.
A9( with template)
HJ-08
see Note 2.
A10( with template)
HJ-09
see Note 2.
A11( with template) A12
HJ-10
see Note 2.
A13( with template)
HJ-11
see Note 2.
A14( with template)
HJ-12
see Note 2.
A15( with template) A16
HJ-13
see Note 2.
A17( with template)
HJ-14
see Note 2.
A18( with template)
HJ-15
see Note 2.
A19( with template)
HJ-16
see Note 2.
A20( with template)
HJ-17
see Note 2.
A21( with template) A22
HJ-18
see Note 2.
A23( with template) A24 A25
HJ-19
see Note 2.
A26( with template) A27
HJ-20
see Note 2.
A28( with template) A29 A30
HJ-21

Prepared by: Wang Peng August 5th , Reviewed by: year month day

接 头 编 号 表
焊 接 工 艺 规 程
接头编号
接头焊接
工艺卡编号
无损检测要求

A31( 带试板) A32 A36
HJ-22
见注2
A33( 带试板) A34 A35
HJ-23
见注2
B1
HJ-24
见注2
B2
HJ-01
见注2
B3
HJ-02
见注2
B4
HJ-03
见注2
B5
HJ-04
见注2
B6
HJ-05
见注2
B7 B8
HJ-25
见注2
B9
HJ-07
见注2
B10
HJ-08
见注2
B11
HJ-09
见注2
B12 B13
HJ-10
见注2
B14
HJ-11
见注2
B15
HJ-12
见注2
B16 B17
HJ-26
见注2
B18
HJ-13
见注2
B19
HJ-14
见注2
B20
HJ-15
见注2
B21
HJ-16
见注2
B22
HJ-17
见注2
编制: 年 月 日 审核: 年 月 日

Joint No. Sheet
Welding Procedure Specification
Joint No.
Joint Welding Procedure Card No.
NDT Requirement

A31( with template) A32 A36
HJ-22
see Note 2.
A33( with template) A34 A35
HJ-23
see Note 2.
B1
HJ-24
see Note 2.
B2
HJ-01
see Note 2.
B3
HJ-02
see Note 2.
B4
HJ-03
see Note 2.
B5
HJ-04
see Note 2.
B6
HJ-05
see Note 2.
B7 B8
HJ-25
see Note 2.
B9
HJ-07
see Note 2.
B10
HJ-08
see Note 2.
B11
HJ-09
see Note 2.
B12 B13
HJ-10
see Note 2.
B14
HJ-11
see Note 2.
B15
HJ-12
see Note 2.
B16 B17
HJ-26
see Note 2.
B18
HJ-13
see Note 2.
B19
HJ-14
see Note 2.
B20
HJ-15
see Note 2.
B21
HJ-16
see Note 2.
B22
HJ-17
see Note 2.
Prepared by: Wang Peng August 5th , Reviewed by: year month day
接 头 编 号 表
焊 接 工 艺 规 程
接头编号
接头焊接
工艺卡编号
无损检测要求

B23 B24
HJ-18
见注2
B25 B28
HJ-19
见注2
B26 B27
HJ-27
见注2
B29 B30
HJ-20
见注2
B31 B32 B33
HJ-21
见注2
B34 B35
HJ-22
见注2
B36 B37 B38 B39
HJ-23
见注2
B40
HJ-28
见注2
D1
HJ-29
见注2

编制: 年 月 日 审核: 年 月 日

Joint No. Sheet
Welding Procedure Specification
Joint No.
Joint Welding Procedure Card No.
NDT Requirement

B23 B24
HJ-18
see Note 2.
B25 B28
HJ-19
see Note 2.
B26 B27
HJ-27
see Note 2.
B29 B30
HJ-20
see Note 2.
B31 B32 B33
HJ-21
see Note 2.
B34 B35
HJ-22
see Note 2.
B36 B37 B38 B39
HJ-23
see Note 2.
B40
HJ-28
see Note 2.
D1
HJ-29
see Note 2.

Prepared by: Wang Peng August 5th , Reviewed by: year month day
焊 接 材 料 汇 总 表
焊 接 工 艺 规 程

母 材
焊 条 电 弧 焊 SMAW
埋 弧 焊 SAW
气 体 保 护 焊 GTAW/GMAW
焊条
规格
烘干温度/时间
焊丝
规格
焊剂
烘干温度/时间
焊丝/规格
保护气体
纯 度
Q345E、 Q345E-Z25
+Q345E、 Q345E-Z35、 Q345E-Z25

H10Mn2
Ф4
SJ101
300-400℃/2h
THY-51A/Ф1.2
CO2
99.8%

编制: 年 月 日 审核: 年 月 日
Welding Consumables Summary
Welding Procedure Specification

Base metal
SMAW
SAW
GTAW/GMAW
Welding rode
specifications
Drying temperature/time
Welding wire
specifications
flux
Drying temperature/time
Welding wire/specifications
Shielding gas
purity
Q345E、 Q345E-Z25
+Q345E、 Q345E-Z35、 Q345E-Z25

H10Mn2
Ф4
SJ101
300-400℃/2h
THY-51A/Ф1.2
CO2
99.8%

Prepared by: Wang Peng August 5th , Reviewed by: year month day
焊 接 工 艺 规 程
焊 缝 返 修 工 艺 要 求

1、 焊缝外观经检查不合格, 返修时其工艺要求应遵照下表规定进行。

规 格 类 型
返 修 工 艺 要 求
焊缝尺寸不符合要求, 弧坑及缺陷
采用熔化极气体保护焊, 按相应要求进行补焊, 并用砂轮认真修磨, 使其与原焊缝或母材圆滑过渡。
咬边
焊接接头不允许有咬边。
气孔、 砂眼、 裂纹
先用碳弧气刨, 将缺陷清除干净( 包括前后20mm) , 并用砂轮修磨后再补焊, 最后用砂轮修磨。
高低不平, 宽窄不一或焊缝高度突变
先用碳弧气刨, 根据具体情况清除, 用砂轮修磨, 再用熔化极气体保护焊补焊, 最后再用砂轮进行修磨, 使其与母材或焊缝圆滑过渡。
注: 1、 焊接材料及规范参数同原工艺。
2、 对于内在缺陷, 应用碳弧气刨清除, 确认后, 用砂轮修磨后再补焊, 焊后检查项目及要求同原要求, 最后再用砂轮修磨, 使其与原焊缝和母材圆滑过渡。焊补工艺应遵照《焊接接头返修、 申请处理单》的规定进行 。
3、 焊缝返修时, 焊工应具有原焊缝焊接资格, 且应由技术熟练者担任。在返修过程中应接受检验人员的监督, 返修后按规定打上返修焊工钢印。
编制: 年 月 日 审核: 年 月 日
Welding Procedure Specification
Weld Repair Technology Requirement

1、 If the weld appearance is not accepted, the technology requirement during repair as per the specification in the table below.

Specification and Type
Weld Repair Technology Requirement
The weld size doesn’t comply with the requirement, crater and defect
Apply GMAW, welding repair as per corresponding requirement, polish with grinding wheel to ensure smooth transition with original weld or base metal.
undercut
Undercut on welding joint is not allowed.
blowhole、 sand hole、 crack
Clean the defect with carbon arc gouging,(including 20mm front and back), polish with grinding wheel and then welding repair.
Uneven, varies in width or weld height prominent
Clean with carbon arc gouging as per specific situation, polish with grinding wheel, welding repair with GMAT, and finally polish with grinding wheel finally, to ensure smooth transition with base metal or original weld .
Note: 1. The welding consumables and specifications are the same with original technology.
2、 For inner defect, cleaned with carbon arc gouging, polished with grinding wheel after confirmation and then perform welding repair. The check items and requirement after welding is the same with original requirement, to make smooth transition between original weld and base metal. Welding repair technology should follow《Welding joint repair、 disposal application sheet》.
3、 During the repair of the weld, the welder should be qualified to the original weld and with experienced skill. Receive the supervision of inspector during repair, die-stamping the repair welder stamp after repair according to the specifications.
Prepared by: Wang Peng August 5th , Reviewed by: year month day

接 头 焊 接 工 艺 卡
接头简图:

注: 对于不等厚的对接, 较厚处按图纸削薄。
操作注意事项:
1、 坡口角度及间隙要符合工艺要求。
2、 埋弧焊焊接时注意不要焊偏。
3、 每层焊完后应认真清除熔渣, 如发现表面存在缺陷应用砂轮清除后进行补焊, 并修磨平整, 再继续施焊。
4、 焊件施焊前, 应在始焊处100mm范围内预热到100-125℃以上。
5、 定位焊采用熔化极气体保护焊, 焊接材料为THY-51A。
接头焊接工艺卡编号
HJ-01
接头形式
对接
焊接工艺评定报告编号
PQR-02B
母 材
Q345E-Z25
厚度, mm
53
Q345E-Z25
53
焊 缝
金 属

厚度, mm

焊工持证项目
SAW-1G( K) -07/09
焊接位置
平焊
层
焊接方法
填充材料
焊接电流
电弧电压(V)
焊接速度(m/h)
线能量(kJ/cm)
背面清根方式
碳弧气刨、 砂轮机
牌 号
直径
极性
电流(A)
预热温度(℃)
≥100
1、 2、 3
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-31
28.3-32
24.8
层间温度(℃)
100～140
4、 5、 6
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-31
28.3-32
24.8
焊后热处理
消除应力
7、 8、 9
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-34
28.8-35
26.7
后 热

10、 11、 12
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-34
28.8-35
26.7
钨极直径

13、 14
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-35
25.7-35
30.8
喷嘴直径

脉冲频率

脉宽比(%)

气体成分

气体流量

编制: 年 月 日 审核: 年 月 日

Joint Welding Procedure Card
Joint sketch:

Note: For butt welding with differenrt thickness,the thickner position should be tapered as per drawing.
Operation notes:
1、 The bevel angle and clearance shall comply with technology requirement.
2、 Do not appear slanting welding during SAM.
3、 Clean carefully the slag after welding each layer, if there is surface defect, clean with grinding wheel and then welding repair, polish to flat, then continue welding.
4、 Preheat within range of 100mm of the welding starting position to above 100℃ -125℃ before welding.
5、 Tacking welding with GMAW, welding consumable is THY-51A。
Joint Welding Procedure Card No.
HJ-01
Joint type
Butt-welding
PQR No.
PQR-02B
base metal
Q345E-Z25
thickness, mm
53
Q345E-Z25
53
Weld metal

thickness, mm

welder
certified
item
SAW-1G( K) -07/09
welding position
flat welding
layer
welding method
filling material
welding current
arc voltage (V)
speed (m/h)
energy input (kJ/cm)
Back gouging method
Carbon arc gouging、 grinding wheel

brand
diameter
polarity
current (A)

preheat temperature (℃)
≥100
1、 2、 3
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-31
28.3-32
24.8
interlayer temperature (℃)
100～140
4、 5、 6
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-31
28.3-32
24.8
post-weld heat treatment
Eliminate stress
7、 8、 9
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-34
28.8-35
26.7
post heat

10、 11、 12
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-34
28.8-35
26.7
tungsten electrode diameter

13、 14
SAW
H10Mn2/SJ101
Φ4
DC-
550-630
28-35
25.7-35
30.8
nozzle diameter

impulse frequency