焊接控制.doc

Cspc Nanhai Petrochemicals Project
SEPCO Electric Power Construction Corp

CSPC NANHAI PETROCHEMICALS PROJECT

CSPC 南海石化项目

WELDING CONTROL

焊接控制

PROJECT PROCEDURE: PR-8710-8100-0038

项目程序: PR-8710-8100-0038

SEPCO Electric Power Construction Corporation

山东电力基本建设总公司

REV版次
DATE
日期
REASON FOR ISSUE
修订原因
BY
编制
Chk’d 审核
QA
审查
APPR 批准
A
21 Aug 2003
Issued for Review
ZRC
LMX
XLR
GGS
B
13Sept. 2003
Issued for Review
ZRC
LH
GSX
LJG
00
7 Oct 2003
Issued for Approve
ZRC
LH
GSX
YJQ
01
20 Oct 2003
Issued for Use
ZRC
GWJ
LWD
LJG
02
28Nov.2003
Issued for Use
GWJ
LWD
GSX
YJQ

修改记录
Revision Information

版次
Rev
章节号
Section No.
主要修改内容
Description of main changes
02
3.
Modify “QC1,QC2,QC3” to “QC1-W,QC2-W,QC3-W”
Attachment pages
Modify “QC1,QC2,QC3” to “QC1-W,QC2-W,QC3-W”
Attachment
Adding “thickness report”,” grade assessed sheet for subentry project”,modify” Weld Record Acceptance Sheet”

WELDING CONTROL焊接控制

目 录TABLE OF CONTENTS

No Page

1. 目的 Purpose 64
2. 范围 Scope 64
3. 定义 Definition 64
4. 参考文件 Reference 64
5. 职责 Responsibilities 64
6. 程序 Instruction 75
7. 记录Records 1815
8. 附件 Attachments 1916
1． 目的 Purpose
本程序规范了中海壳牌南海石化工程汽电联产项目中SEPCO对SEP1/2进行焊接控制、焊接热处理和探伤的监督，以确保其符合工程设计及规范的要求。This procedure provides the SEPCO requirements for monitoring SEP1/2 in their control of welding, post weld heat treatment, and NDE, to ensure them compliance with applicable project, design and Code requirements, on the Steam & Power Project of CSPC Nanhai Petrochemicals Project.
2． 范围 Scope
本程序适用于SEP1/2在中海壳牌南海石化工程汽电联产项目永久厂房的制造和安装的过程中进行的焊接，焊接热处理及探伤活动。This procedure applies to SEP1/2 welding, post weld heat treatment, and NDE activities during fabrication and installation of permanent plant items on the Steam & Power Project of CSPC Nanhai Petrochemicals Project.
3． 定义 Definitions
SEP1/2 山东电力建设一、二公司 SEPCO No.1/2 Construction Company
CMD 施工管理部Construction Manager Department
QC1-W 焊接焊工施工班组Welding WelderErection Group
QC2-W 施工队或 工程处焊接质检或焊接工程师Welding Inspector or Welding Engineer Of of Construction (or Erection) Team
QC3-W 一、二公司施工部焊接质检或焊接工程师CMD Welding InspectorInspector or Welding Engineer Of of SEP1, SEP2
4． 参考文件 References
PR-8710-8100-0025 焊接程序Welding Program
PR-8710-8100-0026 焊工培训与考核程序 Welder Training and Qualification Procedure
WI-8710-8100-0003C 焊接材料控制 Weld Material Control
PR-8710-8100-0055 测量和校验设备Measuring and Test Equipment
5． 职责 Responsibilities
5.1 SEP1/2焊接工程师负责各自施工范围内焊接程序、程序资格认定测试、WPS 以及 PQR 资格认定记录的现场准备、发布并维持；
SEP1/2 welding engineer shall prepare, issue, and maintain welding procedures, procedure qualification testing, WPS, and PQR qualification records at site in his responsible construction area respectively.
5.2 SEP1/2 NDE工程师负责各自施工范围内无损检测程序准备、发布和维持；
SEP1/2 NDE engineer shall prepare, issue, and maintain NDE procedures in his responsible construction area respectively.
5.3 CMD焊接工程师负责焊接全过程的监督管理，包括有关作业文件的审批。负责与BSF及有关方的协调和沟通；CMD welding engineer is responsible for the supervision of overall welding operations, including review and approval of job documents, coordination and contact with BSF in relevant aspects.
5.4 焊接施工班组焊工(QC1-W)负责自己所焊焊缝的外观检查。

Welding WelderErection group (QC1-W) will check the weld after complete welding operation.
5.5 施工队或工程处焊接质检或焊接工程师(QC2-W)、，公司级一、二公司施工部焊接质检或焊接工程师(QC3-W)负责按比例对焊缝进行外观检查和验收。
Welding inspector or welding engineer from construction (or Erection) team (QC2-W), CMD welding inspector or welding engineer from SEP1 or SEP2 (QC3-W) will check and accept the weld in proportion.
6． 程序 Procedure
6.1 焊接技术管理 Management of Welding Technique
6.1.1 SEP1/2工地级焊接工程师根据工程需要和要求确定各自的焊接工艺评定任务，具体组织实施，并将焊接工艺评定报告报CMD、BSF焊接工程师批准；
Welding engineers at jobsite from SEP1/2, in response to construction requirement, shall know their respective welding quality requirements, do good arrangement of actual operations and then submit welding PQRs to CMD、BSF welding engineer for approval.
6.1.2 根据批准的焊接工艺评定报告，由SEP1/2工地级焊接工程师编制用于南海石化汽电联产项目焊接施工的焊接工艺规程（WPS），报CMD及BSF焊接工程师审批；
With approved welding procedure qualification record, welding engineers from SEP1 /2 shall prepare Welding Process Specification for CSPC Nanhai Petrochemicals Complex Steam & Power Project, and also submit it to CMD and BSF welding engineers for review and approval.
6.1.3 SEP1/2各专业工程处（施工处）负责焊接的技术员工程师，根据施工图纸及有关规范、标准和程序编制主要焊接工程一览表，绘制主要焊接工程施工技术记录图。主要焊接工程一览表应包括各种管道的等级和采用的焊接工艺规程（WPS）。还应包括焊后热处理、无损检测、硬度或金相试验，以及材料光谱分析（PMI）的频率。主要焊接工程一览表报BSF焊接工程师批准后出版、发放，发放范围包括CMD焊接和热处理技术员工程师、焊接质检员和无损检测人员。
All welding techniciansengineers from SEP1/2 Construction (or Erection) Divisionteamss shall , in accordance with construction drawings and relevant specification, standard and procedure, prepare the Weld Task Schedule and Major Weld Operation Technique Diagram. Weld Task Schedule shall cover all piping grades, applied weld process, also post-weld heat treatment, non-destructive test, hardness/metallographic test, material spectral analysis. Major Weld Operation Technique Diagram, after submitted to BSF weld engineer for approval, shall be issued to all CMD personnel who are responsible for weld, heat treatment, quality inspector and non-destructive test techniciansengineers.
6.1.4 SEP1/2工地级焊接工程师制定主要焊接工程作业指导书编制计划，报CMD批准，并由PMC审核后实施；Welding engineers from SEP1/2 shall prepare the Documentation Requirement of Major Weld Operation Guide, then submit it to CMD and PMC review for approval prior to its implementation.
6.1.5 专业工程处（施工处）的焊接技术员工程师根据焊接作业指导书编制计划，编写本单位焊接作业指导书，并送CMD和PMC审批；
Welding techniciansengineers from Construction (or Erection) teams respective construction divisions shall, in response to Documentation Requirement of Major Weld Operation Guide, prepare their own Weld Operation Guide and then submit it to CMD and PMC for approval.
6.1.6 SEP1/2需编写通用焊接标准（GWS），并上报SEPCO项目部，由CMD和PMC审批：
SEP1/2 should write General Welding Standard(GWS), and submit to SEPCO CMD and PMC for approval.
6.1.6 7 各工程处（施工处）焊接技术员工程师根据图纸、变更文件编制指导施工的焊缝记录单。焊缝记录单见附录14；焊接技术员工程师应将以下内容有关信息填写或打印到记录单中：
Welding techniciansengineers from all Construction (or Erection) teamsconstruction divisions shall, in accordance with drawing and change order, prepare their Weld Record Sheet. Weld Record Sheet in Attachment 14. Welding techniciansengineers shall write down the following information onto record sheet.

选用的焊接程序（从经CMD批准的焊接程序中选取）selected weld procedure (select among weld procedures approved by CMD)
系统号/管线号（或部件号）system ident.no./pipeline ident.no.
焊接材料型号 weld material model
焊缝号（现场设计的小口径管道可一条管线或一张图纸共用一张记录单，在附页中记录焊缝号）
weld ident. No (for small bore design at jobsite, one sheet of record may be used for either one section pipe or one sheet of drawing, with weld indet.No in attached page)
焊接标准 weld standard
母材材质、规格 material specification and size
ITP编号 ITP numbering
焊缝细节 weld details
预热和热处理要求/NDE方法、比例等。Requirement on preheating and heat treatment/NDE
method, proportion, etc.
6.1.78 以上焊接信息由焊接技术员工程师编制汇总成表后，交专职工程师或技术组长审查。
The above weld information, after documented by welding engineer into forms, will be submitted to discipline engineer or technique team leader for review and approval.
6.1.89 专业工程处（施工处）焊接技术人员工程师，应深入现场检查焊接作业指导书的执行情况，及时解决施工中的技术问题，并做好焊接施工技术记录；
Welding techniciansengineers from Construction (or Erection) teams construction divisions shall remain at jobsite to inspect the implementation of Weld Operation Guide, so as to timely solve any technique problem and keep good record of weld performance.
6.1.910 工地级焊接工程师，在指导各工程处（施工处）焊接技术管理的同时，应深入现场，做好现场的技术监督；
Welding engineers at jobsite, mean while giving weld technique guide to weld operators from Construction (or Erection) teamsrespective construction divisions, shall stay at jobsite for the purpose of strengthening technical supervision at jobsite.
6.1.101 工程处（施工处）焊接技术人员工程师做好焊接竣工资料的整理和工程总结，工地级焊接工程师做好竣工资料的审核和焊接工程总结工作。
Welding techniciansengineers from Construction (or Erection) teamsconstruction divisions shall make preparation of as-built information and work summary in weld aspect , and while welding engineers shall be responsible for these information review and then developing summary about weld work.
6.2 焊工培训 Welder Training
执行PR-8710-8100-0026焊工培训与考核 execute PR-8710-8100-0026 Welder Training and Examination
6.3 焊接材料管理 Weld Material Management
执行WI-8710-8100-0003C焊接材料控制 execute WI-8710-8100-0003C Weld Material Control
6.4 焊接设备管理 Weld Equipment Management
6.4.1 各专业工程处（施工处）负责所使用焊接设备的日常维护、保养，并做好维护、保养记录；物资机械部负责对焊接设备的维修，并对焊接设备的维护、保养进行监督检查。
All Construction (or Erection) teamsconstruction divisions shall do good management of weld equipment, such as daily maintenance, keeping record, while material/machinery divisions shall insist on supervision and inspection of weld equipment maintenance and repair.
6.4.2 焊接及热处理设备的测量表计，应按期进行校验，确保工艺参数准确可靠，具体执行PR-8710-8100-0055 测量和试验设备
Measuring gauge or meter for weld and heat treatment equipment must have current calibration certificate and be re-calibrated as required to insure accurate technical parameters by executing PR-8710-8100-0055 Measuring and Test Equipment.
6.5 工地焊接 Weld Operation at Jobsite
6.5.1 重要系统或重大项目开工前，应由焊接工程师对焊工进行技术交底。焊接的准备工作（车间或现场）应根据SEPCO已获批准的GWS去做。
Welding engineers shall give technical explanation to welder prior to the commence of key or
major work items. Welding preparation (In workshop or jobsite) shall be done in accordance with SEPCO approved General Welding Standard (GWS).
6.5.2安装班组负责现场管道焊缝号的标识，焊工根据焊缝记录单现场核对焊缝编号后进行工作。焊工在每条焊缝焊完后，认真清理，检查合格后，在焊缝附近用油性记号笔（不锈钢必须使用专用记号笔）标出焊缝号、焊工号及完成日期。
Installation team shall be responsible for the identification of pipe weld location at jobsite, while welder, for doing specified weld operation in accordance with weld identification no. in reference to Weld Record Sheet. Welder must, after completing any weld operation, make clear, and then mark with oily pen (or with specially purpose pen if welding on stainless steel) the weld indent. No. welder numbering and completion date.
6.5.3现场设计的管道，管道工程师应在管道立体竣工草图上，标注焊缝位置。
For piping designed at jobsite, piping engineers shall mark weld location at three-dimensional
piping as-built sketch.
6.5.4对于公称直径大于80mm的大口径管道焊缝由于变更文件而造成的数量增加，应按照PR-8710-8100-0047 “设计变更控制”要求进行。Possibly more big bore pipe 80mm or larger nominal diameter because of change requirement shall be dealt with in accordance with PR-8710-8100-0047 Design Change Control.
6.5.5 工地级焊接质检员应对工地的焊接活动，进行随机监督，并做好记录。监督记录见附录K。
Welding Quality Inspector shall maintain random supervision of welding activities at jobsite, and keep sound record, as seen in Attachment K for supervision record.
6.5.6 如果焊缝有见证点（W点）或停工待检点（H点），工程处（施工处）焊接技术人员应及时通知工地级焊接质检员会同CMD焊接质检员进行检查H点必须等有关人员检查完, 并在焊缝记录单上有关栏中签字，焊接班长才允许焊工施焊。
If Witness Point or Hold Point has been confirmed in weld operation, welding techniciansengineers shall time notify welding quality inspector to do inspection in coordination with CMD welding inspector. Weld team leader shall no right to assume weld operation at Hold Point until authorized inspectors have concluded the quality inspection and signed on appropriate column in Weld Record Sheet.
6.5.7在施焊之前，焊工应根据有关的程序，检查坡口组对，确认符合要求时，在焊缝记录单上相应的栏目内签字后方能进行施焊。
Before weld operation, welder shall, in accordance with relevant procedure, inspect weld point status. No welding is permitted until confirming its being in compliance with requirement and then signing at appropriate column in Weld Record Sheet.
6.5.8对于φDN≥150159的I类管道焊缝，必须由焊接技术人员工程师或焊接质检员检查坡口组对合格后，并在坡口组对栏签字后方可施焊。其余焊缝，焊接技术人员或焊接质检员进行抽查。
For Class 1 weld withφ DN≥150,9 welding techniciansengineers or weld quality inspector must first inspect weld-point status, then sign on appropriate column in sheet prior to conducting weld operation. For other weld operation, welding techniciansengineers or quality inspectors shall take random inspection of welding result.
6.5.9焊缝完成后，焊接工程师技术人员应及时通知工地级焊接质检员和CMD焊接质检员进行验收。
After having finished the weld operation, welding engineerstechnician shall make a prompt notification to welding quality inspector and CMD quality inspectors counterpart for acceptance.
6.5.10管道焊接验收后，记录在相应的焊缝记录单上。
The acceptance results of pipeline weld shall be recorded on corresponding Weld Record Sheet.

6.5.11有编号的大口径支吊架和钢结构焊缝，验收后记录在支吊架/钢结构验收记录单上。（支吊架/钢结构验收记录单见附录12）
For welding of numbered large bore pipe hanger and steel structure with it, the acceptance result shall be recorded on Acceptance Record Sheet of Hanger and Steel Structure (See Attachment 12).

6.5.12小口径支吊架及没有编号的支吊架施工时，现场巡检，管线检查时验收并记录在相应的管线检查记录上。
For small bore pipe hanger and same ones but without numbering, following up inspection and pipeline work acceptance shall require recording on appropriate record sheet.
6.5.13记录单上的焊缝完成后，焊接质检员或焊接工程师及相关检验人员应在记录单正面中的“焊缝外观检查”栏内签字，表示该批焊缝已完成外观验收
Welding quality inspector or welding engineer shall, after the weld operation has been finished as required on record sheet, sign in the column of Weld Appearance Inspection, indicating the appearance acceptance passes through.
6.5.14焊接准备应符合 WPS 中所说明的详细规定。如果进行了热切割，焊接准备就需要进行打磨或机械加工，以去除切割热影响区.
The weld operation shall be prepared in compliance with detailed requirement given in WPS. If hot cutting has been done, weld preparation must include grinding or machining it for the purpose of eliminating the effect caused by hot cutting.
6.5.15准备铁基钢所使用的手工工具（砂轮、钢丝刷等）不得用于奥氏体钢。不锈钢丝刷只能用于不锈钢或镍合金。Some manual grinding tool (such as grinding wheel, steel wire brush, etc) used for machining carbon steel material shall not be used on austenic steel. Similarly stainless steel brush is only permitted for stainless or nickel alloy.
6.5.16在暴露场所，如果气候状况（风、雨等）无法保证焊接符合要求的规范标准和质量，施工单位必须提供有遮盖的预防措施，或者在安装好此类遮盖物之前暂停作业。如果要焊接的部件表面是湿的，或者天气刮大风，则不能进行焊接作业，除非焊工和/或操作者及工件得到了正确的防护。如果接头表面潮湿，应通过加热喷灯、批准的溶剂、预热设备或其他设计批准的方法进行干燥。
In the open site where weather elements cause the weld not up to required standard and quality, construction division shall take precautions against adverse influence prior to conducting welding operation. In the case of weld member being wet in surface or heavy wind being blown, welder and/or operator must be well protected at the meanwhile the weld member has been properly treated. The contact between weld members, if in humid, should be pretreated by means of heating lamp, approved solvent, also other drying solution.
6.5.17应采用夹钳、焊接夹子、临时点焊或其他合适的方式正确装配以便焊接。除低合金钢可采用低碳钢焊条与碳钢附件相焊接，奥氏体不锈钢可采用奥氏体焊料与碳素钢相焊接外，用于装配的焊接式附件材料应与母材相匹配。
Clamp fixation, instant spot welding or other suitable means should be used for proper welding. Apart from low alloy steel being appropriate for the welding