钢结构工程目测工艺.doc

Doosan Babcock
Project：UTE Pecem & Itaqui
Visual Inspection Procedure
Document No: 06361/HHSF/MI/22350/X./0715
Page 4 of 4
Issue: C

Visual Inspection Procedure
目视检测工艺
1. Introduction: 引言
As in order to ensure UTE PECEM & ITAQUI Power Projects steel structures with qualified welds and as a result to get our own welding quality and welding control to a higher level, we will apply visual check, acceptance check to the welds fully comply with AWS D 1.1-2008 <> and relative contract technical specification. 为了确保UTE PECEM & ITAQUI. （电力工程的钢结构焊接合格以及让我们自己的焊接质量和焊接控制达到一个更高的水平，我们将通过焊接目测及验收使其完全符合 AWS D 1.1<<结构焊接标准>>以及相关的合同技术规范。）
2. References and Standards: 参考标准
Visual inspection shall be implemented with referenced to Table 6.1-Visual Inspection Acceptance Criteria and Figure 5.4-Acceptable and Unacceptable Weld Profiles of AWS D1.1-2008. （目视检测参考标准严格执行AWS D1.1-2008中有关焊缝的外形及尺寸要求，如表6.1（目检验收标准）；图5.4（合格和不合格焊缝剖面形状）。）
3. Safety and Environment: 安全与环境
3.1. In order to prevent from electricity harms, all the electric facilities and working pieces must contact the ground, the operating area must be keeping dry, and the operators must wear gloves and rubber-soled shoes. Whenever damaged electrical wires was found shall be discarded right away. （为了避免电流噪声的伤害，所有的电力设施和工作件必须保持和地面接触，作业区必须保持干燥并且操作者一定要戴上手套穿上胶鞋。损坏的电线一经发现应立即丢弃。）
3.2. In order to prevent from the harmful dust, fumes and arc, every operator must wear protective equipments such as gauze face mask, glasses and etc. （为了防止有害粉尘，烟雾及弧光，每个操作者必须穿防护装备例如纱布口罩，眼镜等等。）
3.3. The operators shall wear earplugs to protect themselves away from noises in the shop floor. （为了防止自己在车间受到噪音干扰操作者需戴上耳塞。）
3.4. In order to prevent from any harms from molten metal, spark, welding spatter and heat arises in welding, cutting operation, the operators must wear boot (or otherwise with leg wrapping), fireproofing gloves and head (face) mask. （为了防止从熔融金属，火花，焊溅物以及焊接高温，切割作业中受到任何伤害，操作者必须穿靴子（或其他的腿部保护），戴上防火手套以及头（面）罩。）
3.5. All the steel members shall be stacked in a manner orderly, steadily and easy for inspection. （所有钢构件应有序，稳定的堆叠以便于检查。）
3.6. Enough lighting shall be furnished at workshop. Necessary lighting equipment such as torch shall be furnished to check some hidden areas. （车间要有足够的照明。必要的照明设备如手电筒可以检查隐秘的地方。）
4. Inspection Personnel: 检验人员资质
4.1. Certified welding inspector (CWI) by AWS (check the PJP welds on columns and plate girders). AWS焊接认证人员（在圆柱和板梁上检验本分熔透焊缝）
4.2. Certified quality personnel involved in construction industry. 从事建筑行业的质量认证人员。
4.3. Trained inspectors by the CWI, they will perform under controlling and supervising of the CWI. 焊接检测师培训检验人员，他们将在焊接检测室监控下工作。
5. Inspection Conditions: 检验条件
5.1 The distance between eyes and the tested surface shall not exceed 600mm in direct visual inspection. The angle between sighting line and the tested surface shall be no smaller than 30°. Mirrors may be used to improve the angle of vision.（直接目测检验时，眼睛与被检表面的距离不得大于600mm，视线与被检表面所成的视角不小于30°，使用镜子可以改善视角）
5.2 The tested surface shall be given adequate lighting, generally not less than 1000 Iux.（被检的表面应有足够的照明，一般检验时光照度不得低于1000 Iux）
5.3 Also the magnifying glass shall be used for tiny defect inspection.（可以使用2～5倍的放大镜，对细小缺陷进行鉴别）
5.4 Such tools as weld leg scale, magnifying glass, flashlight, etc shall be used for inspection.（要配备检验的工具如焊脚尺、放大镜和手电筒等）
6. Procedures to be Implemented: 检验程序
6.1 Inspection prior to Welding 焊前检验
6.1.1 Inspection of Trial-Assembly Components（预组构件的检查）
① The groove forms, groove angle, groove depth and the blunt edges shall comply with the requirements of WPS.（预组构件的坡口形式、坡口角度、坡口深度及钝边应符合焊接工艺及规范要求）
② The fusion face shall be free from such defects like interlayers, cracks, damages, burs, etc. （坡口面不得有夹层、裂纹、加工损伤及毛刺等缺陷）
③ The groove of low-carbon steel and alloy steel as well as the neighboring areas within 25mm shall be free from moisture, grease, dust, organic coatings, galvanizing or other foreign substances, which might damage the welding quality. （低碳钢及合金钢坡口及其附近25mm范围内的母材表面不得附有水份、油脂、污垢、有机涂层、镀层等影响焊接质量的物质）
6.1.2 Assembled Components Inspection构件组对检查
After components are assembled, the matches and gaps between the components shall be inspected. The unfitness, angle gap and distortion of butt joints, the length and gaps of lap joints and the gaps between T-joints and corner joints shall comply with the requirements indicated in 5.22 and 5.23 of AWS D1.1:2008. （构件组对后，应检查接头贴合面、组对间隙、接头错边、等进行检查；T型接头和角接接头的间隙应符合焊接工艺及AWS D1.1:2008中5.22及5.23的规定）
6.1.3 Welding Materials Inspection 焊接材料的检查
① Electrodes, wires and flux shall have Material Certificates or Re-test Reports and the quality shall comply with the requirements indicated in 5.3 of AWS D1.1:2008. 焊条、焊丝、焊剂必须具备产品质量证明书或复试报告，质量指标应符合AWS D1.1:2008中5.3条规定；
② The electrodes and flux shall be baked according to Welding Consumable Control Procedure (06361/HHSF/WP/22350/X./0722). （焊条、焊剂的烘干，应符合焊材管理办法的规范要求）
6.1.4 Preheating Inspection 预热检查
The preheating temperature shall be measured with temperature pens, thermometers, thermocouples or infrared thermometers, to ensure the preheating temperature, its extent and distribution complying with WPS (06361-HHSF-WP-22350-X.-0707). （预热温度应用测温笔、温度计、热电偶或红外线测温仪进行测量，预热温度、预热宽度及温度的分布应符合焊接工艺要求）
6.2 Welding Inspection 焊接检验
6.2.1 Welding methods, operations and sequences shall comply with WPS (06361-HHSF-WP-22350-X.-0707). （焊接方法、焊接操作方式、焊接顺序应符合焊接工艺要求）
6.2.2 For manual arc welding, submerged arc welding and gas-shielded welding, the welding parameters shall be checked to ensure their complying with WPS (06361-HHSF-WP-22350-X.-0707). （有线能量要求的手工电弧焊、埋弧焊及气体保护焊等应对焊接工艺参数进行检查，焊接参数应符合焊接工艺要求）
6.2.3 Interlayer surfaces shall be inspected after cleaning, to make sure that the interlayer surfaces, joints between welding pass and grooves, and groove surfaces shall be clean and free from the cracks, slag, porosity, etc. （多层焊道清理后的层间表面应进行检查，层间表面、焊道与坡口的接合部位及坡口表面应清洁、无裂纹、夹渣、气孔等缺陷）
6.2.4 Interpass temperature of welding passes that need preheating shall be controlled to be the same with preheating temperature.（有预热要求的焊道应注意层间温度的控制，层间的温度与预热温度要求相同）
6.2.5 For base metal required preheating, unwelded welds after a pause，the preheating temperature should meet the temperature required by the process before restarting welding. （母材有预热要求的焊缝，未焊接完的焊缝进行停顿，重新进行焊接前，须重新进行预热达至工艺要求温度）
6.2.6 The surface shape of welds after back gouging shall comply with the requirements of WPS (06361-HHSF-WP-22350-X.-0707), and the surface shall be free from defects like incomplete fusion, slag, porosity, cracks, etc. （焊接背面清根后的表面形状应符合焊接工艺的要求，表面不得有未融合、夹渣、气孔、裂纹等缺陷）
6.3 Inspection after Welding 焊接后检验
6.3.1 Inspection Tools 检验工具
Welding inspection ruler, measuring gauges and other inspection equipments shall be calibrated and approved by Qualified Inspection Department.（检验时的焊接检验尺、量具和仪器必须经计量检定部门的检验合格）
6.3.2 Inspection after welding shall be performed after welds cleaning to ensure the Welds and the areas around free from slag and spatter.（焊接后检查应在焊缝清理完毕后进行，焊缝及焊缝附近区域不得有焊渣及飞溅）
6.3.3 After welding, the weld length shall be inspected to make sure the actual weld length not less than the required length in drawings and also to make sure the spacing between welds not larger than the spacing stipulated in drawings. （焊后应检查焊缝长度，焊缝长度不得小于图纸规定长度，焊缝间隔不得大于图纸规定长度）
6.3.4 Visual inspection of welds surface shall be done prior to NDE inspection and seal inspection (if NDT is required). The acceptance criterion shall be as per Form 6.1 of AWS D1.1:2008.焊缝表面目测应在无损检查、密封试验前进行（有要求做无损检测时）；焊缝目检验收标准为AWS D1.1:2008中表6.1；
6.3.5 If post welding heat treatment is needed, the heating rate, heating temperature, warm holding time, cooling rate, difference in temperature of various parts during different stages and the heat-expansion and cold-contraction in each part shall be inspected. The heating range shall also be inspected for welds that are local heat treated. Inspection results shall meet the requirements of Heat Treatment Procedure and Clause 5.8 of AWS D1.1:2008.（焊后热处理应检查加热速度、加热温度、保温时间、冷却速度、各阶段各部位的温差及各部位的热胀冷缩量。对于局部热处理的焊缝还应检查加热范围。检查结果应符合热处理工艺要求及AWS D1.1:2008中5.8要求）
7. NCRs and Repairs: 不合格品及返修
7.1 Once non-conformance welds are found in finished products during visual or NED inspection, such products shall be segregated and disposed in accordance with Non-Conformance Management Procedure and no further fabrication actions or following procedures shall proceed. Meanwhile, the responsible inspector shall issue the NCR Report (Appendix-A in Non-Conformance Management Procedure) and subimt this report to Chief Engineer for review. （检验员目测或无损检测检查时，发现不合格焊缝，需按照《不合格品管理程序》进行处理。对不合格焊缝的构件进行隔离，禁止流入下道工序；检验员同时要开据《不合格报告书》，并提交经总工程师审核）
7.2 After reviewing the NCR report, Chief Engineer shall put forward feasible repair proposals or methods in due time. Without Chief engineer’s approval, no repair actions shall be applied to the non-conformance products. （总工程师在审核完NCR报告后，需在恰当的时间内提出可行的返修建议或整改方法；未经总工程师审核通过，工厂不可对不合格品进行整修）
7.3 Inspectors should clear know defects position, defects properties, cause, and repair requirements before repairing. Repair more than twice should be approved by client’s technical engineer.（返修前焊接质检员应清楚了解焊接缺陷位置、性质、原因及返修要求，两次以上的返修需经客户技术人员审批）
7.4 The surface after defects removed shall meet repair requirements, and the length removed be 50mm longer than the defective length of both ends, and have a certain slope（清除缺陷后的焊接表面，应能满足焊接修补的要求，清除长度应比缺陷长度两端各长50mm，并有一定的坡度）.
7.5 Inspection of welding repair shall be required as the same as the official welding inspection. （焊接返修的检查应和正式焊接焊缝检查的要求相同）
7.6 Non-Conformance Report shall be closed in time by the responsible inspector once the repaired products pass double-inspection.（整改复检合格后，相关检验员应及时关闭《不合格报告书》）