焊接专业施工组织设计27804.docx
目录第一章 工程概况及编制依据·························································11.1工程概况·····································································11.2编制制依据···························································································21.3主要要焊接工工程量及及焊接方方法····································································2第二章 项目组组织机构构设置··············································································72.1 焊接人人员的配配备及职职责···········································································72.2 焊焊接人员员应具备备的资格格条件····································································992.3 焊接组组织机构构·····················································································10第三章 焊接材材料管理理··················································································1103.1 焊接材材料管理理制度················································································1103.2 焊接材材料检验验制度················································································1113.3 焊接材材料复查查检验················································································1113.4 焊接材材料保管管制度················································································1123.5 焊接材材料烘干干制度················································································1123.6 焊接材材料发放放及回收收制度········································································1133.7 过期焊焊接材料料处理制制度···········································································13第四章 焊接机机械设备备管理··············································································134.1 焊接用用气体的的供应及及布置·······································································1334.2 焊机电电源及焊焊机集装装箱布置置·····································································1334.3 热处理理机电源源及热处处理机布布置···································································144.4 焊接材材料烘干干机电源源及布置置·····································································1444.5 焊接机机械设备备管理··················································································14第五章 主要施施工方案案和技术术措施·······································································1445.1 焊接工工艺评定定及焊工工的岗前前培训·······························································1445.2 焊接方方法····························································································1555.3 焊接坡坡口形式式及组装装要求········································································1175.4 焊接工工艺及热热处理规规范···········································································195.5 焊接接接头质量量检验················································································2265.6 不合格格焊口处处理···················································································265.7 焊接过过程管理理·····················································································27 5.88 质质量检验验及验收收··················································································228第六章 重要部部件或特特殊钢材材的焊接接施工方方案·······················································296.1 SA3335-P911焊接施施工方案案········································································296.2 SA2213-T911焊接施施工方案案········································································316.3 15NNiCuuMoNNb5(WWB366)焊接接施工方方案····························································32第七章创优优工程焊焊接工艺艺质量要要求···································································337.1 TT/P991高合合金耐热热钢焊接接工艺质质量要求求························································337.2奥氏氏体不锈锈钢及镍镍基合金金管焊接接工技术术要求···················································357.3中低低压管道道焊接工工艺质量量要求······································································36第八章 焊接质质量管理理及质量量保证措措施································································368.1 施工质质量目标标·····················································································368.2 质量管管理···························································································378.3 质量保保证措施施·····················································································378.4 施工各各个环节节的控制制与检查查····································································388.5 特殊条条件下焊焊接质量量保证措措施·································································3388.6 焊接接接头的标标识···················································································388.7 质量标标准···························································································38第九章 焊接施施工中的的环境保保护、劳劳动防护护及安全全文明施施工·····································3389.1 执行标标准····························································································389.2 安全方方针···························································································399.3 安全目目标···························································································399.4 安全文文明施工工管理体体系···········································································399.5 环境因因素识别别与评价价·············································································399.6 危害因因素识别别与评价价·············································································399.7 应急准准备及响响应···················································································399.8 安全文文明施工工措施················································································4429.9 安全生生产保证证措施················································································4429.10 安全全危害因因素辨识识控制··········································································429.11 环境境因素评评价及控控制············································································459.12 安全全操作规规程····················································································469.13 特殊殊情况下下焊接施施工安全全措施································································4479.14 竣工工后的资资料移交交··············································································5509.15 焊接接作业指指导书编编制计划划·····································································51第十章 强制性性条文的的执行计计划和措措施································································51附录I:焊焊接工艺艺评定目目录及应应用范围围统计表表························································55附录:本本工程常常用钢材材性能一一览表···································································57附录:本本工程常常用焊接接材料性性能一览览表·······························································59附录:本本工程焊焊接一览览表················································································62附录:环环境因素素分析及及评价表········································································68附录:危危害辨识识、风险评评价及控控制对策策表···························································70焊接专业施施工组织织设计第一章 工程概概况及编编制依据据1.1工程程概况1.1.11AAAAAAAAAAAAAAAAAAAAAAAAAAAAA工程程AAAAAAAAAAAAAAAAA锅炉炉为哈尔尔滨锅炉炉厂有限限责任公公司生产产的HGG-21192/25.4-YYM166型锅炉炉,为超超临界参参数、控控制循环环、四角角切向燃燃烧方式式、一次次中间再再热、单单炉膛平平衡通风风、固态态排渣、紧紧身【封闭、全全钢构架架的型直流流炉。主要部件位位置分布布:炉膛膛上部布布置有分分隔屏过过热器、末末级过热热器;水水平烟道道中布置置有末级级再热器器;后烟烟道布置置低温再再热器、低低温过热热器、省省煤器和和吊挂管管。汽水流程:给水由由炉前右右侧进入入省煤器器,流经经省煤器器后由省省煤器出出口导管管进入螺螺旋水冷冷壁下集集箱、经螺旋旋水冷壁壁进入中中间集箱箱至上集集箱出口口连接管管道到混混合集箱箱、再进进入降水水管,从从下降管管汇集到到折焰角角水冷壁壁和水平平烟道水水冷壁之之后进入入汽水分分离器进进行汽水水分离,从从分离器器分离出出来的水水进入贮贮水罐排排往冷凝凝器,蒸蒸汽则依依次经顶顶棚过热热器、包包墙过热热器、中中隔墙、吊吊挂管过过热器、低低温过热热器、分分隔屏过过热器和和末级过过热器。调节过热蒸蒸汽温度度的一级级减温器器装于低低温过热热器出口口到分隔隔屏过热热器进口口连接管管;二级级减温器器装于分分隔屏过过热器出出口到末末级过热热器进口口连接管管上。锅炉主要技技术参数数如下(BMCCR工况况):锅炉型号 HG-21992/225.44-YMM16过热蒸汽流流量 tt/h 21192过热器出口口蒸汽压压力 MMPa(g) 255.4过热器出口口蒸汽温温度 5771再热蒸汽流流量 tt/h 118400再热器进口口蒸汽压压力 MMPa(g) 44.5228再热器出口口蒸汽压压力 MMPa(g) 44.3228再热器进口口蒸汽温温度 3117再热器出口口蒸汽温温度 5669省煤器进口口给水压压力 MMPa(g) 228.887省煤器进口口给水温温度 2883空预器进/出口一一次风温温度 330/33081.1.22汽机系系统1.1.22.1本本期工程程汽轮机机为哈尔尔滨汽轮轮机厂有有限责任任公司生生产、制制造的汽汽轮机型型式:为为超临界界参数、一一次中间间再热、单单轴、三三缸四排排汽、直直接空冷冷凝汽式式汽轮机机;发电电机为哈哈尔滨电电机厂有有限责任任公司生生产的水水、氢、氢氢冷却、静静态励磁磁6600MW汽汽轮发电电机。主主蒸汽,主主蒸汽管管道采用用2-11-2连连接方式式,从过过热器出出口集箱箱双管接接出,在在炉内合合成一路路后单管管引出在在进汽机机前分成成两路分分别接至至汽轮机机左右侧侧主汽门门。第 87 页 共 71 页1.1.22.2再再热蒸汽汽,再热热冷段管管道采用用2-11-2连连接方式式,锅炉炉和汽机机接口均均为2个个,从再再热器出出口集箱箱双管接接出合成成一路后后在进汽汽机前分分成两路路接入。1.2编制制依据火力发电电厂焊接接技术规规程DDL/TT8699-20012火力发电电厂焊接接热处理理技术规规程DDL/TT8199-20010焊工技术术考核规规程DDL/TT679920012焊接工艺艺评定规规程DDL/TT8688-20014火力发电电厂异种种钢焊接接技术规规程DDL/TT7522-20010电力建设设施工质质量验收收及评价价规程(焊焊接篇)DL/T5210.7-2010版铝母线焊焊接技术术规程DDL/TT7544-20001火力发电电厂金属属监督规规程DDL/TT4388-20009电力工业业锅炉压压力容器器监察规规程DDL/TT6122-19996电站锅炉炉压力容容器检验验规程DDL/TT6477-20004压力容器器焊接规规程NNB/TT470015-20111管道焊接接接头超超声波检检验技术术规程DDL/TT8200-20002钢结构工工程施工工质量验验收规范范 GGB/TT 5002055-20001钢制承压压管道对对接焊接接接头射射线检验验技术规规程DDL/TT8211-20002焊接材料料质量管管理规程程JBB/T332233-19996基建安全全管理规规定工程建设设标准强强制性条条文电电力工程程部分220133年版特种设备备焊接操操作人员员考核细细则TTSG Z60002-20110 大同煤矿矿集团塔塔山2×6600MW坑坑口电厂厂(二期期扩建)工工程施工工组织总总设计山西电建二二公司焊焊接工艺艺评定报报告其它:相关关法律、法法规,电电力行业业、建设设部及有有关标准准、规范范。1.3 主要焊焊接工程程量及焊焊接方法法1.3.11 锅炉炉部分1.3.11.1省省煤器系系统、水水冷壁系系统、过过热器系系统、再再热器系系统、中中大径连连接管的的焊接;1)省煤器器系统a.省煤器器焊口共共计27720个个,规格格为44.5×7,材材质为SSA-2210CC。b.炉膛布布置紧凑凑,造成成蛇形管管排片与与片的间间距、每每片管子子与管子子的间距距较小,焊焊接时候候有些局局部地方方是肉眼眼无法观观察到的的,要求求焊工在在焊接这这些位置置的时候候利用镜镜面焊的的方法以以保证焊焊接质量量。(低低温再热热器、低低温过热热器蛇形形管排的的分布情情况和省省煤器类类似,焊焊接方法法同上)2)水冷壁壁系统a.水冷壁壁部件主主要有,前前、后、左左、右侧侧水冷壁壁,后水水冷壁排排管、折折焰角水水冷壁、左左、右侧侧水平烟烟道水冷冷壁;焊焊口共计计190074个个,规格格有38×7.33、31.8×6.22、42×7、44.5×7、63.5×14、89×16,材材质为115CrrMoGG。b.水冷壁壁焊接的的难点主主要在灰灰斗区的的螺旋水水冷壁(拐角和和前、后后水中部部均以散散管连接接且数量量较多),安装装过程中中由于设设备的原原因不可可避免的的会出现现焊口难难以组对对(错口口、折口口)的情情况,为为避免出出现焊接接质量问问题,在在施工过过程中严严格执行行焊接强强条,有无法法达到焊焊接要求求的可跳跳过焊下下一根。无无法焊接接的问题题散管,由焊接接专工联联系项目目部工程程技术科科以书面形形式联系系专业监监理工程程师及甲甲方专业业专工予予以解决决。(其其它部件件遇到类类似情况况,处理理方法同同上)3)过热器器系统a.过热器器系统主主要部件件有:顶顶棚过热热器、包包墙过热热器、吊吊挂管过过热器、低低温过热热器、分分隔屏过过热器、末末级过热热器和流流体冷却却定位管管;焊口口共计1163777个。材材质主要要有155CrMMoG、112Crr1MooVG、SSA-2213TT91、SSA-2213TTP3447H;规格有有44.5×7、63.5×10、42×11、63.5×11.5、51×13.5、51×11、70×11、51×9、63.5×14等(详详细规格格参数见见焊接一一览表)b.需要焊焊前预热热焊后热热处理的的焊口。因因为管排排、管子子间距较较小,管管排焊口口焊前预预热采用用火焰加加热的方方法,使使用远红红外测温温枪测温温,焊后后热处理理采用电电加热的的方法。4)再热器器系统a.再热器器系统主主要部件件有:低低温再热热器和高高温再热热器;焊焊口共计计99774个,材材质主要要有155CrMMoG、112Crr1MooVG、SSA-2213TT91、SSA-2210CC;规格格有57×4.55、60×5、54×5、70×5等。5)中、大大径连接接管中大径管道道主要包包括省煤煤器集箱箱、水冷冷壁集箱箱、包墙墙环形集集箱、前前顶棚集集箱、下下降管及及其连接接管、折折焰角及及水平烟烟道连接接管、水水冷壁平平衡管、顶顶棚旁路路管、包包墙连接接管焊口口及手孔孔;焊口口共计6636个个,材质质主要有有15CCrMooG、SSA-1182FF91、SSA-2210CC、WBB36(规规格较多多,详见见焊接工工程一览览表)。1.3.11.2锅锅炉本体体密封主主要包括括水冷壁壁一次密密封、包包墙过热热器一次次密封、水水冷壁二二次密封封、包墙墙过热器器二次密密封、再再热器、过过热器二二次密封封,为非非承压焊焊接工作作量的主主要部分分。 1.3.11.3锅锅炉燃油油系统。1.3.11.4回回转式空空气预热热器系统统焊接为为直通长长焊缝、角角接焊缝缝、T型型焊缝。1.3.11.5锅锅炉杂项项管道的的焊接,如如工业水水系统,仪仪用压缩缩空气系系统,热热工仪表表管,工工业压缩缩空气系系统,暖暖风器供供汽、取取样、减减温水、放放空气、加加药、吹吹扫蒸汽汽、充氮氮及疏水水系统。1.3.11.6吹吹灰系统统焊接。1.3.22汽机部部分1.3.22.1四四大管道道及高、低低旁路部部分:主主蒸汽管管道焊接接,高压压给水管管道焊接接,热再再热蒸汽汽管道焊焊接,再再热冷段段焊接;1.3.22.2中中低压管管道的焊焊接;1.3.22.3凝凝汽器焊焊接;1.3.22.4除除氧器焊焊接;1.3.22.5油油系统管管道的焊焊接;1.3.22.6封封闭铝母母线的焊焊接;1.3.22.7其其他杂项项管路焊焊接;1.3.22.8热热控仪表表压力管管路焊接接。 1.3.33焊接方方法1.3.33.1承承压管道道部分一般情况下下对于壁壁厚不大大于6mmm的小小径管焊焊口,应应采用手手工氩弧弧焊;壁壁厚大于于6mmm的管子子,应采采用氩弧弧焊打底底、电弧弧焊盖面面(GTTAW/SMAAW);但是对对于焊接接位置困困难,难难以采用用氩加电电组合焊焊时,应应全部采采用全氩氩弧的焊焊接方法法,以保保证焊接接质量。1.3.33.2钢钢结构部部分钢结构的焊焊接应符符合DLL/T6678-19999电电站钢结结构焊接接通用技技术条件件的规规定,钢钢结构部部件焊接接时采用用手工电电弧焊(SSMAWW),使使用的焊焊条按标标准进行行烘焙,焊焊机采用用逆变式式弧焊机机或交流流弧焊机机。焊工工要准备备砂轮机机、扁铲铲、榔头头和钢丝丝刷等清清理工具具。凡是是对接的的方形或或工字形形钢结构构须配备备两名焊焊工对称称分段焊焊,对于于间隙过过大的构构件,对对接前采采用电焊焊补焊而而缩小其其间隙,严严禁填加加金属物物。焊接接较大的的钢柱时时,焊接接途中不不能停焊焊或隔夜夜焊,否否则会产产生裂纹纹。施焊人员在在焊接时时要随时时对焊缝缝进行宏宏观检查查、清理理,特别别是焊缝缝饱满度度,咬边边,表面面裂纹等等是检查查的重点点,对于于重要的的承重钢钢结构,焊完后应以相关标准去做检验,焊工焊完应认真填写自检记录。1.3.33.3锅锅炉本体体密封 所所有密封封焊缝都都采用双双面焊接接的焊接接工艺进进行焊接接,对因因设计原原因造成成局部焊焊接位置置困难无无法施焊焊时,采采用单面面全焊透透。施焊焊时保证证焊缝高高度及成成形,所所有焊缝缝均应打打磨光滑滑、平整整,对于于厚度较较大的密密封扁钢钢,应严严格按施施工设计计图要求求开坡口口,以保保证焊接接质量。密密封焊缝缝对接时时避免添添加密封封材料。对对组合件件的密封封焊缝,尽尽量在地地面组合合时完成成。穿墙墙套管与与墙体密密封焊缝缝在穿墙墙管对口口焊接时时同时进进行。密密封对接接全部开开坡口,开开坡口采采用砂轮轮机打磨磨,采用用小直径径电焊条条、小电电流密度度、较小小的焊接接速度、薄薄焊道。四四角合拢拢的角焊焊缝适当当加厚,密密封焊接接时采用用从中间间向两边边分段跳跳焊法,间间距为22004000mm,管管子与密密封鳍片片焊接时时特别注注意烧穿穿管子,如如发生后后必须割割掉重新新换管。1.3.33.4承承压部件件上的管管座采用用氩弧焊焊打底、电电弧焊填填充盖面面(GTTAW/SMAAW)组组合焊接接方法进进行焊接接,而插插入式插插座采用用手工电电弧焊(SSMAWW)。1.3.33.5汽汽轮机、发发电机的的冷却、汽汽机润滑滑油及工工作油管管道、锅锅炉燃油油管道焊焊口采用用全氩方方法焊接接(GTTAW)或或采用氩氩弧焊打打底、电电焊盖面面焊接方方法。1.3.33.6主主蒸汽管管道、再再热蒸汽汽管道、高高压给水水管道、高高中压导导汽管道道均采用用氩弧焊焊打底、电电焊填充充、盖面面的焊接接方法(GGTAWW/SMMAW)。1.3.33.7大大直径(1000mm)管道或容器接头的焊接,采取焊缝背面清根双面电弧焊。1.3.33.8管管道或容容器上焊焊接非开开孔型管管座、吊吊架、加加强筋等等采取手手工电弧弧焊方法法(SMMAW)。1.3.33.9中中、低压压管道中压管道焊焊接时采采用氩弧弧焊打底底,电焊焊盖面焊焊接工艺艺;低压压管道的的焊接采采用手工工电弧焊焊焊接工工艺。对对于直径径大于1194mmm的管管子采用用两个焊焊工对称称焊。1.3.33.100油系统统管道采用全氩弧弧焊工艺艺,当管管壁6mmm时采采用氩弧弧打底、电电弧焊盖盖面的工工艺。不不锈钢管管道需进进行管内内充氩,每每道口焊焊完后才才允许停停止管内内充氩。1.3.33.111热控仪仪表管的的焊接采用全氩弧弧焊工艺艺,由于于管子外外径小,管管壁最薄薄,适当当留有焊焊缝间隙隙,通常常只焊一一层,既既要根部部焊透,无无焊瘤,外外观又要要成型美美观。焊焊接时为为保证其其质量,焊焊丝选用用最小直直径,采采用较小小的电流流密度,较较慢的焊焊接速度度,点一一个焊一一个,注注意漏焊焊。1.3.33.122铝母线线等铝及及铝合金金焊接焊机采用半半自动铝铝母线焊焊机,焊焊接材料料必须有有生产厂厂家出示示质量合合格证件件。母线焊接采采用氩弧弧焊工艺艺方法。铝铝母线在在点固焊焊之前用用丙酮或或酒精清清洗干净净,层间间清理用用锉刀清清理,或或用不锈锈钢丝刷刷对层间间和外表表清理,需需要现场场加工的的用机械械方法加加工。管管状母线线的补强强衬垫的的纵向轴轴线位于于焊口中中央。焊焊接前对对口平直直,其弯弯折偏移移不大于于0.22%,中中心线偏偏移不大大于0.5mmm。焊接接中每个个焊缝一一气呵成成,除瞬瞬间断弧弧外不得得停焊,母母线焊完完未冷却却前,不不得移动动或受力力。母线线对接焊焊缝的加加强面高高度为224mmm。母母线焊接接中进行行直流电电阻测定定,焊缝缝直流电电阻不大大于同截截面,同同长度的的原金属属的电阻阻值。焊接接头表表面无肉肉眼可见见的裂纹纹、凹陷陷、缺肉肉、未焊焊透、气气孔、咬咬边等缺缺陷。咬咬边深度度不超过过母线厚厚度的110%,且且其总长长度不得得超过焊焊缝总长长的200%。焊完后清理理、自检检、焊口口标识。1.3.44焊接材材料1.3.44.1焊焊接材料料的质量量要求焊接材料严严格执行行相应的的国家标标准。焊焊接工程程中使用用的进口口焊接材材料必须须符合设设计要求求和工艺艺方提交交的技术术文件的的要求。焊接材料均均要有制制造厂的的质量合合格证、焊焊接材料料质量证证明书。对焊接材料料质量有有怀疑时时,按批批号抽查查检验,合合格后方方可使用用。1.3.44.2焊焊接材料料的选用用要求1.3.44.2.1焊接接材料严严格按照照设计要要求及焊焊接工艺艺评定结结果使用用。异种种钢焊接接的标准准:两侧侧钢材均均非奥氏氏体不锈锈钢时,可可选用成成分介于于二者之之间或与与合金含含量低的的一侧相相匹配的的焊接材材料;两两侧之一一为奥氏氏体不锈锈钢时,且且其工作作温度低低于4225,可选选用与奥奥氏体不不锈钢相相应的焊焊接材料料;对于于工作温温度大于于4255的耐热热合金管管子、管管体等承承压部件件进行补补焊或在在其上焊焊接管接接头,若若限于条条件焊后后无法进进行热处处理时,可可选用镍镍基焊材材。1.3.44.2.2钨极极氩弧焊焊应使用用符合有有关规定定的电极极。1.3.44.3焊焊接材料料的使用用焊条使用前前严格按按照产品品说明书书对其进进行烘焙焙,烘焙焙后的焊焊条应放放置在专专用的焊焊条保温温桶内,随随用随取取。焊丝使用前前清除其其表面的的油、污污、锈、垢垢,直至至露出金金属光泽泽。1.3.55充氩1.3.55.1合合金含量量较高的的耐热钢钢(含铬铬量3%或或合金总总含量>>5%)管管子和管管道对接接焊接时时内壁必必须充氩氩气或混混合气体体保护,并并确保保保护有效效。a充气的的方法大大体分为为整根管管子端部部送气,制制作送气气装置伸伸入联箱箱内单根根管送气气,从坡坡口根部部向管内内送气,分分段组装装送气等等,制作作拉环装装置从管管子内部部送气;b通常,施施工现场场制作充充氩气室室的堵塞塞材料为为生活中中使用的的卫生纸纸;商店店中出售售的可食食面包,食食堂大师师傅制作作的可吃吃面团,科科研单位位研究特特制的可可溶纸,马马粪纸,施施工单位位自行设设计铁皮皮和油毛毛毡等制制作的气气室拉环环装置;c气室的的长度根根据管段段的长短短而定,以以保护效效果、节节省气体体为原则则。一般般气室以以焊口中中心线为为准,两两侧各3300mmm为宜宜,以防防预热和和焊接中中烧损,而而失去保保护意义义。第二章 项目组组织机构构设置2.1 焊接人人员的配配备及职职责2.1.11 项项目主任任1人。负责组织公公司质量量环境安安全方针针、目标标、指标标在本单单位的分分解落实实;负责责完成本本部门环环境安全全管理方方案所规规定的指指标和任任务。负责组织编编制质量量计划以以及负责责质量计计划的实实施。负责组织编编制安全全、环境境管理方方案,并并负责在在本部门门贯彻执执行。负责组织对对本工程程处环境境因素与与危害因因素的识识别与控控制。合理组织人人员、材材料、机机械、设设备等资资源,以以确保焊焊接施工工的顺利利进行。全面负责焊焊接施工工中质量量、安全全和环境境保护的的管理工工作。2.1.22 专专责工程程师1人。熟悉公司管管理方针针和管理理目标,协协助处长长(副处处长)在在本部门门贯彻执执行。全面负责本本专业的的技术工工作。负责组织编编制职业业安全健健康与环环境保护护、技术措措施。 深入施工现现场进行行技术指指导和监监督。组织焊接工工程的质质量检查查和验收收工作。组织对不合合格品的的质量评评审工作作,负责责对本部部门不合合格品纠纠正预防防措施的的制定和和落实。2.1.33 焊焊接技术术人员33人。焊接技术人人员必须须经过专专业技术术培训,取取得相应应的资格格证书,持持证上岗岗。熟悉公司制制定的管管理方针针、管理理目标,并并按其要要求开展展技术管管理工作作。掌握