大型油罐焊接程序 WELDING PROCEDURE.doc

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1、【精品文档】如有侵权，请联系网站删除，仅供学习与交流大型油罐焊接程序 WELDING PROCEDURE.精品文档.大型油罐焊接程序 WELDING PROCEDURETable of Contents1. PURPOSE22. SCOPE23. REFERENCES24.WELDING PROCESS FLOWCHART25.REQUIREMENTS35.1 Preparation prior to welding35.1.1 Selection of welding method35.1.2 Management of welding consumable35.1.3 Welding pr

2、ocedure qualification45.1.4 welder qualification45.1.5 welding equipments45.1.6 Clean-up prior to Welding45.2 Control of welding process55.2.1 Weather conditions for welding55.2.2 Tack welding55.2.3 Back gouging55.2.4 Attachments welding55.2.5 Welding order of tanks65.2.6 Welding of bottom plate65.2

3、.7 Welding of tank shells75.2.8 Welding of roof of tank85.2.9 Product test plates85.2.10 Marking of Welds 焊接标记85.3 Inspection of welding seam85.3.1 Visual inspection85.3.2 NDT95.4 Welding seam repairing106. WELDING DOCUMENTS AND RECORDERS11.ATTACHMENT121. PURPOSEThis project is to construct 2 butadi

4、ene tanks, (size:1660010000).The procedure provides some welding process and welding requirements, to ensure welding quality of butadiene tanks to meet requirements of contract and applied specification/standard to satisfy the owner.目的：本工程是建造两台储罐。本程序为确保油罐的焊接施工质量符合合同、适用规范和标准的要求，使业主满意，特制订焊接工艺和焊接要求。2.

5、SCOPEThis procedure is applicable to the tank welding of 00 00 Petrochemical Project 2 butadiene tanks.范围：本施工程序适用于中海壳牌石油化工有限公司2台xx罐的焊接施工。3. REFERENCES3.1 “Vertical cylindrical steel welded oil tank” GBJ128-903.2 “welding evaluation for steel pressure vessel ” JB470820003.3 “mechanical property tests

6、 of product welded test coupons for steel pressure vessels” JB474420003.4“Design and Construction of Large，Welded，LowPressure storage Tanks” API-6203.5 “Code of welding and Brazing Evaluate” SECTION IX ASME code3.6 PMC Relevant Welding Procedures 00-0025 00-00383.7“BUTADIENE STORAGE TANKS, 002&003”

7、SP-8430-0810-0304 3.8 Design Drawing 3.1立式圆筒形钢制焊接油罐施工及验收规范 GBJ128-903.2钢制压力容器焊接工艺评定 JB470820003.3钢制压力容器产品焊接试板的力学性能检验JB474420003.4大型焊接低压油罐设计和施工 API- 6203.5焊接和钎焊评定 ASME 第IX卷3.6 PMC相关焊接文件 00-0025 00-00383.700储罐 002&003 SP-8430-0810-0304 3.8设计图纸4.WELDING PROCESS FLOWCHARTReview drawing Establish WPS Pro

8、cess qualification Welder test Welding preparation Fitting/tack welding Welding Visual inspection NDT (repair) Final acceptance.焊接工艺流程图审查图纸制定WPS工艺评定焊工考核焊接准备组对/点焊焊 接目测检查NDT（返修）最终验收5.REQUIREMENTS要求5.1 Preparation prior to welding 焊前准备5.1.1 Selection of welding methodAccording to relevant documents ( s

9、tandards ，specifications, etc.), we shall adopt SMAW to weld 2 butadiene tanks, polarity is Reversed polarity, DC. 焊接方法选择根据相关的文件（标准、规范等），我们采用手工电弧焊焊接2台xx罐，极性是直流反接。5.1.2 Management of welding consumable焊材管理 According to design documents, material of tank plates is ASTM A516 Gr60, therefore, type of we

10、lding rod is AWS A5.5 E7016-G.根据设计文件，罐板材质是ASTM A516 Gr60，所以焊条型号选用AWS A5.5 E7016-G.。 Certification and testing of welding consumables is to be checked prior to use. For AWS A5.5 E7016-G electrode, diffusible hydrogen content of weld metal deposit shall not exceed 5 ml/100 g weld metal.焊条使用前检查质量证明书和测试

11、报告，对于AWS A5.5 E7016-G.焊条，熔敷金属扩散氢含量应不超过5 ml/100 g。 At-site, all welding consumables for permanent works are to be stored in a controlled lockable store. Welding consumables shall be stored with care under clean, dry conditions in their original unopened packing. 在现场 ，用于正式焊接的焊条应存贮在可封闭的库房里，保持干净、干燥，和原始包

12、装。 Special person must be arranged to manage welding consumables ,including baking ,storage , issue , return ，he must do a record. And site welding engineer must monitor and review consumable strictly. Prior to use, all electrodes shall be newly unpackaged or re-dried according to the manufacturers

13、instructions, baking temperature is between 350400 for low-hydrogen electrode ; baking time is 1 hour ; constant temperature is 100150; and the baking frequency is not over 2 times.指定专人管理焊条，包括烘干、发放、回收，并作好记录。现场焊接工程师必须严格监控。焊条使用前应拆封按照制造商的说明书进行烘干，烘干温度是350400，时间1小时；保温温度100150；烘干次数不得超过2次。 The Welder shall

14、 keep the electrodes in the portable rod ovens . During welding, electrode shall be taken out one by one.焊工应将焊条放在便携式焊条筒内，焊接时一根一根取出焊条。5.1.3 Welding procedure qualificationIn order to weld butadiene tanks, according to “mechanical property tests of product welded test coupons for steel pressure vessel

15、s”(JB4708-2000), we shall qualify the following welding procedure items on site:AWS A516 Gr60 =8mm SMAW vertical double-face welding;AWS A516 Gr60 =15mm SMAW vertical double-face welding.The test plate shall be carried out tensile test, transverse tensile test, and Cv-impact test(-46).焊接工艺评定针对xx罐的焊接

16、，我们将在现场按照JB4708钢制压力容器焊接工艺评定做以下焊接工艺评定：AWS A516 Gr60 =8mm 手工电弧焊 立焊 双面焊AWS A516 Gr60 =15mm 手工电弧焊 立焊 双面焊焊接工艺评定试板需进行拉伸试验、弯曲试验、低温冲击试验(-46)。5.1.4 welder qualificationAll welders to participate the project must be qualified according to “welder training and qualification procedure”(XXCNS0011). Details of we

17、lder qualification see “welder training and qualification procedure” （XXCNS0011）. 焊工资格认证所有参加本项目焊接的焊工必须按照焊工培训和资格认证程序（XXCNS0011）的要求进行考试，详细要求见焊工培训和资格认证程序（XXCNS0011）。5.1.5 welding equipmentsThe welding equipments must possess sufficient power for welding work. Its characteristic shall meet requirement o

18、f construction. Each welding machine shall be provided with suitable cables and attachments (holders, earth clamps, etc) that are in good safe working order, any found to be unsafe shall be removed.XX prepare to put into use of welding equipments see “CEP” of butadiene tanks（XXCNS0001）.焊接设施焊接设备对于所承担

19、的工作必须具有足够的功率，性能能够满足施工现场的需要。每台焊接机器应具备状态良好的合适的电缆及附件（保持器、接地夹等），应停止使用发现的任何不安全的机器。准备投用的焊机参见xx罐施工执行计划（XXCNS0001）。5.1.6 Clean-up prior to WeldingBase material within range of groove and both sides (20mm each) shall be cleared up prior to welding. All surface dirt, such as rust, paint, grease and water etc,

20、 must be cleared up to show metal luster.焊前清理焊接之前应对焊缝坡口及坡口两侧25mm范围内的母材进行清理，清除表面的锈、油漆、油脂、水等污物，直至露出金属光泽。5.2 Control of welding process 焊接过程控制5.2.1 Weather conditions for weldingUnder any kind of following welding environment, welding work shall not be allowed to perform unless effective protection mea

21、sures are taken:a) Rainb) Wind speed8m/s (for manual arc welding)c) Ambient humidity90%焊接气象条件 下列任一情况下，如果没有有效的防护措施，不得进行焊接工作： a)下雨； b)风速8m/s（手工电弧焊）； c)空气相对湿度90%。5.2.2 Tack weldingLength of tack welding is not less than 50mm, and space between welding spots is not less than 200mm.Qualified welders usin

22、g the parameters of an approved WPS shall only make tack welds. Tack welds shall either be removed completely, or have their start and stop ends feather ground in order to include the tack(s) into the finished weld. Tack welds should be inspected by the welder for cracks prior to inclusion in the fi

23、nal weld. Weld filler metals used for tack welding must be the same as the intended WPS.罐组对时点焊长度不小于50mm，间距不小于200mm。点焊只能由合格的焊工按照批准的焊接程序规范参数进行。应完全清除点焊，或者打磨掉点焊的起始点和结束点，以使焊点与焊缝成为一体。正式焊接之前，焊工应检查是否有裂缝。点焊采用的焊材必须与焊接工艺指导书相同。5.2.3 Back gougingFlame back-gouging shall not be used, the back-gouging and fabricat

24、ion of back grooves use grinder or arc air-gouging. Residual carbon deposits produced by arc air-gouging shall be removed from the groove by grinding. Before applying weld metal from the second side, the prepared surface shall be examined by dye penetrant inspection.清根 不能用火焰割，背面坡口的清根可用打磨或碳弧气刨。碳弧气刨留下

25、的渗碳层应该磨除。背面焊接前，坡口表面应做渗透检查。5.2.4 Attachments welding附件焊接5.2.4.1 Temporary Attachments Weld filler metals used for attachments（lifting ear, etc.）welding must be the same as the intended WPS of the tanks.If attachments need be removed, they shall not be knocked off base material. Attachments may be rem

26、oved by any suitable means, followed by grinding with the base material. When thermal cutting is used to remove attachments, at least 1/8 inch (3mm) shall be left for finish removal by grinding and the ground area shall be visually examined for defects. Any defects founded shall be removed by additi

27、onal grinding and repaired, if necessary. 临时附件临时附件（吊耳、卡具等）在罐板上焊接时采用的焊材必须与罐的焊接工艺指导书相同。当去除附件时，不得将附件从母材上敲掉。去除附件之后应对母材进行打磨。如果采用热切割方式取下附件，应至少留下 1/8 英寸 (3mm) 进行打磨抛光去除，并对打磨区进行外观缺陷目视检查。发现的所有缺陷均应通过再次打磨去除，必要时进行补焊。5.2.4.2 Attachments of tanks Attachments of tanks include stairsway, platform, reinforce ring, ma

28、nhole, nozzles, etc. Welding of such attachments should be in accordance with the requirements of the welding seam dimension which is specified by the design drawings. Welding consumable should be the same as the intended WPS of the tanks.罐附件罐附件包括梯子、平台、加强圈、人孔、管口等。这些附件的焊接，应符合设计图纸对焊缝尺寸的要求，焊材应与罐本体焊接工艺指

29、导书上的相同。5.2.5 Welding order of tanks According to the relevant codes and standards, our construction experience, and eructing order, we determine the welding order as the following:Bottom plate annular plate(outer 300mm) the 8th , 9th course vertical seams horizontal seam between the 8th and 9th cour

30、se roof plate the 7th course vertical seamshorizontal seam between the 7th and 8th course the 6th course vertical seams horizontal seam between the 6th and 7th course the 5th course vertical seams horizontal seam between the 5th and 6th course the 4th course vertical seams horizontal seam between th

31、e 4th and 5th course the 3rd course vertical seams horizontal seam between the 3rd and 4th course the 2nd course vertical seams horizontal seam between the 2nd and 3rd coursethe 1st course vertical seams horizontal seam between the 1st and 2nd course the shell-to -bottom annular plate welds annular

32、plate (residual part) seam between annular plates and bottom platesAttachments (nozzles, manhole, stairsway, platform, etc) should be installed and welded during the installation of plate which attachments should be in.罐焊接顺序根据规范标准、施工经验和罐组装顺序，确定罐的焊接顺序如下： 罐底中幅板 罐底边缘板（外侧300mm） 第8圈、第9圈纵缝 第8圈、第9圈间环缝 罐顶焊缝

33、 第7圈纵缝 第7圈、第8圈间环缝 第6圈纵缝 第6圈、第7圈间环缝 第5圈纵缝 第5圈、第6圈间环缝 第4圈纵缝 第4圈、第5圈间环缝 第3圈纵缝 第3圈、第4圈间环缝 第2圈纵缝 第2圈、第3圈间环缝 第1圈纵缝 第1圈、第2圈间环缝 大角缝 罐底边缘板（剩余部分） 收缩缝附件（管口、人孔、梯子平台等）在所在罐板安装时进行安装焊接。 5.2.6 Welding of bottom plateIn order to control welding deforming, the welding of bottom plate will use method of free shrinkage

34、and choose reasonable welding sequence and welding process.罐底板焊接为了控制焊接变形，罐底焊接采用自由收缩法，选用合理的焊接顺序和焊接工艺。5.2.6.1 Welding of middle size plateThe welding seam of middle size plate is in form of lap joints, and shall adopt method of alternate seam welding, at first welding long piece of middle size plate,

35、in second welding small piece of edge plate, at first short weld, then long weld. The pass of primary layer shall be welded with method of backstep sequence. The welding length of alternate section is 400mm.中幅板焊接中幅板焊接接头是搭接形式，采用隔缝施焊法，先焊中幅长板，后焊边缘小板，先焊短焊缝，后焊长焊缝，初层焊道采用分段退步焊接，隔400mm焊400mm。5.2.6.2 Welding

36、 of annular plateThe welding seam of arched annular plate is in form of butt joins, and shall be welded by several welders arranged symmetrically at same time. The gantry plate shall be provided for reinforcing prior to welding. When the welding is conducting, at first welding in rang of 300mm outsi

37、de, every layer shall be staggered with 3050mm, the other welding seam shall be welded after welding of the seam between the bottom and tank shell, and before welding of the seam between annular plate and middle size plate.边缘板焊接弓形边缘板焊接接头是对接形式，由多名焊工对称分布采用手工电弧焊同时施焊，焊接前应设置龙门板加固。焊接时先焊外侧300mm范围，焊接时每层错开30

38、-50mm，余下的焊缝在大角缝焊接后、收缩缝焊接前进行焊接。5.2.6.3 Welding of the shell-to -bottom annular plate weldsThe welding of the shell-to - bottom annular plate welds should be carried out after the longitudinal welding of the bottom loop wainscot is done. The welding should be carried out subsection by several pairs of

39、 welders arranged symmetrically, from both the inside and outside part of the tank in the same direction. The pass of primary layer shall be welded with method of backstep sequence.The weld toes shall be blended smooth to avoid stress intensification.大角缝焊接大角缝焊接应在底圈壁板纵缝焊接完后进行。由数对焊工从罐内外均布，沿同一方向进行分段焊接,

40、初层焊道采用分段退焊。焊趾应平滑过渡，避免应力集中。5.2.6.4 Welding of seam between annular plate and middle size plateShould be carried out after the fillets between the bottom and tank shell is finished. Take the primary welding by backstep sequence or skip sequence.收缩缝焊接收缩缝焊接应在大角缝焊接后进行，初层焊道采用分段退焊或跳焊。5.2.7 Welding of tank

41、shells Big grooves of horizontal and vertical seams of tank shells are outside, so weld the outside first. Clean the back with carbon arc cutting, and burnish them with grinding wheel. Welders should be evenly arranged and with the generally same direction and speed. The pass of primary layer shall

42、be welded with method of backstep sequence, and each vertical seam not longer than 500mm and each circular seam not longer than 600mm. Vertical seams should be reinforced by arc plates before the welding.罐壁焊接焊缝的大坡口在外侧，所以先焊外侧。清根用碳弧气刨，然后用砂轮机打磨。焊工均匀布置，沿同一方向、相同速度焊接。初层焊道分段退焊，立缝每段不超过500mm，横缝每段不超过600mm。立缝焊

43、接前应用弧板加固。5.2.8 Welding of roof of tankRoof of tank is in form of lap joint, double-face welding. Short welding seams first and then the long ones. With low current, speedily weld 300mm every other 300mm in the way of backstep sequence.Welding order: Radial welding seams of middle size plates circula

44、r seams of middle size plates, in the order of from the inner to the outside Vertical abutment joints of rim plates Lap joints between rim plates and edge covered angle iron Lap joints between rim plates and middle size plates罐顶焊接罐顶焊缝采用搭接，双面焊。先焊短焊缝，后焊长焊缝，300mm为一段分段退焊，小电流快速焊。焊接顺序：放射线焊缝 环焊缝（由里向外） 边板纵缝

45、 边板与包边角钢间搭接焊缝 边板与中间板焊缝5.2.9 Product test platesproduct test plates shall be made for the vertical welds of the tank. At each third course one product test plate shall be made. Total 3 product test plates shall be made for each tank. Thickness is 15mm, 10mm, 8mm, and welding position is vertical, and

46、 welding process is same as the process of tanks welding.After the plates welding, they shall be inspected visually, acceptance standard is same as tank welding seam.After the plates are accepted, according to “mechanical property tests of product welded test coupons for steel pressure vessels ” (JB4744-2000), they shall be carried out tensile test, transverse tensile test, and Cv-impact test(-46).产品焊接试板每三圈罐板做一块产品焊接试板，每台罐共做三块， 厚度分别是15、10、8mm，焊接位置是立焊，焊接工艺与罐焊接相同。试板焊完后进行外观检查和RT，合格标准与罐壁的焊缝相同。试板经检查合格后按JB4744-2000钢制压力容器产品焊接试板的力学性能检验，进行机械性能试验，包括拉伸试验、弯曲试验、低温冲击试验（-46）。5.2.10 Marking of Welds 焊接标记