焊接材料控制程序(中英文).docx

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1、Procedure for Welding Materials Control焊接材料控制程序(IS09001-2015)1. Purpose 目的This procedure sets forth the management requirements for reception, storage, baking & drying, distribution and recycles of welding materials.本程序描述了焊接材料的验收、储存、烘干、发放与回收等的管理。2. Applicable Scope 范围The procedure is applicable for

2、CV and module assembly and erection at HaiYang site of XXX Co. Ltd.本程序适用于公司cv和模块的组装及安装。3. References参考文件ASME Section II Subsection C Edition 2001, including 2002 Addenda.ASME n卷C篇2001版，2002增补ASME Section III Division 1 Subsection NE Class MC Components, Edition2001, including 2002 AddendaASEM III卷NE

3、分卷MC级设备2001版,2002增补Quality Assurance Manual for Haiyang Project HY-QAM海阳项目质量保证手册HY-QAM4. Responsibility 职责5. 1 Technical Department 技术部 格不同时，它们之间必需用隔板隔开，并做好标记。5.5.4 The constant temperature should be automatically controlled by device calibrated, after set up by baking operator. Baking personnel sho

4、uld keep records on baking.恒温温度经烘干员设定后，由经过标定并在有效期内的装置自动进行控制。烘 干员做好恒温记录。6. 6 Distribution of Welding Material (Level II Warehouse) 焊接材料 的发放(二级库)5.6. 1 The construction team leader will fill in collection list (Appendix 8) of welding material according to the WPS, which approved by welding engineer. T

5、he welder can only withdraw welding material according to the collection list. List NO shall be filled in remark blank of welding step in traveler for QC verification at site.施工班组长根据焊接工艺卡，填写附录8焊接材料领用单，并由焊接工程师审 批。焊工凭焊材领用单领取相应的焊材，焊接材料领用单编号填写至流转卡焊 接操作步骤备注栏内，便于QC现场核查。5. 6. 2 The baking operator places e

6、lectrode into portable oven, welding wire canister or soldering flux thermal-insulating vessel for welder s personal use. The quantity of each distribution should not exceed the quantity of half-a-day use; and, the baking operator should confirm a distribution quantity in conformity with the collect

7、ion list of welding material. No welding material is distributed with no collection certificate of welding material. 烘干员把适当数量的焊条放入焊工个人专用的保温筒、焊丝筒或焊剂保温容器 中，每次发放的数量最多不得超过半个工作日所用；烘干员应对照焊接材料领 用单核对发放是否正确，无焊接材料领用凭证不得发放焊材。5. 6. 3 One portable oven can contain only one trademark of electrode, and one welding

8、 wire canister can contain only the welding wire of one trademark.一个保温筒中只允许放同一牌号的焊条，一个焊丝筒中只允许放同一牌号的焊 丝。5.6.4 Re-dry shall not exceed 2 times, after baking twice, welding rod will be disposed following “scrap” . Without special treatment requirement, welding wire can be directly distributed in origin

9、al form. 焊条再次烘干次数不得超过2次，经过2次烘干后焊条按照报废处理。焊丝如 没有特殊处理要求，可按其原样直接发放。5.6.5 When welding material is distributed, the baking operator fills in “thermal-insulating canister or welding wire canister label” and fixes on portable oven, welding wire canister or soldering flux thermal insulating vessel.在发放焊材时，烘干

10、员填写“保温筒、焊丝筒标签”后固定在保温筒、焊丝筒 或焊剂保温容器上。5.6.6 The baking operator keeps records on distribution & recovery of welding materials each time, and the welder should sign on records for confirming.烘干员做好每一次的焊材发放回收记录，领取材料的焊工要签字确认。5. 7 Use of Welding Material 焊接材料的使用5.7.1 During the process of welding, the welde

11、r ensures that portal quiver of welding rod is connected to a power source for heating & portal quiver. The portal oven can maintain the temperature at 70-150. Any operation trouble of the portal oven should be immediately reported, rectified or repaired for ensuring the performance of service.施焊过程中

12、，焊工确保焊条保温筒连接到电源上进行加热、保温。保温筒可在 70150C之间保温。保温筒的任何运行故障都要立即报告，修理好之后方可再 次使用。Example: Temperature of portable oven for E9018 shall be 121149. 例：存放E9018的焊条保温桶内的温度应在121149c范围内。5. 7.2 The welder will take out a welding rod from his exclusive thermal-insulating canister piecebypiece & use the welding rod imme

13、diately after it s taken out. Once welding rod is taken out, the cover of thermal-insulating canister should be closed at any time. 焊工从自己专用保温筒中逐根取焊条，保温筒盖要随时关上，焊条取出后应立 即使用。5. 7. 3 The use of welding rod should start from the end with no label to make sure traceability of whole welding process, and en

14、suring free of oil, rust, scale and other dirt on the surface of welding wire.焊丝的使用应从无标识端开始以保证整个焊接过程焊接材料可追踪性.为保证 焊接质量，使用前应将焊丝表面的油、锈、氧化皮等污物清理干净。5. 7. 4 The welder will put the damaged welding rod and end of welding rod into the waste canister for personal use and return regularly for ensuring there i

15、s no welding rod/wire end in the working area.焊工将损坏的焊条和焊条头放入个人使用的废料筒中，每班施工结束后交回焊 材烘干员处理，保持工作区域没有焊条/丝头。5.7.5 The disk-like welding wire should be kept against dampness. The welding wire on a wire-feeding device overnight should be covered by canvas or plastic cloth for reducing dampness. The welding

16、wire not in use for 2-3 days should be air-tightly packed & returned to the warehouse for storage.对于盘状焊丝，保管应注意防止其受潮，在送丝机上过夜的焊丝应用帆布或塑 料布罩住，减小焊丝的受潮机率。如果23天不用的焊丝需密封包装回库储存。5. 8 Recovery and re-bake requirement Welding Material 剩余焊材的回 收与再次烘干5. 8. 1 When a shift is over or welding completed, the welder wi

17、ll return the welding rod thermal-insulating canister and/or welding wire canister as well as left welding material to baking room and moreover, carry back the end of welding rod, which will be recovered as wastes after the baking operators inspection and signature of both sides.每班焊接施工结束时，焊工把焊条保温筒和/

18、或焊丝筒与剩余焊材一起交回烘干 室；同时带回焊条头，经烘干员检查记录后，经由双方签字后作为废品回收。5. 8. 2 If low-hydrogen electrodes have never be exposed to atmosphere and portable oven share the same temperature with insulation oven that recovered electrodes can be directly put back into insulation oven.Otherwise, recovered electrodes shall be

19、painted at the end, blue color for first recovery, and yellow for second recovery.低氢型焊条归还时还保存在保温筒中且未暴露于空气中，且保温桶内温度始终 与烘干箱温度一致时，则可将其直接放入保温箱内。此外，为便于控制回收的 焊条，回收后在焊条根部用少量油漆进行标记。蓝色代表回收过一次，黄色代 表回收过两次。5. 8. 3 Low-hydrogen electrodes which have been exposed to atmosphere over 1 hour shall be sent back for b

20、aking. When those electrodes have been reissued, construction team leader shall remark it on construction record (See record in HY-WP-SP-002, Procedure for Welding CVBH). If electrodes have been recovered twice, then these electrodes shall be discard.低氢型焊条若曾暴露于空气中超过一小时，则在归还后应将其放入烘干箱烘干。 当这些焊条再次发放时，施工

21、班长应在施工记录中注明这些焊条曾暴露于空气 环境中。如果这些焊条回收次数超过2次，则不可以继续使用，做报废处理。5.8.4 The buried-arc soldering flux un-melted in SAW welding can be recovered for re-use in a vacuum device, collection disc, sweeping or other methods. The recovered soldering flux should be baked according to the requirements, and then is add

22、ed and evenly mixed with new soldering flux at a ratio, and distributed for use.SAW焊接过程中未熔化的埋弧焊剂可以用真空装置、收集盘、扫集或者其它方 法回收再使用。回收后的焊剂按要求进行烘干，然后按比例加入新焊剂混合均 匀后发放使用。6. Appendix 附录Temperature and Humidity Records 温度和湿度记录隹）温度和湿度记录表. docWelding Material Label in Baking Oven 烘干箱内焊材标签.烘干箱内焊材标签. docWelding Mater

23、ial Lable in Constant Temperature Cabinet 恒温箱内焊材标签恒温箱内焊材标签. docBaking Records of Welding Material 焊材烘焙记录焊材烘焙记录表.d OCDistribution Records of Welding Material 焊材发放记录焊材发放记录表.d ocWelding Materials Label 焊接材料标签焊接材料标签.docLabel of Thermal-insulating Canister and Welding Wire Canister 保温筒、焊丝筒标签保温筒焊丝筒标签.docC

24、ollection List of Welding Material 焊材领用单焊材领用单.docWarehouse in/out record焊材出库/入库记录焊材出库入库记录表doc4. 1. 1 Welding Engineer 焊接工程师1) Be responsible for post training of baking operators;负责对焊材烘干员进行上岗培训；2) Be responsible for technical guidance of weld material drying; 负责焊材烘干的技术指导；3) Prepare technical require

25、ments for controlling of welding materials. 确定焊材控制的技术要求；4) Prepare welding materials requirement planning, distribution plan and distribution sheet of welding materials.编制焊接材料需求计划、分发计划和焊接材料领用单；4. 1. 2 Material Section 物资组1) Be responsible for reception, storage, maintenance and distribution of weldi

26、ng materials.负责一级库中焊接材料的接收和贮存、保管和发放；2) Be responsible for providing quality certificates and verification report ( if applicable ) of welding materials提供焊接材料质量证明文件，如果有复验，还需提供复验报告；3) Be responsible for preparing and recording welding material release record for distribution from Level I to Level II w

27、arehouse, see appendix X for record form.编制并记录一级库中焊材发放记录，记录样表见附件9。4. 2 Construction Management Department 工程夸B4. 2. 1 Welding Material Baking Operator 焊材烘干员1) Be responsible for storage, baking, maintenance, distribution and recovery of welding materials in Level II Warehouse;负责二级库焊接材料的存储、烘干、保温、发放与回

28、收；2) Record temperature and humidity of Level II ware house (See Appendix 1 for record form). Prepare welding material label in the baking oven (See Appendix 2 for record form). Prepare welding material label in maintenance oven (See Appendix 3 for record form). Prepare baking record of welding mate

29、rials (See Appendix 4 for record form).记录二级库的温度和湿度(见附录1)和焊接材料的烘干记录(见附录4)。编制 烘干箱内焊接材料标签(见附录2)和恒温箱内焊接材料的标签(见附录3)；3) Prepare special record for welding materials distribution; see record form for appendix 5. The record shall include specification and classifications of welding materials, heat NO, lot N

30、O, distribution time, maintenance records, signature of withdrawal personnel. Prepare warehouse in/out record, see appendix 9.负责对焊材的发放建立专门记录，见附件5o记录内容包括焊材规范、规格、 炉批号、发放时间、保温记录、领用人。编制出库入库记录表格，见附表9。4) Dispose the recycled waste welding rods and welding rod ends and Place them in a fixed location.负责对回收的

31、废焊条和焊条头做出处理，存放于固定位置。4. 2. 2 Welder/Welding Operator 焊工/焊接操作工1) After receiving welding electrodes, put them into portal oven immediately.焊条领用后，立即将其装入保温桶中；2) Welding materials received shall be correctly used on designated welding seams.将领取的焊接材料，正确地使用到指定焊缝上；3) Unused welding materials and electrode e

32、nds shall be returned to baking room.将未使用完的焊接材料和焊条头退回烘干房；4. 3 Quality Management Department 质量管理部1) The inspectors implement acceptance inspection for welding materials;检查人员对焊接材料进行接收检查；2) The inspectors will supervise & inspect the management, use of welding materials.质量人员对焊接材料的管理和使用进行监督、监查。5. Detai

33、led Descriptions 详名田说明5. 1 Acceptance Inspection of Welding Material 焊接材料的验收5. 1. 1 Welding material, which provided by SNPEMC with complete and clear labels, integral package, and complete quality documents can be inspected and then accepted.SNPEMC提供的焊接材料必须标志齐全、清晰，包装完整，质量文件齐全，方可 验收入库。5. 1. 2 ASME w

34、elding materials shall be identified by label (see appendix6. after acceptance.ASME焊接材料验收合格后，贴上附录6的标签5. 2 Storage of Welding Material 焊接材料的保管5. 2. 1 The welding material to be used for ASME code items should be stored separately and with obvious identifications.对于ASME规范产品用焊材，应有明显标志并单独存放。5.2.2 Recomm

35、ended storage conditions for welding material, which is provided by manufactory, shall be preferred and followed, the corresponding requirements identified in this procedure shall be satisfied where without recommended presentation.应首选和遵循制造厂推荐的焊材贮存条件。当没有推荐介绍时，应满足本程序 中明确的相应要求。If welding materials are

36、 not removed from manufacturer package, they may store at ambient temperature in level I warehouse. Once electrodes are taken from manufacturer package, they shall be stored and dried according to manufacturer instruction in level II warehouse.若焊材包装没有完好无损，可以按照周围环境存放在一级库中。但焊材一旦从 生产厂包装中取出后，应立即根据厂家要求在二

37、级库中进行烘干，保温。5. 2. 3 The welding material shall be placed on the shelf with at least 300mm distance away from ground and wall.焊材应存放在货架上，货架应离地、离墙至少300nin以上。5. 2. 4 The level II warehouse (baking room) shall be provided with air conditioner, dehumidifier and temperature & relative humidity indicator for

38、 controlling temperature and humidity in the room. 在焊材二级库(烘干房)内应配置空调、除湿机、温湿度计，控制室内的温度和 湿度。5. 2. 5 In the Level II warehouse (baking room), the temperature shall be controlled at the range of 20 to 40, and relative humidity should be controlled as lower than 50%.在焊材二级库(烘干房)内，温度应控制在2040,相对湿度应控制在50% 以下

39、。5. 3 Distribution of Welding Material (Level I warehouse)焊接材料的发 放(一级库)5. 3. IThe administrator of Level I warehouse (welding material warehouse) shall distribute welding material to Level II warehouse (welding material baking room) according to the requirements of Welding Engineer, and then make re

40、cord. Welding engineer shall sign on the record (see appendix 9 for record).一级库房(焊材仓库)管理员根据焊接工程师要求，将焊材发往二级库(焊材 烘干室)并做好焊材出库记录。焊接工程师在出库记录上签字，出库记录建附录 9o5.3.2 Welding engineer will determine the type and quantity of welding material that distributed to welder /welding operator by Level II warehouse baki

41、ng operator.一级库管理员向二级库发放的焊材的类型、数量由焊接工程师决定。5. 4 Baking of Welding Material 焊接材料的烘干5. 4. 1 Before the baking welding electrode, baking operator shall check and confirm the model/trademark, specification and heat or lot No. of welding material in conformity with the quality certificate and in-store rec

42、ord of welding material before putting electrodes into the baking oven.焊条在烘干前，烘干人员须逐包核对焊材的型号/牌号、规格、炉/批号，当与 质量证明书和入库记录完全相符时，方可放入烘干箱内。5.4.2Baking temperature of welding material shall supplied by manufactory and meet the requirement of specification. When temperature ranges are different, obvolute par

43、t will be taken as baking temperature. When temperature ranges are totally different, baking temperature shall be confirmed by owner or design party.焊接材料的烘干温度应由生产厂家提供并满足焊材分类标准。当两者烘干温度 有所差异时，取交叉重叠部分作为实际烘干温度。当两者没有交叉重叠部分时, 应按照设计方或业主方的要求对焊接材料进行烘干。For example: For E018M-H4R, manufactory recondition bakin

44、g temperature is 370, ASME SFA5. 5 baking temperature is 260427. The actual temperature will be used is 370427.例：E9018-MH4R焊条，厂家推荐烘干温度为370 , ASME SFA5. 5推荐烘干温 度为260427。实际制定的烘干温度为370427o5. 4. 3 The welding material should be baked for immediate use according to the actual demands, preventing welding

45、electrodes from uneven heating or humidity discharge failure in baking.焊材随用随烘的原则，避免焊条烘干时，受热不均和潮气不易排出。5.4.4 Baking personnel should bake welding rod strictly in conformity with the baking procedure, and sudden baking and sharp cooling should be prevented for avoiding fall-off of scale.烘干人员严格按照要求进行焊条烘

46、干，严禁爆烘、急冷，以防止药皮开裂脱落。5. 4. 5 One baking oven can bake only the welding rod of one trademark at the same time. Different welding rod ovens/batch No. and specifications should be separated by partition and be indicated.一台烘干箱同一时间内，只能烘同一牌号的焊条。焊条炉/批号、规格不同时， 它们之间必需用隔板隔开，并做上标记。5. 4. 6 Soldering flux used fo

47、r SAW welding of carbon steel and low alloy steel: soldering flux with damaged package must be rejected or baked for one hour at no lower than 260. The unpacked soldering flux must be immediately distributed. If unpacked soldering flux is to be used, the top one-inch-thick soldering flux must be rej

48、ected. The damp soldering flux must be prohibited in use.对于碳钢和低合金钢SAW焊用的焊剂：包装损坏的焊剂必须予以废弃或在使用 前不低于260烘干1小时。打开包装后焊剂必须立即发放，如使用已打开包 装的焊剂，最上面1英寸厚的焊剂必须废弃。已潮湿焊剂严禁使用。5. 4. 7 The baking temperature should be automatically controlled by the device calibrated, after set up by baking operator. Baking personnel should keep records on baking.烘干温度经烘干员设定好后，由经过标定并在有效期内的装置自动进行控制， 烘干员做好烘干记录。5. 5 Maintenance of Welding Material 焊接材料的保温5. 5. 1 After baking, welding electrode shall be kept in maintenance oven. Holding temperature shall be supplied by manufacturer, and