凝汽器组合安装焊接作业指导书.doc

CSPC NANHAI PETROCHEMICALS PROJECT南 海 石 化 项 目Work Instruction For Condenser Welding凝汽器组合安装焊接作业指导书WORKING INSTRUCTION: WI-8710-8100-0098SEPCO Electric Power Construction Corporation山东电力基本建设总公司SEPCOREVDATEREASON FOR ISSUEBYCHKDREVIEWAPPRA26.FEB.2004Issued for ApprovalX.WZHAO S.LXIAO T.PTIAN G.HB20.MAY.2004Issued for ApprovalX.WZHAO S.LXIAO T.PTIAN G.H0027.MAY.2004Issued for use X.WZHAO S.LXIAO T.PTIAN G.H目 录TABLE OF CONTENS1工程概况PROJECT GENERAL DESCRIPTION2编制依据REFERENCES3职责RESPONSIBILITIES4施工准备PREPARATION FOR CONSTRUCTION5 资源配置resource allocation6施工工序和施工方法WORKING PROCEDURE AND METHOD7附录 Appendix 修改记录Revision Information版次Ver.章节号Section No.主要修改内容Description of main changesB4.9点焊使用的焊条和焊接要求与正式焊接相同。The welding rod used for spot welding and the welding requirement are the same as the formal welding.1工程概况PROJECT GENERAL DESCRIPTION1.1汽电联产项目汽轮机厂房凝汽器共有4台，供货时主要分膨胀节、壳体、热井三大部分整体供货。安装顺序：热井就位凝汽器壳体拖运轨道的安装凝汽器吊装至拖运轨道上凝汽器壳体拖运壳体顶起、轨道拆除壳体就位找正热井与壳体连接膨胀节就位并与壳体初找正膨胀节与汽缸连接凝汽器最终定位焊接凝汽器附件安装。 There are 4 condensers in turbine building for S&P unit project, supply the cargo dividing mostly into three parts as follows: expansion joint, shell, heat sink, and treat them as the integer. The erection sequence is as follows: Location of heat sink Erection of shell hauling track for condenser lift the condenser onto the hauling track hauling the condenser shell lifting the shell and removing the track location and alignment of shell jointing for heat sink and shell the expansion joint locates and primitively aligns with the shell jointing for expansion and cylinder final location and welding of condenser accessory installation of condenser .1.2主要焊接工作有四部分：汽缸与膨胀节的焊接、膨胀节与壳体的焊接、壳体与热井的焊接和管道等附件的焊接。 The main welding work is divided into four parts: jointing for cylinder and expansion joint, jointing for expansion joint and shell, jointing for shell and heat sink, jointing for shell and pipe, as well as the jointing for shell and accessories. 2 编制依据 reference21相关设计图纸及文件Correlative design drawing and document 22 电力建设施工及验收技术规范（火力发电厂焊接篇 DL5007-92） Construction and acceptance technique specification for electric power construction (Welding chapter for thermal power plant DL5007-92)23 火电施工质量检验及评定标准（焊接篇96版） Quality inspection and assessment standard for thermal power construction（Welding chapter for edition of 96）24 电力建设安全工作规程（火力发电厂部分2002版） Safety work regulations for electric power construction (part of thermal power plant for edition of 2002)25 电力建设安全健康与环境管理工作规定（2002版） Safety health and environmental management work stipulation for electric power construction (Edition of 2002) 26 PR-8710-8100-0026 焊工培训与考核 Welder Training and Examination Rev.0027 PR-8710-8100-0223 焊接消耗品控制 Consumable stores control for welding Rev.0028 PR-8710-8100-0055 测量和校验设备Measuring and Test Equipment Rev.0029 PR-8710-8100-0038 焊接控制Welding Control Rev.042.10 PR-8710-8100-0025 焊接程序WELDING PROGRAM Rev.002.11 PR-8710-8100-0213 NDE管理程序NDE Management2.12电站钢结构焊接通用技术条件(DL/T678-1999) Common technique conditions for power station steel structural welding (DL/T678-1999)3 职责 responsibility31 焊工负责管道的焊接，并检查自己所焊焊缝的外观。 Welders are responsible for welding the pipe and inspecting the appearance of weld bead welded by self. 32 班组焊接质检（QC1）、工程处焊接质检(QC2)、公司级焊接质检(QC3)负责对焊工日常工作的监督，并按比例对焊缝进行外观检查和验收。 QC1, QC2 and QC3 are responsible for supervising the daily work of welder and inspecting and accepting the appearance of weld bead in proportion.33 焊接工程师负责焊工考试、焊工档案管理、焊接程序、焊接资格认定测试、WPS 以及 PQR 资格认定记录的现场准备、发布并维持，并负责检查、指导焊工和焊接质检的工作。 Weld engineer is responsible for the welder examination, welder files management, weld procedure, cognizance test for procedure qualification, site preparation, issuance and maintenance for qualification cognizance record of WPS and PQR, as well as for inspecting and directing welders and the work of welding quality control. 34 NDE工程师负责无损检测程序准备、发布和维持以及NDE检测及填发NDE报告。 NDE engineer is responsible for the preparation, issuance and maintenance of NDE procedure and NDE detection and filling in and issuing the NDE report. 35基建总公司（以下简称SEPCO）焊接工程师负责施工协调和质量验收。 Weld engineer in Shangdong Electric Power Construction corporation (SEPCO for short) is responsible for the construction coordination and the quality acceptance.4施工准备PREPARATION FOR CONSTRUCTION4.1焊接工艺规程（WPS）和焊接工艺评定(PQR)满足现场焊接需要。 WPS and PQR meet the requirement of site welding.4.2焊机、热处理机、焊条烘干箱等工器具准备齐全，并经过校验。 Tools and instrument such as welding machine, heat-treatment machine, welding rod baking oven are all ready and they have been verified. 4.3使用的各种焊接材料齐全，具有相应的合格证。 All kinds of used weld material are all ready, and have relative qualified certificates. 4.4现场焊接搭设好防风、防雨设施，管道内也不得有穿膛风。 The windshield and rain-proof equipment for site welding has been set up, there is no draft inside the pipe. 4.5焊件在组装前应将焊口及附近母材内、外壁的油、漆、垢、锈等清理干净，直至发出金属光泽。清理范围如下：每侧各为20mm。 Clean up the oil, paint, dirty, rust which are in the weld bead and inside & outside the wall of base material thoroughly prior to assemble the weldment. The cleaning range is as follows: 20mm for each side.4.6对接单面焊的局部错口值不应超过焊件厚度的10%，且不大于1mm。对接双面焊的局部错口值不应超过焊件厚度的10%，且不大于3mm。角焊缝错口值不应超过10%的板厚且不大于2mm。 The partial value of fissure of displacement of butt one side weld shouldnt be over 10% of the thickness of weldment ，and no more than 1mm. The partial value of fissure of displacement of butt double side weld shouldnt be over 10% of the thickness of weldment, and no more than 3mm. The fissure value of the corner weld should be over 10% of thickness of steel plate, and no more than 2mm. 4.7每个项目开工前，安装部门应提前足够的时间通知焊接队开工的日期、系统、项目、管线号、图纸号、材质、规格等，以便焊接队有充足的准备时间。 The erection department should inform the welding team in advance about the commencement date, system, item, pipeline number, drawing number, material characteristic, specification and so on before the commencement of each project, so as to make the welding team have enough time to prepare it. 4.8开工前，班长派出焊工到技术组接受技术和安全交底。 The team leader send welder to the technique group to receive the real intentions of technique and safety before commencement.4.9点焊使用的焊条和焊接要求与正式焊接相同。 The weld rod used for spot welding and the weld requirement are the same as that of the formal welding. 5 资源配置resource allocation51 主要施工机具如下The main construction machinery and tools are as follows：ZX7-400逆变焊机（contra-variant welder） 10台；焊条烘干箱 Baking oven of welding rod 2台；焊条保温筒 heat-insulated mould of welding rod 20个；电焊钳 Electrode holders 20把；钢丝刷 Steel wire brush 20把；记号笔 Sign pen 12只；手电筒 Flashlight 12只；52 人员配置：Personnel allocation焊接工程师和质检员 Welding engineer and QC inspector 2人；安全员 Safetyman 1人；焊工 Welder 10人。6施工工序和施工方法WORKING PROCEDURE AND METHOD6.1 热井与壳体的焊接 Jointing for the heat sink and the shell 6.1.1 材质：热井和壳体的材料均为低碳钢P265GH(EN10028)。 Material characteristic: The material for heat sink and shell are all the low carbon steel P265GH(EN10028)。6.1.2 适用的焊接工艺规程（WPS）:HZ-016（见附录一）； Applied WPS: HZ-016 (Refer to appendix 1)6.1.3 焊接方法 Welding method ：SMAW；6.1.4 焊接材料 Welding material ：E4315，3.2mm、4.0mm；6.1.5 接头形式 Form of joint ：角焊缝 Corner weld ；6.1.6点焊 ：每段点焊长度应大于50mm，间隔300mm； Spot welding: The length of spot welding for each section should be greater than 50mm, and it is at intervals of 300mm; 6.1.7 焊接 Welding ：a. 采用4名焊工对称布置在壳体的四周，同时由左向右施焊，保持方向和速度基本一致。Collocate it around the shell symmetrically by four welders, at the same time, weld it from the left to the right, keeping the direction and the speed consilient basically. b. 所有连接焊缝均采用多层多道焊，严禁单层单道焊。Weld all connecting welding bead with the method of multilayer, strictly prohibit welding it with the method of single layer. c. 每个连接点（如两条焊缝之间的接头，两个焊工之间的接头等）的每道或每层焊缝间的接头要错开50-100mm。 The joint between weld bead of each layer for each junction( such as joint between two pieces of weld bead, joint between two welders and so on ) should be staggered by 50-100mm。d. 焊工施焊时，采用小电流、分段跳焊、小摆动等焊接方法减小焊接变形；Employing the method of low current, subsection skip welding, small swing and such methods when welding in order to reduce the welding distortion; 6.2膨胀节与壳体的焊接 Jointing for expansion joint and shell 6.2.1 材质：膨胀节的材质是低碳钢P265GH(EN10028)，厚度是20mm，壳体一侧的材质是低碳钢P265GH(EN10028)。接口部分为4m1.3m的方形结构。 Material characteristic: the material characteristic of expansion joint is the low carbon steel P265GH(EN10028)，20mm thick, the material characteristic of one side of shell is the low carbon steel P265GH(EN10028)。The part of interface is the quadrate structure of 4m1.3m. 6.2.2适用的焊接工艺规程（WPS）:HZ-016（见附录一）； Applied WPS: HZ-016 (Refer to the appendix 1); 6.2.3焊接方法 Welding method ：SMAW；6.2.4焊接材料 Welding material ：E4315，3.2mm、4.0mm；6.2.5接头形式 Form of joint ：角焊缝 Corner weld ；6.2.6点焊：每段点焊长度应大于50mm，间隔300mm； Spot welding: the length of spot welding for each section should be greater than 50mm, and it is at intervals of 300mm; 6.2.7焊接 Welding ：采用4名焊工，要点与6.1.7相同。Employing four welders, the key point is the same as the 6.1.76.3 排汽缸与膨胀节的焊接 Jointing for cylinder and expansion joint 6.3.1材质：膨胀节的材质是低碳钢P265GH(EN10028)，排汽缸的材质是低碳钢，厚度是25mm。 Material characteristic : The material characteristic of expansion joint is the low carbon steel P265GH(EN10028)，the material characteristic of cylinder is low carbon steel, the thickness is 25mm. 6.3.2适用的焊接工艺规程（WPS）:HZ-016（见附录一）； Applied WPS: HZ-016 (Refer to appendix 1);6.3.3焊接方法 Welding method ：SMAW；6.3.4焊接材料 Welding material ：E4315，3.2mm、4.0mm；6.3.5接头形式 Form of joint ：角焊缝 Corner weld ；6.3.6点焊：每段点焊长度应大于50mm，间隔300mm； Spot welding: The length of spot welding for each section should be greater than 50mm, it is at intervals of 300mm; 6.3.7焊接 Welding ： 采用2名焊工对称施焊，除了与6.1.7相同的要求外，应安排专人统一指挥，机务班组安装千分表监测汽缸台板变形情况， 如有异常立即通知焊工停焊，以便采取措施处理。Do the symmetrical welding by two welders except for the requirement which is the same as the 6.1.7, send special person to direct it, steam turbine team erect the dial gauge to monitor the distortion situation of cylinder bedplate, inform the welder to stop welding if something exceptional happened in order to take measures for disposal. 6.4 管道的焊接 Pipe welding 6.4.1 焊口规格及焊接工艺 Welding bead specification and welding process ：序号Number 管口编号Nozzle No.规 格Specification 焊口数Quantity of welding bead 材 质Material characteristic 焊接方法Welding method 焊接消耗材料Consumption material for welding 1P114.322个St35.81GTAWJ502N168.34.51个St35.81GTAWJ503O323.97.11个St35.81GTAW+SMAWJ50+E50154M88.93.22个St35.81GTAWJ506.4.2接头形式：V型坡口对接，坡口角度3035度，对口间隙12mm； Form of joint : V type groove butt, the groove angle is 3035 degrees, the clearance of welding bead is 12mm； 6.4.3 NDE方法及比例：采用射线（RT）方法，10抽检，或按照图纸要求。 NDE method and proportion: Employing the RT method, selective examination of 10, or according to the drawing requirement . 6.4.4 采用氩弧焊打底过程中，应严格检查根部情况，杜绝根部缺陷。 Strictly examine the root condition and put an end to the root deficiency in course of rendering with argon arc weld. 6.4.5 盖面时应注意焊缝外观质量。 Pay attention to the appearance quality of welding bead when welding the surface. 6.4.6焊后仔细清理表面焊渣，并检查是否有表面缺陷。 Clean up the surface scoria after welding and examine whether there is surface deficiency or not. 7附录Attachment: 附录一：JSA-8560-8101-0247 Condenser Welding Job Safety Analysis凝汽器组合安装焊接工作安全风险分析 附录一： JSA-8560-8101-0247 Condenser Welding Job Safety Analysis凝汽器组合安装焊接工作安全风险分析 JOB SAFETY ANALYSIS工作安全分析 Date（日期 ）：31 JAN 2004 Job Title工作名称: Condenser Welding凝汽器组合安装焊接LOCATION地点：Erection Site安装现场JSA No JSA编号: JSA-8560-8101-0247DEPARTMENT部门WET1焊接队SUPERVISOR主管人: TITLE OF PERSON WHO DOES JOB工作执行人职务:PREPARED BY 编制： REVIEWED BY 审查: APPROVED BY 批准：Environmental Conditions环境条件Inside内部 Outside 外部 Cold 冷 Heat 热 Wet 湿 Dust 灰尘 Vapors/Mist 水汽 Noise 噪音 Vibration 震动 Other 其它 Heavy Rain 大雨Primary Job Functions & Position 基本工作行动Lifting 举重 Grasping 抓取 Pushing 推 Sitting 座 Reaching 延伸 Bending 弯曲 Kneeling 跪Standing 直立 Pulling 拖 Squatting 蹲 Other 其它SEQUENCE OF BASIC JOB STEPS工作步骤POTENTIAL HAZARD潜在危险风险评估RAM （H 、M、L）RECOMMENDED ACTIONOR PROCEDURE 控制行动措施ACTION BY 执行人DATE DUE完成日期REMARK备注Welding work焊接施工Asphyxiation 窒息MTo keep air ventilation using exhaust fan.使用抽风机保持现场空气畅通.Slip, trip or fall on same level滑倒 绊倒或坠落Injure by fall of ground地面跌倒伤害MLook at the road during walking, gazing around is forbidden; dont be nervous during working.提高工作警惕性，走路时要看脚下，不能东张西望，工作时不要紧张Contact with hot surface or substance 烧伤烫伤MHeat insulation measure shall be taken for welding preheat; welding operator shall wear specified working clothes; warning board such as “Danger: High Temperature!” shall be hung in high temperature area.焊接预热时，应采取隔热措施；焊工穿专用工作服，在高温区域悬挂“高温危险”等警示牌。Sunstroke中暑Mkeep air ventilation and prepare for sunstroke-prevention articles.保持现场空气畅通，配备必要的防止中暑的物品Contact with electricity or electric discharge触电MInspect whether there is any naked part on the wires; equip each welding machine with circuit breaker. Working platform and welding machine must have reliable earthing.施工前仔细检查电焊线有无裸漏漏电现象，所有电焊机加装漏电保护器，工作平台必须接地可靠，焊机接地正确Explosion 爆炸Exposure to fire火灾MWelding lead shall be kept away from heat source, and must not contact with wire rope, rotating machine; moreover, it must not be set on oxygen cylinder or acetylene cylinder. There mustnt be flammable or explosive objects around welding area. firefighting equipment shall be equipped on site and shall be monitored by specified personnel if necessary.禁止将电焊导线靠近热源、接触钢丝绳、转动机械或将其搭设在氧气瓶、乙炔瓶上,禁止在易燃易爆区域施焊，现场配备消防器材，必要时派专人进行监护.Methods should be used to prevent spark from splashing when sth. Flammable such as paint is nearby. Welders should close the welding machines and check work site to find if survival spark is in the vicinity when welding is over and before weldersleaving.当附近有油漆等易燃物时，应当有防止火花飞溅的措施。当焊工离开现场之前，应关闭焊机并检查是否有残存的火星。Aloft work高空作业Fall of person from height高空坠落HHighrise operator shall wear individual protecting appliance and safety harness , anchor them securely;高空作业人员应穿戴好个人保护用品，并扎安全带，其应悬挂在上方牢固可靠处；walk slowly, no running at height;高空行走时要缓慢，不能跑；do not stand outside the handrail while working or use the handrail to lift something;不得站在栏杆外作业或凭借栏杆起吊物件；Injury by hand tool传递工具伤害Mfall-prevention-rope shall be fastened correctly during handing small tools;传递小型工具时应系好防坠绳；Slip, trip or fall on same level滑倒 绊倒或坠落Hlook at the road during walking ,gazing around is forbidden;走路时要看脚下，不能东张西望；hollow, pit near working area shall be equipped with cover board, safety net or fence;高处作业区周围的孔洞、沟道等应设盖板、安全网或围栏；struck by falling object落物伤人Hthe removed workpiece and residual stock shall be placed at reliable locat