焊接控制程序.doc

WELDING CONTROL PROCEDURE1. 焊口编号Weld joint numbering在管道预制工作开始前，须对管道单线图中的所有焊缝进行编号，编号工作按照以下规定进行。Prior to piping fabrication, all weld joints shall be assigned a unique weld number in isometric drawing. Numbering work shall be carried out in accordance with the specification as follows.1.1预制厂的焊口与现场焊口分开进行编号。Shop welds and field welds shall be identified and numbered.1.2每页图纸中的焊口，分预制厂的焊口和现场焊口均从1开始编号,按照工艺流向进行，先编主管焊口，再编支管焊口。Each sheet shall start with 1 and be numbered with the flow, workshop joints and field joints shall be numbered separately. Sequence is main pipe at first and then branch.1.3现场焊口位置的确定，由各技术人员根据对图纸的熟悉及施工经验进行。Field weld location shall be defined by technicians by construction experiences and familiarity to drawings.1.4预制厂的焊缝编号以SW为前缀，从SW1开始往后编。现场的焊缝编号以FW为前缀，从FW1开始往后编。Shop weld shall be numbered with the prefix “SW” such as SW1. Field welding joint shall be numbered with the prefix “FW” such as FW1 etc. 1.5加强板的焊缝及管架与管道相连的焊缝等附属焊缝也需要进行编号，根据工艺流向，在两管道焊缝之间的附属焊缝，编号方法为在前一道管道焊缝编号后加X1、X2来表示附属焊缝。比如在SW3与SW4之间有两个管架的附属焊缝，则附属焊缝的编号为SW3X1、SW3X2.Attachment welds, such as reinforcement welds, welds between supports and pipes, shall be numbered. For the attachment weld between the weld joint of the two pipes, it shall be numbered and denoted with adding X1, X2 at the end of the fore weld joint number. For example, the attachment weld of two pipe supports between SW3 and SW4, its attachment weld joint number are SW 3X1 and SW3X2 respectively.1.6为在单线图中便于分辨不同类型的焊缝，将用三种不同的印章来分辨，圆形的为现场焊缝，六边形为预制厂焊缝，四边形为附属焊缝，所有印章均采用蓝色印泥标识在单线图上，印章如下所示。For facilitate to distinguish different typical weld joint, we will use three stamps with blue inkpad for distinguishing weld joint in the isometric, such as roundness is site weld joint, hexagon is pre-fabrication shop weld joint and quadrangle is attachment weld. Stamp as following:1.7所有的焊缝编号一经给定，不得更改。如在施工过程中发现需要增加焊缝，则增加焊缝的编号接已经编好焊缝编号的最后一个数字往下编即可。不要为了保证焊缝编号的连续性而对所有的焊缝进行重新编号。All weld joint numbering are permanent without modification. During the construction work, added weld joint shall be numbered which following the last number of finished weld joint number. No re-new numbering is not permitted. 1.8在施工过程中，如有焊口取消，则将这道焊口的编号取消，不要将这个编号再用于其它焊口。If any weld joint is being called off, we will cancel its number and not any more use this number to other weld joint.1.9焊缝登记表的建立Registration list of weld joint在单线图的焊口编号标识经大林审核通过后，将焊口的相关情况输入到焊缝追溯表中（焊缝追溯表的格式见附件），焊缝追溯表一旦建立，将作为整个过程中的控制依据。After weld joint numbering of isometric has been reviewed and approved by Daelim, relative information of weld joint shall be imputed into traceability list (for details, please see the attachment) and it shall be as a control reference. 1.10非焊接型式管架的控制Non-weld pipe support control为便于对非焊接形式管架安装情况的控制，对非焊接形式的管架也进行编号。编号方法与附属焊缝的编号方法相同，只需将附属焊缝编号中的X改称Y即可。非焊接形式管架的编号也输入到焊缝追溯表中进行控制。For facilitate to control the installation of non-weld pipe support, it shall be numbered yet. The numbering method is the same as attachment weld and change the number X of attachment weld into Y. Non-weld pipe support numbering shall be imputed into traceability yet for controlling.1.11管段编号Spool Numbering为对预制好的管段进行辨识，须对管段进行编号。每两道现场焊口之间部分的管道即为一个管段。管段编号有以下三部分组成：The pre-fabricated spools shall be numbered for distinguishing. The pipe between the field weld joint per two passes is as a spool. The spool number shall be composed of the following three parts: 管道单线图号+本条管线总管段中的第几段/本条管线的总管段数Pipe isometric Number, spool number of header for this pipeline and header spool numbers of this pipeline2、材料标识及追溯Material Mark and Tracing为保证地上工艺管道制作、安装过程中材料的正确使用以及便于准确追溯，按照公司质量管理程序的要求及TEAM IIP的相关要求，按以下规定对所有的管道组成件进行标识。For facilitate to trace the material and ensure to use correctly material during the process piping fabrication and installation, all pipe components shall be marked according to following regulation and conformance with the requirement of quality control procedure of TCC and TEAM IIP requirement.在管道组成件喷丸处理，底漆和中间漆结束后，因原有标识被除去，对管道组成件进行重新标识。After finishing the shot blasting, primer and intermediate coat work, re-do marking work shall be carried out because the origin mark has been removed.2.1材质标识：Material Marka材质的标识用油漆进行，用于标识的油漆必须无害，无硫磺并且不含锑、砷、铜、铅、汞、钠、钒并且对正式管道的油漆不能有伤害。Material shall be marked with paint. The paint for marking is not content of stibium, arsenic, copper, lead, mercury, natrium and vanadium and not damage to the pipe paint.b. 对于管子和对焊管件，沿着各部位做上连续条纹的色标。各色标条纹尽可能宽，大约在25mm左右。For the pipe and butt-welding fittings, continuous stripe color code shall be marked along the various items. Various color code stripe are widened as soon as possible with wideness of about 25mm.c.对于所有其他的材料，在两个单独位置上做上色标（构件反面）。色标直径大约25mm。For all other materials, the code color shall be marked at the two isolated locations (component inverse) with diameter of about 25mm.具体材料的颜色要求Colors Required for Specific Materials材料类型Material Type材料设计Material Designation颜色Color碳钢Carbon SteelAPI 5L Gr.B (Smls. & EFW)API 5L Gr.B (Galvanized)ASME A53 Gr.BASME A105ASME A234 Gr.WPBASME A216 Gr.WCB1 纯白(Solid White)1纯白(Solid White)1纯白(Solid White)1纯白(Solid White)无标识(without Code)1纯白(Solid White)（See Note 2）碳钢（优质的）Carbon Steel （Killed）ASTM A106 Gr.BASTM A672 Gr CB60 Class 32ASTM A515 Gr60无标识色Without Color Code碳钢（低温冲击试验）Carbon Steel(Low Temperature Impact Tested)ASTM A333 Gr6ASTM A671 Gr CC60.S2 CL.32ASTM A350 Gr LF2ASTM A420 Gr WPL6ASTM A516 Gr70ASTM A352 Gr LCB1 纯红(Solid Red)1 纯红(Solid Red)1 纯红(Solid Red)1 纯红(Solid Red)1 纯红(Solid Red)1 纯红(Solid Red)不锈钢 Stainless SteelASTM A312、特殊不锈钢Special SS304L型 Type 304L316L型 Type 316L321型 Type 321LDIN 1.43611 纯黑(Solid Black)1 纯粉红(Solid Pink)1 纯兰(Solid Blue)2 纯红(Solid Red)2.2对于不同要求油漆的标识：Paint mark for various requirements因在预制厂管道表面只是喷完中间漆，本项目现场油漆主要有以下不同的要求，为保证不同要求油漆的管道不混用，管道中间漆完成后需进行颜色标识，标识色带的宽度定为10mm，以便与材质的色带区分。标识用油漆要求与材质的色带要求相同。颜色按照下表要求进行。Only intermediate coat work for pipe surface of pre-fabrication shop has been finished. After finishing the intermediate coat work, color code work shall be carried out to avoid pipe confusion and the width of color strap is 10mm to facilitate to distinguish the material color strap. Paint requirement for marking is the same as the requirement of material color strap. Color accord to the following table. 材质Material操作温度Operation Temperature表面处理Surface Preparation底漆Primer中间漆Intermediate Coat面漆Finish Coat色标Color Code不保温的不锈钢Non-insulating SS60T150Sa1TC304（150）TC304（150）黄色Yellow151T350Sa1TC306（50）TC306（50）绿色Green不保温的碳钢和低合金钢Non-insulating CS and Low Alloy SteelT120Sa2.5FP102（75）UC201 (125)TC301（50）黄色Yellow121T200Sa2.5FP101（75）TC302 (40)TC302（40）绿色Green201T400Sa2.5FP101（75）TC303（20）蓝色Blue401T600Sa3TC303（20）TC303（20）黑色Black保温的碳钢和低合金钢Insulating CS and Low Alloy Steel-20T150Sa2.5TC304（150）TC304（150）紫色Purple2.3炉批号的追溯：Heat Number tracing:为保证材料的准确追溯，在管道、管件喷砂、喷漆将原有标识覆盖前需将材料的炉批号进行记录，在中间漆喷涂完毕后用油漆将材料的炉批号移植到新的已涂漆表面。对于管子，每次切割后，需对管子的炉批号再次移植，确保每节管子上都能显示其炉批号。标识油漆的颜色与中间漆的颜色不得一致并且不得对中间漆有危害。For facilitate material to trace. The material heat number shall be marked before blasting and painting of pipe and pipe fitting and covering the original mark. After finishing the intermediate coat work, material heat number shall be removed to painted surface. Pipe heat number shall be removed again as soon as finishing cutting work of pipe. Paint color for marking is not the same with intermediate paint color and not damage to intermediate coat.3.焊接日报Daily report for welding为对每天的焊接工作及无损检测工作进行有效的控制，各级管理部门按照以下程序进行每天的焊接控制工作：All levels management department shall carry out the daily welding control work according to the following procedure to control daily welding work and NDT test work.3.1焊接日报的时间范围Time range for daily report of welding每天焊接日报中的焊接工作量为从上一天中午12点到当日12点之间现场（或预制厂）所完成的焊接工作。Daily Welding work quantities in the welding daily report: finished Welding work quantities from previous day 12:00 PM to the day 12:00.3.2焊接日报的格式Format of welding daily report见附表一：焊接日报See the attachment table 1: welding daily report3.2焊接日报的完成流程Flow Diagram of Welding Daily Report各施工班组长统计本日完成的焊接工作量于每天下午2：00前交往焊接检查员Various construction Forman is responsible for calculating daily welding work quantities and submitting it to welding inspector.焊接检查员收到班组报表后到现场核实工作并进行焊缝外观检查，检查结束后报往技术员After receiving daily report, welding inspector shall review it on site and carry out visual inspection of weld joint and report it to the technician.技术员将收到的焊接工作量数据数日到电脑中的焊接控制系统中Technician shall input the welding work quantities data into the welding control system.技术员将打印出的焊接日报交MOODY(FOR SHOP)或SCPM(FOR FIELD)的现场检查员确定需进行无损检测的焊口Technician shall submit welding daily report to site inspector of the MOODY or SCPM and they will decide weld joint needing NDT testing or no