大口径管道焊接作业指导书.doc

CSPC Nanhai Petrochemicals ProjectSEPCO Electric Power Construction Corp.CSPC NANHAI PETROCHEMICALS PROJECT南 海 石 化 项 目Work Instruction For Large Bore Pipe Welding大口径管道焊接作业指导书WORKING INSTRUCTION: WI-8710-8100-0067SEPCO 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.H目 录TABLE OF CONTENTS1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Construction procedure and plans 7工作安全分析（JSA-8560-8101-0147）修改记录Revision Information版次Ver.章节号Section No.主要修改内容Description of main changesB2增加“PR-8710-8100-0218 焊缝跟踪程序 Rev.00”Add the “PR-8710-8100-0218 Weld bead tracking procedure Rev.00”1工程概况PROJECT GENERAL DESCRIPTION1. 1汽电联产项目STG部分的大口径管道主要有低碳钢(ASTM A106B)、P11、P22共3种材质，具体规格见下表所示： The large bore pipe in part of STG for S&P project mostly includes three kinds of material characteristic such as low carbon steel(ASTM A106B), P11, P22, refer to the following sheet on the detailed description:材质 Material characteristic规格Description 材质Material characteristic 规格DescriptionCS(ASTM A106B)88.9X5.49ASTM A335 P1188.9X7.6288.9X7.62114.3X8.56114.3X6.02168.3X10.97114.3X8.56219X12.7168.28x18.24323.8X17.45219.08x12.7406.4X21.41219.08x23.01457X23.8219.08x6.35610X30.94219.08x7.04ASTM A335 P22273.05X31.8273.05x28.58323.8X37.6273.05x7.8355.6x41.1273.05x9.27610X69.6323.85x17.45323.85x33.32323.85x6.35355.6x7.92406.4x40.46406.4x7.92406.4x9.53457.2x23.8457.2x7.92508x9.53609.6x14.27609.6x9.53762x9.5813x9.532 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 PR-8710-8100-0025 焊接程序WELDING PROGRAM Rev.0024 PR-8710-8100-1001 通用焊接标准General welding standard Rev.0125 PR-8710-8100-0213 NDE管理程序NDE Management Rev.0226 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 WI-8610-8100-0004C 气体管理Gas Management Rev.002.11 PR-8710-8100-0215 焊接热处理Welding Heat Treatment Rev.002.12 火力发电厂焊接热处理技术规程（DL/T819-2002）Welding heat treatment technique regulations for thermal power plant （DL/T819-2002）213 PR-8710-8100-0218 焊缝跟踪程序 Rev.00 Weld bead tracking procedure3 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、焊工资格认定测试、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具有相应资质的焊工和热处理工。 Provide qualified welder and heat-treatment worker.4.3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. 4.4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. 4.5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. 4.6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1015mm。 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: 1015mm for each side.4.7对接单面焊的局部错口值不应超过壁厚的10%，且不大于1mm。 Partial value of fissure of displacement of butt one side weld shouldnt be over 10% of thickness of wall, and no more than 1mm. 4.8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. 4.9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. 410焊接材料应存放于干燥、通风良好、温度大于5，且相对空气湿度小于60%的库房内。焊条使用前应按其说明书要求进行烘焙，重复烘焙不得超过两次。焊丝使用前应清除锈垢和油污，至露出金属光泽。 The welding material should be stored the dry storeroom where it has good ventilation, and the temperature is over 5，the relative air humidity is less than 60%. Bake the welding rod according to the instruction requirement prior to use it. Dont bake it repeatedly over two times. Clean out the rust and oil contamination before using the wire for welding till it exposes the metal gloss.411坡口的制备应以机械加工的方法进行。如使用火焰切割切制坡口，则应将割口表面的氧化物、熔渣及飞溅物按7.6.1条的要求清理干净，并将不平处修理平整。 The groove preparation should be done with the method of machinery process. If use the flame to cut the groove, the oxide of notch surface, sinter and splash object should be cleaned up according to the requirement in item 7.6.1, and make the accidented place level.5 资源配置resource allocation51 主要施工机具如下The main construction machinery and tools are as follows：ZX7-400ST逆变焊机（contra-variant welder）30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；氩弧焊枪 Argon arc welding torch 20把；钢丝刷 Steel wire brush 20把；记号笔 Sign pen 20只；手电筒 Flashlight 20只；测温笔 Color pencil 20只。52 人员配置 Personnel allocation：焊接工程师和质检员 Welding engineer and QC inspector4人；安全员 Safetyman 1人；焊工 Welder 20人。6施工工序和施工方法WORKING PROCEDURE AND METHOD6.1焊前预热Preheating before welding6.1.1焊接前按照预热工作单规定的温度和方法预热。Preheating piping by “preheat working sheet” before welding。6.1.2施焊过程中，层间温度应不低于规定的预热温度的下限，且不高于400。 The interlayer temperature should be no lower than the stated lower limit of preheating temperature, and no higher than 400 in course of welding. 6.2 焊接 Welding 6.2.1开工前由班长将焊缝验收记录单交给有相应资质的焊工，焊工应严格按照上面规定的WPS施焊。 The monitor will hand in the Acceptance record for welding beadto the qualified welder before commencement, the welder should do the welding strictly according to the stated WPS . 6.2.2氩弧焊打底的焊层厚度应3mm。 The thickness of welding layer rendered by argon arc welding should be less than or equal to 3mm。6.2.3为减少焊接变形和接头缺陷，直径大于194mm的管子对接焊口宜采用二人对称焊。 Weld the butt welding bead of pipe of which the diameter is more than 194mm with the method of symmetrical welding in order to reduce the welding distortion and the joint deficiency. 6.2.4焊工焊完一个焊口后，应打磨焊口表面和附近区域，清除飞溅和尖锐棱角等，并对焊口外观进行目视自检（visual test），对咬边等表面缺陷马上修补。 Burnish the weld surface and the nearby area and clean out the splashing objects and acuminous edges and so on after welding a weld bead, also do the visual test to the appearance of welding bead, repair the surface deficiency such as the undercut at once. 6.2.5支架管部焊接的要求（包括检验、预热、热处理）与管道焊缝相同，并按照相同的等级要求做NDE检验。The requirement of support pipe welding (including inspection, preheating, heat treatment) is the same as the pipe welding bead, and do the NDE test according to the same grade. 6.2.6焊接质检员应巡视现场，监督焊接全过程，检查焊接质量。The weld QC inspector should patrol the site and supervise the whole course of welding, and also inspect the welding quality. 6.2.7多层多道焊的接头应错开。The joint of multilayer should be staggered. 6.3 焊后热处理(PWHT)6.3.1热处理工人应严格按照热处理工作单规定的要求进行热处理工作。The worker should perform PWHT according to the given parameter by “PWHT SHEET”.6.3.2降温过程中，温度在300以下可不控制。It can be out of control if the temperature is lower than 300 in course of dropping in temperature.6.4 焊口的返修 Patching of welding bead 6.4.1焊接缺陷超过标准时，可采取挖补方式返修。但同一位置上的挖补次数一般不得超过2次。Patch it with the method of mending when the welding deficiency exceeds the standard. However, the mending time in the same position cant generally exceed two times. 6.4.2 由焊接工程师制定焊接返修工艺，并由具有相应资质的焊工进行返修焊接，返修记录应与该焊口的焊接记录存放在一起。The welding engineer establishes the welding patching process, and the qualified welder do the patching welding, the patching record should be put together with the welding record of weld bead. 6.4.3需进行热处理的焊接接头，返修后应重做热处理。 Do the heat treatment over again to welding joint which needs the heat treatment after patching.6.4.4每个焊工取得资质后最初焊接的焊口要在记录单上注明。The first batch weld should be remarked on the Acceptance record list of welding bead after qulification.6.5质量检验 Quality inspection6.5.1每个焊口焊接完成后，焊工本人应立即进行100%外观自检，然后由QC2、QC3按照规定的比例进行复检，原则上在当天晚上进行NDE检验。 The welder should do the appearance test in person after welding each weld bead, then to check it again by QC2, QC3 according to the stated proportion, in principal, do the NDE test at night on the same day.6.6记录 Record6.6.1焊工在对口点焊完成后，在焊缝记录验收单上相应栏内签上名字；在每个焊口完成后在相应栏内签上名字和日期。 After spot welding the weld bead, the welder will sign it up in the relevant column of the Acceptance record list of welding bead; Sign the name and date in the relevant column after finishing each welding bead. 6.6.2在焊缝验收记录单上的全部焊口完成后，班长应将其交给焊接工程师。 The monitor should hand it in to the weld engineer after finishing all welding beads in the Acceptance record list of weld bead. 6.6.3焊接工程师把焊缝验收记录单与相应的NDE报告、热处理记录单、焊缝记录图放在一起保存，做为竣工资料。The weld engineer should put the Acceptance record list of welding bead together with the NDE report, heat treatment record and welding map, regarding them as the completion information. 6.6.4每个焊工取得资质后最初焊接的焊口要在记录单上注明。The first batch weld should be remarked on the Acceptance record list of welding bead after qulification.7附件: AttachmentJSA-8560-8101-0147 Large Bore Pipe Welding Job Safety Analysis大口径管道焊接工作安全风险分析72e0d4c292491a9d4f67cf6ad1ba899f.pdf Page 18 of 18 附件 JSA-8560-8101-0147 Large Bore Pipe Welding Job Safety Analysis大口径管道焊接工作安全风险分析 JOB SAFETY ANALYSIS工作安全分析 Date（日期 ）：26 JAN 2004 Job Title工作名称: Large Bore Pipe Welding大口径管道焊接LOCATION地点：Erection Site安装现场JSA No JSA编号: JSA-8560-8101-0147DEPARTMENT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Wire arrangement电线的布置Contact with electricity or electric discharge触电MElectricians should put on personal protective equipment;电工人员应穿戴个人劳动用品；The insulation of wires is good and the naked part with power should have protection measures.用电线路应绝缘良好，裸露带电部分应有防护措施Slip, trip or fall on same level滑倒 绊倒或坠落LCheck the ladder used for laying wires and have slip prevention measures;电线布置使用的梯子，应进行检查，并有防滑措施Exposure to fire火灾MStrictly forbid wires hanging on the brake directly and plugging into socket directly;严禁将电线直接勾挂在闸刀上或直接插入插座内使用Injury by hand tool传递工具伤害MDuring wires laying, fall-prevention-rope should be used in passing and using small tools overhead.布线过程中，高空传递、使用小型工具应系好防坠绳Welding work焊接施工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Falling 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