QP-06- 焊接返修程序.doc

Shanghai Baoye Group Corp., Ltd上海宝冶集团有限公司General Welding Repair ProcedureSBC-JZGS/ASME-06Shanghai Baoye Group Corp., Ltd Procedure Document上海宝冶集团有限公司程序文件Document Name：General Welding Repair Procedure文件名称：焊接返修程序Document No：文件编号：SBC-JZGS/ASME-060Issue for Use2014.05.16李海娇李昆Revision No.版本号Reason for issue/Revision发布/修改原因Issue Date编制日期Issued by编制者Approved by批准1. Scope 范围1.1 This procedure is prepared to establish repair procedure for defects on the material, welds and pressure parts of Code items which is frequently found on the material and welds. This procedure is supplementary requirement to the QC Manual.在材料和焊缝上缺陷时常发现，本程序针对材料、焊缝和规范产品上的压力部件的缺陷制定返修程序。本程序是质量管理手册的补充要求。2. Repair of Defects in Materials 材料上的缺陷返修2.1 When unaccepted defects found on the pressure parts during the receiving inspection. Examiner shall report to QC Engineer, If nonconformity exists, QC Engineer shall prepare NCR. 当在接受检验过程中，在压力部件上发现严重的或不能接受的缺陷时，检验员应向质控工程师报告。如果发现不合格存在，质控工程师应准备NCR。2.2 QC Engineer shall be responsible for proposing the disposition of NCR. QC Engineer shall put the number of NCR on the Process Check List (PCL). Design Engineer is responsible for proposed repair method.质控工程师应负责计划NCR的部署。质控工程师应将NCR的编号记录在过程检查单上（PCL）。设计工程师负责提出返修方法。2.3 If the defects shall be repaired by welding, the qualified WPS and welder or welding operator shall be used in repair, the repair method including removing the defects and visual check or NDE examination if it is necessary. 如果缺陷需要焊接来返修，应使用合格的WPS和焊工或焊接操作者。返修方法应包括去除缺陷的方法和外观检查，如果有需要的话还应使用无损探伤。2.4 AI shall be informed the kind and extent of defect, methods of removing defects, repair methods and intended NDT or testing before repair. All inspection and examination reports and results shall be presented to the AI to assist him to make the decision on the acceptance of the material repair.在返修前，AI应被通知缺陷的长度和种类，除去缺陷的方法，修理的方法和无损探伤或试验。所有的检验、检查报告和结果应出示给AI，以便帮助他决定是否接受材料返修。2.5Defective material that can not be satisfactorily repaired or repair is unacceptable to the AI, it shall be rejected.对于AI来说，如果对缺陷材料的返修不满意或返修不可接受，它应被拒绝。2.6All welding repair on the material shall be conducted to fully comply with the ASME Code requirements. After repair and found acceptable by inspection and examination, material can be used for the Code items.所有在材料上的焊接返修应完全根据ASME规范的要求执行。在返修并经检查之后确认可接受时，材料才可以使用在规范产品上。3. Repair of Defects in Welds 焊缝上的缺陷返修3.1 Defects such as irregular surface profiles, overlap, too much high and low shall be repaired by grinding. Defects such as lack of penetration, lack of fusion, slag inclusion, porosity, undercut, under-fill etc. were randomly found in the welds by visual check shall be repaired by welding. Defects shall be thoroughly removed after repair. The visual check shall be conducted after removing defects. Repair welding shall be performed by qualified and experienced welders according to the original WPS. Welding consumables used for repair shall be controlled as the original. Repair weld shall also be identified by stamping or recording down welder identification number. After repairing, the visual check shall be performed and the results shall be made available to the AI during his next visit. After repairing, the nondestructive testing shall be carried out again If the defects are internal defects which are found through the nondestructive testing methods，and the results shall be presented to the AI.可以由目视检测发现的缺陷，例如不规则外形、交迭、太高或太低应用打磨来返修。缺陷如未焊透、未熔合、夹渣、多孔、咬边、（孔型）未填满等应用焊接来返修。在返修之前，缺陷应彻底地被除去。返修后应该进行目视检测。返修焊接应由合格有经验的焊工根据原来的WPS进行操作。返修使用的焊材应按照原始的规则管理。返修焊接也应用印章或记录标记上焊工的识别编号。在返修后，应进行目测，并在AI下次拜访时出示目视结果。如缺陷是通过无损检测手段发现的焊缝内部缺陷，缺陷返修后应再次进行无损检测，并重新评定，其结果应提交给AI。3.2When defects regularly found in the welding, QC Engineer shall carry out investigation on the possible causes. NCR shall be issued and proposed dispose shall be collected from relevant departments. If deemed necessary, new WPS or re-qualification of welder shall be carried out. All repair related inspection and examination shall be indicated on the Process Check List. AI shall be informed before, during and after welding. All repair related examination and inspection results or reports and NCR shall be made available to the AI for review and acceptance.当在焊缝上发现有规律的缺陷，质控工程师应调查可能的原因。NCR应被下发并且处理方法应被从各个相关部门收集。如果认为有必要，新的WPS或焊工资格应被执行。所有与返修相关的检验和检查应在过程检查单上说明。AI应在焊接之前、之时和之后被告知。所有与返修相关的检验和检查的结果或报告、NRC都应为AI的评审和接受准备好。4. Repair of Defects caused by Testing 检测引起的缺陷返修4.1 When defects occurred during the pressure testing or other operation such as assembly, the defects shall be repaired according to paragraph 3.0.当缺陷在压力试验或其它操作时出现，如装配，则应根据3.0进行返修。4.2 After repair including welding repair, visual and/or dimensional check shall be carried out to ensure that no defects existed in the welds, and possible deformation or deviation in dimensions of the repaired pressure vessel shall within to lerance of the AS