大中径管焊接技术措施.doc

目录Content1编制依据11 Basis of compilation12工程概况22 Engineering profile23施工应具备的条件33. Conditions prepared before the construction.34施工主要机具及材料54 Main equipment and material55主要施工方法和步骤115 Main construction method and process116劳动力配备及工期要求236 Labor allocation and construction duration237施工质量标准和工艺要求247 Construction quality standard and technology requirement248安全施工要求268 Construction safety requirement279成品及半成品保护要求299 finished and semi-finished products protection2910应注意的质量问题2910 Quality problems2911应提供的质量记录3011 Quality records3012附件3012Attachment301编制依据1 Basis of compilation1.1广东电力设计院及哈尔滨锅炉厂提供的设备图纸和技术资料1.1 Equipment drawings and technical information provided by Guangdong electrical power plant design institute and Harbin boiler factory.1.2火力发电厂焊接技术规程DL/T869-20121.2 “The thermal power plant welding technical regulations” DL/T869-20121.3 电力建设施工质量验收及评定规程（焊接篇）DL/T5210-20101.3 “Regulations for construction quality acceptance and evaluation of electric power projects” （welding section）DL/T5210-20101.4火力发电厂焊接热处理技术规程DL/T819-20101.4 “The thermal power plant welding heat treatment technical regulations” DL/T819-20101.5火力发电厂异种钢焊接技术规程 DL/T75220101.5 “The thermal power plant dissimilar steel welding technical regulations” DL/T75220101.6焊接工艺评定规程DL/T868-20041.6 “welding procedure qualification regulations” DL/T868-20041.7焊工技术考核规程DL/T67920121.7 “welder technical examination regulations” DL/T679-20121.8焊接材料质量管理规程JB/T3223-19961.8 “Welding materials quality management regulations” JB/T3223-19961.9管道焊接接头超声波检验技术规程 DL/T82020021.9 “Piping welding joint ultrasonic inspection technical regulations” DL/T82020021.10钢制承压管道对接焊接接头射线检验技术规程DL/T82120021.10 “Steel pressure pipes butt welding joint radiography testing technical regulations” DL/T82120021.11火力发电厂金属光谱分析导则(电力工业部基建司199315号文) 1.11 “Thermal power plant metal spectral analysisguideline” (infrastructuredivision of power industry ministry 199315 article)1.12电力建设安全工作规程DL5009.120021.12 “Power plant construction safety working regulations” DL5009.120021.14焊接和钎焊评定标准ASME IX1.14 “Welding andbrazingevaluation standard” ASME IX1.15动力管道ASME B31.11.15 “ Power pipeline” ASME B31.11.16无损检验ASME Section V1.16“ Non Destructive Examination” ASME Section V 1.17 ASME. BOILER PRESSURE VESSEL CODE 1.18 ASME PART C-WELDING MATERIAL1.19 Reference documentb. WP - 01 - Rev. 00_Written Practicec. UT Procedure SOP RT - 002d. RT Procedure SOP RT 0032工程概况2 Engineering profile2.1厂址位置2.1 Location of plant2.2 电厂规模2.2 Scope of power plant本项目拟建设一台额定出力为670MW超临界燃煤机组，规划容量为2670MW超临界燃煤机组。This project plans to build 670MW supercritical coal-fired power plant, total planning capacity is 2670MW supercritical coal-fired unit.2.3 适用范围 Scope of application本技术措施适用于本工程中所有大中径管(直径89)的焊接，主要包括省煤器出口管、低再进口集箱、省煤器集箱、部分水冷壁集箱、高压给水、给水再循环、中压给水管道、低压给水、部分抽汽管路等大中径管。各项目的规格、材质、焊接参数等以设计院和厂家图纸标注为准，焊口数量以实际安装焊口数量为准。由于图纸未到齐，具体项目的规格、材质及数量等不详。 This scheme is applied for welding works of all the tubes of medium and large diameter( those with diameter 89),including economizer outlet pipe, low temperature reheater inlet header, economizer header, water wall header, HP water feeding, water feed recirculation, IP/LP water feed pipe, extraction steam pipe. The specification, material and welding parameter shall be subject to the drawing of design institute and factory, the welds number shall be based on the actual installation welds number. The detail cannot be assured on account of incomplete drawings. T91管的焊接技术措施详见T/P91钢焊接技术措施。For the T91 tubes welding, please see “T/P91 steel welding technical measures”.3施工应具备的条件3. Conditions prepared before the construction.3.1 人员要求3.1 Requirements for personnel 3.1.1参加本项工程的焊工必须按照ASME IX的标准取得印度尼西亚当地劳工部的相应技术考核项目焊工合格证才有资格参加本工程项目的施工。参加施焊的焊工上岗前必须经过模拟考试，且经技艺鉴定合格LBE/BV、HEI认可后方能上岗施焊。3.1.1The Welders who participate in this project must obtain the appropriate technology certified by Indonesian local Department of Labor according to ASME IX ,and take exams as well as should be qualified and approved by LBE / B & V, and HEI before working.3.1.2施焊前焊工必须接受技术人员的技术和安全交底，技术人员认真填写工艺卡和交底记录，并执行安全技术交底双方签字制度。3.1.2 Welders must accept technology and safety disclosure from technical personnel before welding, technical personnel should fill process cards and disclosure record, and perform safety technical disclosure system of signed by both sides. 3.1.3质检人员应经过专业培训，持证上岗，且具有较强的责任心和丰富的现场施工经验。焊接外观检验由认证的焊接检查员进行检查。3.1.3 Quality control personnel should have professional training certificate, and have strong sense of responsibility and a wealth of experience in the construction site. Visual welding inspection shall be inspected by certified welding inspector.3.1.4热处理工应经过专业培训取得相应证书持证上岗，且应严格遵守措施中的有关规定。3.1.4 Heat treatment workers should have the appropriate training certificate, and should strictly follow the relevant provisions of the construction scheme.3.1.5工地安全员为专职负责人员，各班组另设安全员，负责检查监督施工人员按照安全技术交底和有关安全规程进行施工。3.1.5 Construction site safety officer should be full-time staff, each team should also set up another part-time safety officer, shall be responsible for the inspection and supervision of construction personnel in accordance with safety and technical disclosure and relevant safety regulations for construction.3.2作业环境要求3.2 Operating environment requirements3.2.1施工地点及周围不能有易燃易爆物品的存在，并保证道路畅通。3.2.1 The construction siteand the surroundingcannot havethe inflammable and explosive materials, and shall ensuring smooth traffic. 3.2.2高空作业时，应搭设适合焊工施焊的平台，平台要牢固可靠，且设有防护栏。脚手架、脚踏板必须要绑扎牢固。3.2.2 When the high-altitude operations, should erect welding platform for welders, the platform should be strong and reliable, and with fences.Scaffold and plank must be tied firmly.3.2.3氩弧焊接时，风速不大于2m/s,电弧焊风速应不大于8m/s；施工作业前要搭设防风、防雨棚。3.2.3 During TIG welding, wind speed should be less than 2m/s; the wind speed should be less than 8m/s for electric-arc welding. Shall erect wind-proof sheds and rain-proof sheds before the construction.3.2.4在电焊机、热处理机集中布置处应有充足的动力电源，并搭设防雨、防水等设施。施工现场附近备有集中焊接二次线接线盘。现场的光照要适宜焊工施焊。3.2.4 At the concentrated arrangement position of welding machine and heat treatment machine should have adequate power supply and should erect rain-proof, water-proof and other facilities.Near the construction site should have secondary wire patch board for concentrated welding.The site light should be suitable for welding.3.3工艺评定3.3 Welding procedure qualification本工程的所有焊接工艺评定由北京电力建设公司焊接技术培训中心出具，以此为依据制定出符合ASME标准的PQR/WPS并提交HEI,LBE/BV审阅，保证焊接质量。All welding procedure qualification of the project are issued by the welding technology training center of Beijing Electric Power Construction Company. In order to guide the site construction, and to ensure the welding quality, shall compile the PQR/WPS based on the welding procedure, and should meet the ASME standard.4施工主要机具及材料4 Main equipment and material4.1焊接机具4.1 welding equipment4.1.1施工用电焊机主要采用ZX7-400逆变焊机，锅炉上布置90台电焊机，锅炉房0米层、运转层、炉顶平台及焊接工作量较大的平台层集中布置电焊机集装箱，且统一布线。在锅炉组合场布置40台电焊机。电焊机采用集装箱式布置方案。电焊机二次线采用快速插头，随用随取；同时又可以使电焊机灵活运输至其它场所。焊机将定期进行校准。维护和校准后将在每台机器上贴上标签。确保电源线和接地电缆拥有足够的长度，不允许通过设备，阀门，结构和光栅等进行接地。4.1.1 The project mainly adopts ZX7-400 Inverter welding machine, 90 welding machines shall be arranged on boilers. Shall concentrated arrange electric welding machine container on the boiler room 0 m layer, operation layer, roof platform and the platform layer with larger welding workload, the wiring should be uniform. Shall arrange 40 sets of electric welding machine at the boiler fabrication yard.Shall adopt container-type layout scheme for electric welding machine arrangement. Shall use quick plug for welding machines secondary line, to guarantee the occasional use; while the welding machine can be transported to other places flexibly. Welding machines will be maintained and calibrated periodically. A maintenance and calibration sticker will be attached on each machine. Ensure sufficient length of power and grounding cables are available. Grounding through equipment, valves, structures and gratings will not be allowed.4.1.2焊口热处理使用DWK-180/360KW型远红外热处理机。在锅炉上布置2台热处理设备，汽机房内2台，组合场1台。要求设独立电源或双电源供电，保证设备正常运行。4.1.2 Weld heat treatment using DWK-180 / 360KW far infrared heat machine.Arrangement 2 sets of heat treating equipment on the boiler, and arrangement 2 sets of heat treating equipment in the turbine house, and arrangement one heat treating equipment in the fabrication yard. Require setting up an independent power supply or dual power supply, to ensure normal operation of equipment.4.1.3焊接施工中使用的工具及计量仪表器具如下表：4.1.3 Welding construction tools and measuring instruments:序号No.机 具 名 称Name of machine and tool单位unit数量quantity型 号specification备 注remark1砂轮机grinding machine台set1250/380V2角向磨光机angle grinder个pcs.8100/220V个pcs.4125/220V个pcs.4150/220V3电磨光机 electric grinder个pcs.10220V4氩弧表 argon arc meter块pcs.120Y40/(01-28)MPa5电焊钳 electrodeholder把pcs.160300A6氩弧焊把argon arc welding holder把pcs.100QQS85-160A7面罩 mask个pcs.100头戴Head mounted8护目玻璃 hand shield块pcs.1009-10#9小型手电筒 small flashlight个pcs.805#10电流钳型表Clip-style ammeter个pcs.20-400A此外每名焊工还应备有扁铲、钢丝刷、工具袋等用具。Moreover, each welder should be equipped with flat spade, wire brush, tool bags and other tools.所有用于不锈钢材料的焊接工具将被单独存放。All welding tools grinder to be used for stainless steel materials will be seperately stored and handled in Boiler pressure parts welding area. 4.2焊接材料4.2 welding material4.2.1 焊接前技术人员必须查明所施工项目的材质和规格，以便正确选用相应的焊接材料和确定合适的焊接工艺和热处理工艺。4.2.1 Welding technician must identify the materials and specifications for the construction project, in order to select the appropriate welding materials and to determine the appropriate welding process and heat treatment process.4.2.2所有焊接材料应有制造厂的质量合格证书。合格证将提交LBE/BV批准。供货的焊材应符合如下标准：4.2.2 All welding materials should have qualified quality certificate from the manufacturer. And the certificates will be submitted to LBE/BV for approval. The welding materials shall meet the following standards:不锈钢焊条 Stainless steel electrode: GB/T983-2012低合金焊条Low content alloy electrode： GB/T5118-2012 碳钢、低合金钢焊丝Carbon steel, low content alloy steel welding wire: GB/T8110-20084.2.3焊条、焊丝的选用，应根据母材的化学成份、机械性能和焊接接头的抗裂性、焊前预热、焊后热处理以及使用条件等因素综合考虑。4.2.3 The selection of Welding rod and welding wire should be based on the chemical composition and mechanical properties of the base material, crack resistance of welded joints, preheating, PWHT and conditions of use and other factors.4.2.4同种钢焊接时，焊缝金属性能和化学成份应与母材相当。4.2.4 When the same type steel welding, the metal performance and chemical composition of the welding seams should be matched with base material.4.2.5 异种钢焊接时，应符合下列要求：4.2.5 When dissimilar steel welding, shall meet the following requirements:4.2.5.1异种钢焊接接头的焊接材料选择宜采用低匹配原则，即不同强度钢材之间焊接，其焊接材料选适于低强度侧钢材的。4.2.5.1 Welding materials dissimilar weld joints should be used to adopt undermatching principle, welding of different intensity should use low strength steel.4.2.5.2 A类异种钢焊接接头，选用焊接材料应保证熔敷金属的抗拉强度不低于强度较低一侧母材标准规定的下限值。4.2.5.2 A class of dissimilar weld joints, use welding material to ensure that the tensile strength not less than the lower limit of the lower side of the base material strength standards.4.2.5.3 B类及B类与A类组成的异种钢焊接接头，宜选用合金成分与较低一侧钢材相匹配或介于两侧钢材之间的焊接材料。4.2.5.3 Dissimilar weld joints Class B and Class B combined with Class A , use welding material with low alloy composition or between two sides steel material.4.2.5.4 C-I、C-II及其与A、B类组成的异种钢焊接接头可以选用合金含量较低侧钢材匹配的焊接材料，也可以选用奥氏体型或镍基焊接材料。4.2.5.4 CI, C-II and its relationship with A, Class B composed of dissimilar weld joints alloy content can be selected to match the lower side of the steel welding material, you can also use welding austenitic or nickel-based materials.4.2.5.5 与C-III组成的异种钢焊接接头，选用焊接材料应保证焊缝金属的抗裂性能和力学性能。焊接材料的选用应符合下列规定：4.2.5.5 And C-III consisting of dissimilar weld joints, the selection of welding materials should ensure the performance and mechanical properties of the weld metal cracking. Selection of welding materials shall meet the following requirements:a.当设计温度不超过425时，可采用Cr、Ni含量较奥氏体型母材高的奥氏体型焊接材料。a. When the design temperature does not exceed 425 , we can use Cr, Ni content than high austenitic austenitic base metal welding materials.b.当设计温度高于425时，应采用镍基焊接材料。b. When the design temperature is higher than 425 , nickel-based welding materials should be used.c.两侧为同种钢材，应选用同质焊接材料，在实际条件无法实施选用同质焊接材料时，可选用优于钢材性能的异质焊接材料。c. adopt the same welding material if both sides use the same steel, if the actual condition cannot meet using the homogeneous welding material, heterogeneous steel welding materials better than steel material can be used.4.2.5.6 常用钢材类组别划分Common steel class category类组别class category钢号示例Steel sample类别号category组别class组别号classA碳素钢Carbon Steel（含碳量C0.35%）Q235,Q245R普通低合金钢Ordinarylow-alloy steel（ReL400MPa）Q345R,Q370R,Q390,13MnNbMoR普通低合金钢Ordinarylow-alloy steel（ReL400MPa）Q420,Q460,15MnVNi,18MnMoNbR,15Ni1MnMoNbCuB珠光体型热强钢Pearlitic heat resistant steel12CrMoG,15CrMoG,12Cr1MoVG,15CrMoR,14Cr1MoR,ZG15Cr1MoIV,ZG20CrMoV贝氏体型热强钢Bainitic heat resistant steel12Cr2MoG,07Cr2MoW2VNbB,12Cr2Mo1R,12Cr2MoWVTiB,12Cr3MoVSiTiB马氏体型热强钢Martensitic heat resistant steel10Cr5Mo,10Cr9Mo1VNb,10Cr9MoW2VNbBN,11Cr9Mo1W1VNbBN,10Cr11MoW2VNbCu1BNC马氏体型不锈（耐热）钢Martensitic stainless steel (heat-resistant) steel12Cr13,20Cr13铁素体型不锈（耐热）钢Ferritic stainless steel (heat-resistant) steel10Cr17,06Cr13Al奥氏体型不锈（耐热）钢Austenitic stainless steel (heat-resistant) steel06Cr19Ni10,12Cr18Ni9,07Cr9Ni11Ti,10Cr18Ni9NbCu3BN,07Cr25Ni21NbN,07Cr18Ni11Nb,08Cr18Ni11NbFG4.2.6焊接材料应存放在干燥、通风良好、温度大于5，且相对空气湿度小于60%的库房内。不锈钢焊条将被单独存放，并进行清楚地标识，与碳钢材料区分开来。4.2.6 Welding materials should be stored in a dry, well-ventilated, temperature greater than 5 , and the relative air humidity less than 60% of the storehouse. The stainless electrodes will be separately stored and clearly marking comparing with the CS material.4.2.7焊条在其使用前应按说明书(生产厂家)要求进行烘干,重复烘烤不得超过两次。焊丝焊条必须表面光滑整洁，对非镀铜或防锈处理的焊丝，使用前应进行除油、除锈及清洁处理。4.2.7 Before the use of electrode, baking temperature and duration of baking shall refer to the manufacture instruction, and shall not be dried more than twice.Welding wire and electrode surfaces must be smooth and clean, for non-copper wire or rust treated wire, should decreasing, descaling and cleaning before use. 4.2.8焊条在使用时应装入温度80110的焊条保温筒内，随用随取。4.2.8 all electrodes to be used must be put in the welding electrode quiver with temperature 80110 for use at any time4.2.9钨极氩弧焊用的电极，宜采用铈钨棒。4.2.9 Should adopt cerium tungsten rod for the TIG welding electrodes.4.2.10焊接用气体4.2.10 welding gas氩气购置时，应有合格证，符合GB4842-2006 edition的规定，纯度99.95%。 使用过程中如发现有异常时立即停止使用。When purchasing argon, there should be certificate, meet the regulations of GB4842-2006 edition, purity shall be 99.95%. If there is anomaly during the using process, should immediately stop using.对于充氩气或混合气体的步骤如下：a. 采用水溶解性材料对管子两端进行封堵。b. 对管子内进行填充气体;c. 焊接后，溶解度的材料将通过水压试验除去。The procedure for Argon procedure is as followed:a. Sealed two ends of tube with appropriated solubility material. b. Filling the gas (Argon) into the pressure tubes; After welding, the solubility material will be removed by water pressure test.4.3工程中使用主要钢材及焊接材料4.3 main steel material and welding material 序号No.类别category钢材材质steel material焊接材料welding material氩弧焊丝Argon arc welding wire电焊条electrode1碳钢及普通低合金钢Ordinary carbon steel and low alloy steel20TIG-J50(ER70S-2)J507(E7018)20GTIG-J50(ER70S-2)J507(E7018)SA106CTIG-J50(ER70S-2)J507(E7018)WB36BOEHLER DMO-1GBOEHLER FOX EV652耐热钢Heat-resistant steelSA-335P12、15CrMoGTIG-R30(ER80S-B2)R307(E8015-B2)SA 213-T22、SA-335P22TIG-R40(ER90S-B3)R407(E9015-B3)12Cr1MoVGTIG-R31(ER80S-G)E5515-B2-V12Cr1MoVG+15CrMoGTIG-R30(ER80S-B2)R307(E8015-B2)5主要施工方法和步骤5 Main construction method and process5.1本工程使用的主要焊接方法有：氩弧焊、氩弧焊打底手工电弧焊盖面。5.1 The main methods in this project are: GTAW, GTAW+SMAW5.2焊接环境要求：大于05.2 Welding environment requirement: greater than 05.3焊接施工基本工艺流程：5.3 Welding construction basic technology process:准备对口点固（预热）打底焊接填充焊接盖面焊接自检（最终热处理）无损检验光谱。其中四个重要工序为：对口、焊接、热处理、无损检验。每道工序完成且合格后方可进入下道工序，否则禁止下道工序施工。PreparationAligning Tack welding （preheat）primer weldingfilling weldingfacing weldingSelf-test (final heat treatment)Non-destructive test (NDT) PMI. Four important procedures (points): aligning, welding, heat treatment and non-destructive test. The next procedure can be conducted until this procedure is finished and qualified to pass the test, otherwise the next procedure is prohibited.5.4焊前准备5.4 Preparation before welding5.4.1合格焊工在焊接大中径管前，应进行模拟练习，并经检查合格后方可正式焊接。5.4.1 Before the welding of Alloy medium and large diameter tubes of boiler pressure part, the qualified welder should carry out simulation practice , and carry out formal welding after qualified inspection.5.4.2焊口组对时，应做到内壁（根部）齐平，如有错口，其错口值不应超过下列限值：a）对接单面焊的局部错口值不应超过壁厚的10%，且2mm。b）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。5.4.2 keep the inner wall(root) flush during welds assembly, if any misalignment during, the misalignment value shall not exceed the limiting value: a) for the butt welding by one side, the part misalignment value shall not exceed 10% of the wall thickness and less than 2mm. b) for the butt welding by both sides, the part misalignment value shall not exceed 10% of the thickness of weld piece and less than 3mm5.4.3施焊