Qenos焊接工艺规程和维修.ppt

WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 焊接工艺规程和维修WELDINGPROCEDURESANDREPAIRS WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 ThispresentationprovidesabriefintroductiontoWeldingProceduresandRepairsperformedby oronbehalfof Qenos 本演示稿提供了一个由凯诺斯 或代表凯诺斯 进行的焊接工艺规程和维修的一个简要介绍 2页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 HISTORY历史Priorto1995 themajorityofPressureVesselscameunderthecontroloftheRegionalGovernmentRegulator1995年之前 绝大多数压力容器由地区政府监管机构控制RegionalGovernmentemployedInspectorswereappointedtooverseeNewFabricationWeldingandOn SiteWeldingRepairs地区政府聘请的检查员被指派监督新设备焊接和现场焊接维修 3页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 4页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 ManySmallerVesselstogetherwithmostPipingwerenotcoveredbytheRegionalregulations 许多较小容器含大多数管线并未被地区法规所涉及 Anyfabrication modificationsorrepairstoEquipmentItemshadtobemanagedinternallybyQenospersonnel 任何设备部件的制造 改动或维修必须由凯诺斯员工内部管理 5页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 QenosmanagedWeldingworkhadtomeetrespectiveStandardsand orCoderequirements凯诺斯管理的焊接作业必须符合相应的标准和 或规范要求Thisrequiredthefollowing 有下列要求 TheappointmentofaWeldingInspectororWeldingSupervisor任命一名焊接检查员或焊接主管 DevelopingandMaintainingQualifiedWeldingProcedures 制订和遵守合格焊接工艺规程 6页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Requirements continued 要求 续 QualificationofandRoutineTestingofWeldingOperators焊工资质和日常考核ArrangingforanyrequiredNDEandHydrostaticTesting asprescribedintherespectiveStandardand orCode 安排所有所需NDE和净水压试验 按相关标准和 或规范中的规定 MaintainingHistoryRecordsofWeldingprojects 保存焊接项目的历史记录 7页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 DE REGULATION解除管制In1995 theRegionalGovernmentelectedtomakeIndustriesaccountableandresponsibleforallWeldingFabricationandRepairwork 1995年 地方政府投票通过让行业负责全部的焊件制造和维修作业 8页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 DE REGULATION解除管制Qenosthenhadtoself manageALLWeldingwork 凯诺斯接下来必须自我管理所有的焊接作业 9页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 EnsuringthatwehadappropriatelyexperiencedWeldingInspectorsandSupervisors确保我们有相应经验十分丰富的焊接检查员和主管EnsuringthatwehadanexperiencedWeldingEngineer确保我们拥有一名经验丰富的焊接工程师 10页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 Determiningtherequiredscopeofwork 确定所需作业范围 DefiningtheapplicableEngineeringStandardorCode 定义可执行的工程标准或规范 11页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 Determiningthemostappropriateweldingtechnique 确定最合适的焊接技术 页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 Determiningwhetherworkbestdoneeither 确定在以下情况下是否最好地完成作业 In Situ现场RemovedfromplantlocationbutRepairedonSite已从装置位置拆除但在现场维修RemovedfromplantlocationandsenttoFabricationContractor sworkshopforrepair 已从工厂位置拆除并送至制造承包商的车间进行维修 13页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 Establishingwhetherpre heatandpostweldheattreatmentisrequired 确定是否需要预热或焊后热处理 Specifyingaparticularweldingprocessand orconsumables ifappropriate 指定特定的焊接工艺和 或耗材 如适用 14页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 Developingadetailedrepair modificationSpecification制订详细的维修 改动规范SelectingsuitablyexperiencedContractEngineeringFabricationcompany s 选择具有丰富适当经验的合约工程制造公司 页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 DiscussingproposalwiththeContractcompaniesWeldingEngineer andmodifySpecificationifappropriate 与承包公司焊接工程师讨论提议 并在适用时修改规范 16页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 EnsuringthatcontractorhasandQualifiedWeldingProcedureandQualifiedWeldingOperators 确保承包商有合格的焊接工艺规程和有资质的焊接操作人员 17页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 Forcomplexwork ensuringthattheContractorassignsaWeldingSupervisor 复杂作业时 确保承包商任命了焊接主管 18页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 EnsuringthattheassignedWeldingSupervisorisconversantwiththejobrequirements 确保任命的焊接主管熟悉作业的要求 19页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 ContractortoorganiseforNATANDEInspectionofwelds ifthisisstipulatedintheSpecification 承包商需安排焊缝的澳大利亚测试机构协会无损探伤检查 如果在技术规范中规定 ContractortoprovideadetailedManufacturersDataReportfortherepairwork 承包商需提供维修作业详细的制造商数据报告 20页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 QenosWeldingInspectortowitnessWeldingasrequired凯诺斯焊接检查员应按要求在焊接时在场 QenosWeldingInspectortowitnesstheHydrostaticTesting ifapplicable 凯诺斯焊接检查员在水压测试 如适用 时应在场 21页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 QenosWeldingInspectortoSign OffonVesselAcceptanceontheWorkPermit thisallowsMaintenancetopreparethevessel andfortheOperationsgrouptoputvesselbackintoservice 凯诺斯焊接检查员应在容器验收时在作业许可上签字 这允许维修部门准备容器 并由操作组将容器重新投入使用 22页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 Qenos WeldingResponsibilitiesencompassedthefollowing 凯诺斯焊接责任包含以下内容 QenosWeldingInspectortoupdateVesselHistoryinSAPfollowingcompletionofallrepairwork thisincludedestablishingthenextInspectioninterval 凯诺斯焊接检查员须在所有维修作业完成后 在SAP中更新容器历史 这还包含确定下次检查间隔 23页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 CURRENTARRANGEMENTSFORFIXEDEQUIPMENT固定设备的当前安排ThevastmajorityofFixedEquipmentonthevariousQenossites mustbeRegisteredwiththerespectiveRegionalGovernmentbody 在各个凯诺斯场所的绝大多数固定设备必须在相应的地方政府机构处注册 Alterationsand orRepairscanbeperformedwithoutadditionalapprovalsubjecttothefollowingconditionsbeingmet 满足下列条件时 更改和 或维修作业无须额外批准即可进行 24页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 CURRENTARRANGEMENTSFORFIXEDEQUIPMENT固定设备的当前安排SelfManagedRepairs Alterations自主管理维修 更改LikeforLikeReplacement s对等更换WeldRepairsassociatedwithcorrosionloss与腐蚀损失关联的焊件维修Additionsofsamesizednozzles subjecttoCoderulesrelatedtoproximitytootherexistingnozzles 增加相等大小的管口 需遵循与其他现有管口靠近程度相关的规范法则 25页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 CURRENTARRANGEMENTSFORFIXEDEQUIPMENT固定设备的当前安排SelfManagedRepairs Alterations自主管理维修 变更AllNew orRepairsto ExistingPiping全新或维修现有管道Repairsand orModificationstoTanksandotherNon Registeredequipment 储罐和其他未登记设备的维修和 或改动 26页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 CURRENTARRANGEMENTSFORFIXEDEQUIPMENT固定设备的当前安排MajorAlterations重大改动MajorAlterationsoftenrequirethatweobtainaNewDesignApprovalfromtheRegionalGovernmentRegulator重大改动往往需要从地方政府监管员得到新设计的批准 Followingapproval allWeldingassociatedwiththeApprovalmustthenbefullymanagedbyQenos 批准后 所有与该批准相关的焊缝须由凯诺斯全面管理 27页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动ThemajorityofmodificationtoPipingusuallycomprises 大多数管道改动通常包括 NewAdditions新加AlterationtoExisting对现有改造RepairstoExisting对现有维修 28页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动AllnewPipingfabricationworkisdoneeitherattheContractorsWorkshoporinaQenosWorkshop 所有新管道的制造工作应在承包商车间或凯诺斯车间完成 Thereisoftenanumberof tie in weldsthatwillneedtobedoneinthefield经常有很多的 搭接 焊将需要在现场完成 29页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动DependingupontheDesignCodeandServiceConditions eitherFull Partial orNoRadiographicInspectionwillberequired 哪些管道需要射线检查 那些不要 根据设计规范和运行条件的不同 将需要完全 部分射线探伤或不需要射线探伤 30页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动AllPipingSpoolswillbesubjectedtoaHydrostaticTestinaccordancewithCoderequirements 所有管节都需按照规范要求进行一次水压测试 Tie inweldsmaybeether plughydrotested ifassociatedwithaflange orbedeemedasa golden weld andonlyradiographed 搭接焊缝可进行 堵管水压测试 如果与法兰关联 或被视为 黄金焊缝 并仅进行射线探伤 31页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动FollowingInspectionandTesting thecompletedpipespoolswillbesentofftoaSpecialistAbrasiveBlastingContractorwhowillapplytherequiredsurfacecoating 检查和测试后 完成的管段将被送到一家专业喷砂承包商 其将涂装所需的表面涂层 页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动WhereFieldTie InWeldsarespecifiedtheSpecialistAbrasiveBlastingContractorwillinitiallyabrasiveblastthewholepipespool thenapplyatapecoatingaroundthedesignatedweldzone 指定现场搭接焊缝时 专业喷砂承包商将在开始时对整个管段进行喷砂 然后将在指定的焊接区域周围缠上胶带层 33页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动Thiszonewillbeleftun coatedtopreventweldcontamination 保持此区域无防腐层 以避免焊缝污染 34页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动PipeCoatingsspecificallyapplyto 管道防腐层专用于 ThoseforNominalAmbientOperation 用于标称环境操作的管道 ThoseassociatedwithHotOperation 与动火作业相关的管道 35页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动PipeCoatingsspecificallyapplyto 管道防腐层专用于 ThoseassociatedwithColdOperation 与冷作相关的管道 InsulatedPipingwhichoperatesinthe CorrosionUnderInsulation Temperaturerange 保温层下腐蚀 温度范围运行的保温管道 36页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动For CorrosionUnderInsulation QenosincorporatesallequipmentoperatingintheTemperatureRangeofminus4degCtoplus175degC 对于 保温层下腐蚀 凯诺斯采用的所有设备都能在零下4摄氏度到零上175摄氏度的温度范围内工作 37页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 MODIFICATIONTOPIPING管道改动FieldTie InWeldswillrequireaFieldAppliedCoating 现场搭接焊缝作业需要现场施工的防腐层 Dependinguponthenatureandtheseverity thesefieldcoatingsmay ormaynot beidenticaltotheshopappliedcoating 根据性质和严重程度的不同 这些现场的防腐层可能与车间涂装的防腐层完全一样 也可能不一样 页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 WELDINGONEQUIPMENTOTHERTHANVESSELSORPIPING容器或管道以外设备上的焊缝RepairstoEthyleneFurnaceTubesisanExampleofsuchwork 乙烯炉管的维修是此类工作的一个示例 Theserepairsusuallycoverthefollowing 这些维修作业一般包含以下步骤 DeterminingtheextentofCarburisationandtheneedtorepair replacespecifictubes 确定渗碳的程度以及维修 替换特定管道的需要 TheneedtoundertakeSolutionAnnealingpriortoanyWeldingwork 在任何焊接作业前进行固溶退火的必要性 39页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 WELDINGONEQUIPMENTOTHERTHANVESSELSORPIPING容器或管道以外设备上的焊缝RepairstoEthyleneFurnaceTubes 乙烯炉管的维修 Repairscoverthefollowing 维修包括以下内容 EnsuringsuitableWeldingProceduresareavailableandapplicable 确保合适的焊接工艺规程可用与适用 EnsuringQualifiedandExperiencedWeldingOperatorsareavailableandthattheyhaverecentlyperformedsimilarrepairs 确保能找到有资质和经验的焊接工 并且他们在最近进行过类似的维修 40页 WELDINGPROCEDURESANDREPAIRS焊接工艺规程和维修 WELDINGONEQUIPMENTOTHERTHANVESSELSORPIPING容器或管道以外设备上的焊缝RepairstoEthyleneFurnaceTubes 乙烯炉管的维修 Repairscoverthefollowing 维修包括以下内容 Ifrequired perform mock up weldtrialsinworkshop 如需要 在车间进行 模拟 焊接试验 ArrangeforallNDEwork ensuringthatNDETechniciansarebothQualifiedandSuitablyExperiencedintherequiredtechniques 安排所有无损探伤工作 确保无损探伤技工拥有所需技术的资质和适当领域的丰富经验 41页 WELDINGPROCEDURESAN