不锈钢管道施工技术方案(中英文)

7 2 6 不锈钢管道的施工工艺不锈钢管道的施工工艺 Construction Method of Stainless Steel Pipe 不锈钢管道常用的主要有 304 和 316L 由于不锈钢管道自身的特殊性 为了防止不锈钢材质 的碳化 因此要避免碳钢等材料相接触 所以 所有的不锈钢管道 以及不锈钢管道的附件 阀 门 法兰 支架等 必须单独设置仓库存放 且不得采用碳钢货架 应采用木质货架或垫层 做 好防护工作 The most commonly used stainless steel pipe is of 304 and 316L type Due to the features of the stainless steel pipe itself they shall be free from the contact with carbon steel materials etc For this reason all stainless steel pipe the related accessories valves flange and bracing etc shall be stored separately and the racks shall not be of timber rather than carbon steel 不锈钢的工业设备应采用柔软的橡塑保温板材进行首层的覆盖 然后用木工板等进行防护 The stainless steel process equipment shall be covered with soft rubber insulation on top of which wooden panel shall be used for protection 不锈钢管道的支架 一般采用不锈钢的 C 型钢支架 该类支架均为成品型支架 所有的卡箍 等均为不锈钢的材质 The bracing of stainless steel pipe shall be finished C steel bracing products and the fasteners are of stainless steel 不锈钢设备的安装方法与其他设备相似 但是在运输 吊装 就位等过程中 必须采用尼龙 吊索 并且用软体材料做好防护 避免表层被刮 产生痕迹 尤其是表面抛光的设备与材料 应 严格防范 The installation of stainless steel equipment is similar to other equipment However during the transportation erection and move in process nylon rigging shall be used with the surface protection of resilient materials The equipment and materials with marble surface shall be taken care of in particular in accordance with high regulations 1 普通不锈钢焊接工艺普通不锈钢焊接工艺 Regular Stainless Steel Welding 本工艺适用于本工程的不锈钢 304 管道的焊接施工 当不锈钢的壁厚超过 1 2mm 时 可使 用普通直流焊接 使用反极法连接 This method is applicable to the welding of stainless steel pipe 304 for the project Where the wall of the stainless steel pipe is more than 1 2mm conventional DC welding can be used 1 材料要求 Requirement for the Materials 钢管母材和焊接材料必须具有有效的质量合格证明书 证明数据不全时 应进行复验 The main materials and the welding materials must be certified with valid quality assurance where the data on the quality certification is not sufficient a double check shall be required 通常是选择与母材化学成分相近且能够保证焊缝金属性能和晶间腐蚀性能不低于母材的焊接 材料 本工程选择的焊丝应符合 GB4233 84 氩弧焊不锈钢丝 焊条的选用应符合 GB983 85 不 锈钢焊条 Generally the material with similar nature to the main materials and at the same time enabling the metal used for welding joint and the anti corrosive performance to be no less than the main material will be selected The welding thread used for the project shall be in compliance with GB4233 84 Argon Arc Stainless Steel Thread and the welding rod shall be in compliance with GB983 85 Stainless Welding Rod 焊材应放在环境温度 0 以上且干燥通风的地方 焊条使用前应进行烘烤 烘烤温度未 150 200 保温时间为 1 小时 焊丝使用前必须去除表面的油污和氧化物 The welding materials shall be placed in the area with surrounding temperature to be above 0 and good ventilation The welding rod shall be baked before use the bake temperature shall be 150 2000 and lasts an hour The welding thread shall be free of oil stains or oxide before use 手工钨极氩弧焊所使用的氩气纯度要求不得低于 99 9 所采用的钨棒应选用杜钨极或铈钨 极 但尽量选用铈钨极 磨销时 应尽量保持钨极端头几何形状的均匀性 The manual tungsten argon arc weld shall use argon gas with no less than 99 9 purity The grinding shall maintain the even shape of the tungsten end 2 焊接 Welding 当管壁厚度小于 4mm 时 宜采用手工钨极氩弧焊 当管壁厚度 4mm 时 宜采用手工电弧焊 或手工钨极氩弧焊 当管外径 108mm 时 宜采用手工钨极氩弧焊 当管外径 108mm 时宜采用手 工电弧焊或手工钨极焊打底 手工电弧焊盖面 本工程全部采用手工钨极氩弧焊 接头的坡口型 式如下图表 Where the wall of the pipe is less than 4mm thick it s proper to adopt the manual tungsten argon arc weld Where the wall of the pipe is no less than 4mm thick it s proper to adopt manual electrical argon arc weld or manual tungsten argon arc weld when the outer diameter is no more than 108mm it s better to use manual tungsten argon arc weld and when the outer diameter is more than 108mm it s better to use manual electrical argon arc weld or manual tungsten weld as a base and manual electrical weld on top The manual tungsten argon arc weld shall be used for the entire project 坡口型式 壁厚 mm 间隙 c mm 钝边 b mm 坡口角度 c 4mm0 1mm b c 4 10mm1 3mm1 2mm60 70 施焊焊工应持有劳动部门颁发的 锅炉压力容器焊工考试合格证 中相应的合格项目 方可 上岗操作 The welder shall hold the qualification certificate issued by the Labor Department 施焊环境温度要求一般不低于 0 风速不大于 2m s 相对湿度不大于 90 如果达不到上 述要求 且又无有效保护措施时 禁止施焊 The welding temperature shall be no less than 0 and the wind speed shall be no greater than 2m s The relative humidity shall be no greater than 90 If the mentioned requirements cannot be met and there are no effective protections any welding shall not be allowed 3 手工钨极氩弧焊 Manual Tungsten Argon Arc Weld 手工钨极氩弧焊接使用的各种型号的氩弧焊机应经检验合格 完备无损 氩弧焊机的高频引 弧 衰减电流 提前送气 延时停气的性能必须良好 The argon arc welding machines used shall be checked and in a good state The high frequency arc starter current attenuation air supply in advance and delay in air supply stop shall function well 手工钨极氩弧焊采用直流正接法 即 工件接正极 电极接负 The manual tungsten argon arc weld shall be of DC connetion 焊前应将焊缝两侧 15 20mm 宽度范围内油污 脏物清除干净 焊丝必须打磨光 并用丙酮 擦洗干净 The oil stain and dirt 15 20mm on both sides of the welding groove shall be cleared The weld wire shall be burnished and cleaned with acetone 焊接时管内必须充入足够氩气进行保护 采用引弧极或高频引弧装置 严禁在管壁上直接接 触引弧 焊炬移动引保持平稳 尽量不作横向摆动 当焊缝较宽时 焊炬宜略横向摆动 移动速 度缓慢 摆动型式为锯齿形 不宜后退焊炬 送丝速度应均匀 送丝摆动幅度不宜过大 焊丝端 部应自始至终处于氩气保护区域内以防止被氧化 焊炬与焊丝 工件倾角如图 Sufficient argon gas shall be filled into the pipe as a protection during the welding Argon starter shall be used It is prohibited to contact the argon starter directly on the pipe wall The welding movement shall remain steady and avoid any horizontal movement Where the welding joint is much wide the welding can be move horizontally but in a low speed The end of welding wire shall during the entire process within the area protected by the argon gas to prevent oxidation 工件 填充焊丝 熔池 钨极 喷嘴 电弧氩气 焊缝 15 20 70 85 由于手工钨极氩弧的电弧集中穿透能力强 因此应随时注意观察熔池下陷情况 以免熔透过 大或烧穿 应采用左向焊法 在保证焊接质量的前提下 焊接速度应尽量快些 收弧时应将弧坑 处多加一些焊丝 其焊接规范参数如下 As the penetration ability of manual tungsten argon arc weld is rather strong the melting status shall be taken care of any time to avoid over melt With the welding quality guaranteed the welding speed shall be faster 管壁厚度 Pipe Wall Thickness mm 钨极直径 Diameter of Tungsten wire mm 喷嘴直径 Diameter of nozzle mm 焊丝直径 Diameter of Welding Wire mm 焊接电流 Welding current mm 氩气流量 Argon gas flow l min 0 5160 518 286 0 8 11 561 525 356 1 2 1 51 58 91 540 607 2 328 9260 908 4 6310 112 590 15010 6 8411 133160 20012 注 注 若管道较长 氩气流量应适当增大 Note where the pipe is long enough the argon gas flow shall be increased accordingly 2 PE 级不锈钢管道施工工艺级不锈钢管道施工工艺 PE Construction Technique for Stainless Steel Pipe 本工艺适用于本工程 304 BA 316L BA 管的焊接 在此仅以弧焊电源设备 美国 AMI ARC MACHINES INC 207A 焊接 BA 管为例来叙述 如果采用其他型号的焊接设备焊接 BA 管时 请参照该焊接设备使用说明书及本工艺 This technique shall be applicable to the welding of 304 BA 316L BA pipe The following description shall take the argon arc power equipment AMI ARC MACHINE INC 207A BA pipe welding for example When other welding machines are to be used for BA pipe welding please refer to this instruction and method 适用于压缩空气二次配 部分 N2 系统 PCW 系统 部分 以及有机化学品管道 Applicable to compressed air N2 system PCW system and the organic chemical pipe 1 材料要求 Requirement for Materials BA 管 经过溶解 压延 溶解 热处理 研磨等处理的不锈钢管 BA pipe the stainless steel pipe treated with dissolving pressing dissolving heating and grinding 氩气 采用高纯氩 纯度为 99 99 Argon gas 99 99 purity 阀门 活接头 VCR 接头 垫片 Valve flexible joint VCR joint cushion 洁净胶带 洁净布 洁净纸 洁净塑料袋 高纯酒精 超纯水 Clean tape clean cloth clean paper clean plastic bad pure alcohol purified water 所有材料的规格 型号 必须符合设计要求 并有出厂产品合格证 所有材料必须经质检部 门检验合格 方可使用 The specification and model of all materials shall meet the design requirements and have factory quality certifications All materials shall be inspected and approved by quality checking department before use 2 机具设备 Tools and Equipment 弧焊电源 ARC MACHINES INC 207A 即不锈钢全自动脉冲氩弧焊机 该设备采用全电脑 控制程序 不需填充焊丝 利用母材自身熔化成型 焊缝成型好 Argon arc weld power source ARC MACHINES INC 207A i e stainless steel argon arc welding machine This machine is completely operated by computer thru various programmes No welding wire feed is required 焊头 夹头 钨棒 焊把线 发电机 稳压器 液氩钢瓶 过滤器 Welding end clip end tungsten stick wire generator pressure stabilizer liquid argon flask filter 三角支架 割管器 带锯 GF 锯 平口机 夹钳 活扳手 内六角扳手 手电筒 钢丝刷 平锉刀 螺丝刀 气体流量计 Triangle bracket pipe cutting machine GF saw wrench flash light steel wire brush screw knife gas flow meter 其他 安全眼镜 乳胶手套 洁净服 水平尺 角尺 钢卷尺 梯子 Other safety glasses rubber gloves clean clothes level ruler angle ruler steel tape ladder 3 施焊条件 Conditions for Welding 施焊人员必须经培训 考核合格后 方可施焊 The welders shall be trained and tested before doing their job 所有有关预制方面的工作必须在洁净室内进行 All prefabrication work shall be done in clean rooms 如果在洁净要求不具备的情况下 必须采取洁净预防措施 方可施焊 If the clean requirements cannot be met the welding can only be carried out with sufficient clean protections 由于 BA 管自身的洁净要求较高 因此 BA 管的施工必须在洁净的环境下进行 不可以在 露天环境下直接打开包装及封盖 施工人员应戴无尘洁净手套操作 打开管口端盖后 用微型手 电筒照管内壁 管内壁上颗粒及杂质较多 应用超纯水和无尘防静电洁净布反复清洗至合格时为 止 然后再用高纯氩气或氮气吹干 盖上封端 流入下道工序 Since the BA pipe has a very high clean requirement the BA pipework cannot be performed in the open area The workers shall be equipped with clean gloves while opening the cover of the pipe checking the inner wall of the pipe with flashlight If many impurities are found the pipe shall be washed with purified water and cleaned with dust free anti static cloth over and over again until the requirements are met Later dry the pipe with pure argon gas or nitrogen put the cover back and proceed with the next step 4 施焊工艺过程 Welding Process 整个过程可分为以下几个步骤 The welding process is as follows a 选择规范参数 选择焊头 调节转速 选择钨棒及钨棒与管子表面的垂直距离 下料 焊接 Selection of parameters selection of welding end rotary speed adjustment selection of tungsten stick and the space between tungsten stick and pipe surface material in position welding b 施焊准备 Preparations 焊前 应将所有线路 包括电源和气源 连接通 保证牢固 接触好 气路之间的连接 用 管只能是 BA 管 各个接头处必须加垫片 充入管道内的气源线路中必须安装过滤器 以确保气 体纯度 各个接头必须拧紧 以防漏气 然后打开电源开关 设备进入工作状态 Prior to welding connect all wires electrical and gas and make sure the connections are firm The connection pipe for gas circulation can only be BA pipe All joint shall be completed with cushion Filters shall be provided inside the incoming gas pipe to ensure the gas purity All joints shall be fastened to avoid any leak Turn the power on and the equipment runs 选择规范参数运用功能键 LIB 调用磁盘操作系统中以储存的数据目录 按PRINT 键 打印键 将其打印出来 再根据所需要焊接的管径和壁厚 查找数据目录 选择相应的规范参数 Select the parameter and use the functional key of LIB to access the stored data in the system Press PRINT to print it out Search for the data based on the required welding pipe diameter and wall thickness 例如 焊接管径为 1 2 壁厚 0 049 的 BA 管 焊接形式为对接 这时 假设选择的目录编 号为 9 的参数 运用 Screen 键寻找 找到后 按回车键 进入焊接状态 并将 9 号参数打印出来 For example the welding pipe diameter is 1 2 wall thickness 0 049 Assume the selected index number is 9 use Screen to search When a result is found press ENTER to get into the welding status and print out the No 9 parameters 如果打印出来的数据目录中找不到所需要焊接的管径和壁厚 这时就需要操作功能键 PRO 重新输入参数 操作相应的功能键 其操作步骤如下 假设焊接时分四个位置进行施焊 然后运 用功能键 SCREEN 调出刚刚输入进去的目录编号 按回车键进入焊接状态 并将其打印出来 参数设置结束 If the welding pipe diameter and wall thickness cannot be found in the printed data index use PRO to retype in the parameters and follow with proper functional keys as below if the welding shall be of 4 locations use SCREEN to access the index number which was just typed in and press ENTER to get into the welding status print it out Parameter setup is complete c 选择焊头 Selection of Welding Butt 选择焊头 常用的焊头型号如下 Typical welding butts are as follows 焊头型号 Type 适用于最大管径 Max Diameter Applicable 9 750 型0 9 9 1500 型1 5 9 2500 型2 5 9 3500 型3 5 如 需焊 BA 管的管径为 1 2 由于施焊的管径较小 通常选用体积小 重量轻的 9 750 型焊头 If the diameter of BA pipe is 1 2 usually the 9 750 welding butt with light weight and size will be selected d 如何调节转速 How to adjust the rotary speed 如果焊管径为 1 2 的 BA 管 准备采用磁盘操作系统中数据目编号为 9 的规范参数 这时就需 运用功能键 Screen 寻找 9 号 然后按回车键 进入焊接状态 再运用功能键 SET UP 及其相应的 键 使焊头转速与磁盘操作系统中目录编号为 9 的规范参数相一致 操作步骤如下 set up F12 F6 enter C set up C If the welding BA pipe diameter is 1 2 and the parameter will be No 9 as shown in the drive then it needs to initiate Screen to find No 9 Press ENTER to get into the welding status and relaunch SET UP and the related functions to adjust the rotary speed to comply with the parameters under No 9 The operations are as follows set up F12 F6 enter C set up C 其中 按了回车键 enter 以后 焊头开始旋转 旋转结束后 如若显示屏上出现了 calibration complete 测试完毕 则表明焊头的转速已与磁盘操作系统中 9 号的参数 转速 相一致 可以 进行焊接管子 如果显示屏上出现了 Too fast or too slow 太快或太慢 这时就需重新调节焊头转 速 方法是 用一把较小的平口螺丝刀 插入焊头下方的一个小孔内 顺时针或逆时针方向旋转 反复调节 直至显示屏上出现 calibration complete 为止方可 这时焊头的转速与其规范参数 转 速 相一致 可以施焊 When the ENTER is pressed the weld butt starts to rotate When the rotary completes if the display screen shows calibration complete then it indicates that the rotary speed of the weld butt is already in compliance with the parameters under No 9 and pipe welding can be continued But if the display screen shows Too fast or too slow it requires a readjustment of the rotary speed of the weld butt Insert a small screw knife into the hole under the welding butt then rotate clockwise or counter clockwise Repeat the action until the screen shows calibration complete e 钨棒及钨棒与管子表面垂直距离的选择 Selection of tungsten stick and the Vertical distance between the tungsten stick and pipe surface a 钨棒的选择 Selection of Tungsten Stick 每焊一种规格的管子 都有相应规格的钨棒与其相匹配 同一种规格的 BA 管 如果选用的 焊头型号不同 那么所需的钨棒的规格也不一样 因此在焊头上安装钨棒时 请一定要看清钨棒 的规格和型号 谨防出错 There will be certain tungsten stick which matches the welding of the pipe of one kind For the same BA pipe if various weld butts are selected then the tungsten stick shall be of various specifications Therefore when a tungsten stick is to be installed on the weld butt special attention shall be given to the specification and type of tungsten stick to avoid any mistakes b 钨棒与管子表面垂直距离的选择 Vertical distance between the tungsten stick and pipe surface 钨棒与管子表面垂直距离通常也称电弧长度 其尺寸一般是由管子的规格 即壁厚 来决定 这是因为钨棒与管子表面垂直距离越大 电弧越长越不稳定 穿透能力减小 会造成未焊透 熔 合不好 外表面焊缝偏高等缺陷 反之钨棒与管子表面垂直距离越小 电弧越短 穿透能力增强 越容易焊穿 外表面凹陷 因此 一定要合理选择好钨棒与管子表面垂直距离 并用专用的工具 进行校检 The vertical distance between the tungsten stick and the pipe surface is also known as arc length Its size is normally determined by the size of the pipe i e wall thickness The reason is the greater the arc length is the more unstable the arc becomes and consequently the less penetration ability it will have which results in the half penetration and inadequate melting etc And vice versa Therefore it s important to determine a reasonable arc length and conduct a test with proprietary tools 施焊管子的壁厚 Pipe Wall Thickness 所需的垂直距离 即电弧长度 Arc Length 0 02 0 035 0 03 0 049 0 085 0 05 0 091 0 154 0 07 f 下料 Materials In Position 由于 BA 管是高光洁度抛光管 管壁薄 内表面光洁度主要适用于高洁净项目 因此 BA 管必 须在洁净室内切割和刮削端面 且戴口罩及乳胶手套 操作前 必须身穿洁净服 Since BA pipe is of highly burnished pipe with thin wall and the marble inner side will be used for projects with high clean requirements BA pipe must be cut and treated in a clean room The worker shall wear mask rubber gloves and clean uniform before operation a 下料前 Prior to Material Placing 质检人员根据图纸及库房管理人员提供的 BA 管和按 10 的比例 用专门的检测仪器检测管 内表面光洁度是否符合要求 并做好检测记录 如有不合格则该种规格的管子必须全部检测 如 果都合格 则开始检测管内表面是否有微粒杂质等 目测 不合格的管子必须清洗 然后通入 氩气 液氩 或高纯 N2吹扫 直至干净 目测 最后用洁净的塑料盖将两端口封上 流入下道 工序 The QC staff shall check 10 of the BA pipe provided by the storeroom manager in accordance with the drawing using special machines to see if the inner surface of the pipe meets the requirement and keep a note If any failure for a certain pipe is found then all the pipes of such specification shall be checked If the checking result is ok then proceed with the detection of impurities inside the pipe visual inspection All failure pipes shall be washed clean and dry with argon gas liquid or high purity N2 until it s clean by visual inspection Finally put the clean plastic covers onto the ends and proceed to the next step b 下料 切割和端面刮削 Material In position 根据所需管子的长度 用带锯或割管器切割已检验合格的管子 然后 用洁净的塑料盖将管 口封好 如果切割好的管子管口内有铁屑 则必须用洁净布将管口内擦拭干净 再用酒精将管口 内外壁清洗干净 用氩气吹干 再用洁净的塑料盖将管口封好 流入下道工序 施焊 Based on the required length of the pipe cut the approved pipes Then seal the pipe with covers If the pipe contains iron debris in it after cutting then it s required to clean inside with clean cloth and wash the walls with alcohol Dry with argon gas Seal it with clean plastic covers and proceed to the next step g 焊接 Welding 该设备采用液氩作为保护气体 焊前 应将各个阀门打开 调节适当气体流量 检查各个接 头处是否漏气 直至磁盘操作系统中显示 READY TO WELD or TEST 进入焊接状态 为止 例如 焊管径为 1 2 壁厚为 0 049 BA 管 根据选择好的数据目录编号 9 运用 Screen 键 调出 目录编号 9 按回车键 进入焊接状态 选择型号为 9 750 型焊头 连接好然后调节焊头转速 使其与目录编号为 9 的规范参数像一致 在焊头内装入相应规格的夹头 9 750 型 1 2 用专 门的工具安装钨棒并测试钨棒与管子表面的垂直距离是否符合规定的要求 0 05 然后打开磁盘 操作系统中的电磁阀 MANPURGE 清洗焊头 一切准备就绪后 将两节管子装入焊头内 夹紧 使用对应工具对正 使钨棒中心正对管子的缝隙中心 管口不允许有错边 间隙越小越好 同时 将管内通入氩气 调好气流量 按功能键 SEQ START 开始焊接 如果焊接过程中出现意外或紧 急情况 就立即按 SEQ STOP 键 紧急停止键 即可 Liquid argon gas is used as protection gas for the equipment Prior to welding all valves shall be open to adjust a proper gas flow check every joint for gas