焊工培训与考核程序

1、PR-8710-8100-0026 Rev 01Welder training and qualification procedurePage of 20Welder Training and Qualification Procedure焊工培训与考核程序PROJECT PROCEDURE: PR-8710-8100-0026项目程序 : PR-8710-8100-0026REV 版次DATE 日期REASON FOR ISSUE 修订原因BY 编制Chk d 审核QA 审查APPR 批准A16 Sep 2003Issue for ReviewB07 Oct 2003Issue for Ap

2、proval0029 Oct 2003Issue for Use0115Nov.2003Issue for UseContent目录1.Purpose目的42.Scope范围43.Definition定义44.References相关文件55.Responsibility职责66.Procedure程序77.Record记录138.Attachments附录14版次 Ver.章节号 SectionNo.主要修改内容 Description of main changes01All“SEPCO1and SEPCO2 “is changed to “SEPCO1/2 ”. 将程序中 SEPCO1

3、和 SEPCO2 改为 SEPCO1/23Definition of SEPCO is added. 增加了对 SEPCO 的定义4GB code and HB code references are added. 增加了国标、行标等参考标准5增加了 SEPCO1/2 项目经理的职责 Project manager resiponsebilityis added.将”进行任何焊工测试之前至少 24 小时通知 BSF ”改为进行任何焊工测试之 前至少 48 小时通知 BSF“Notifying BSF a minimum of 24 hours in advance of any

4、 welder tests ” is change to “Notifying BSF a minimum of 48 hours in advance of any welder tests . ”5.3Adding content of responsebilities about leader,welding engineer and NDE engineer in weld examination team. 增加了焊工考试小组中领队、焊接工程师和 NDE 工程师的职责。6.4.4Relevant details about weld testing are added. 增加了焊缝检

5、验的相关内容8Appendix D ,Eand Appendix F are added. 增加了附录 D、附录 E 和附录 F 。1 Purpose 目的This procedure regulate the welder training and test management in CSPC Nanhai Petrochemicals Project, ensure every welder in the project qualified in accordance with applicable standard and fulfill project welding work re

6、quirement, and ensure qualified welder in welding work.规范南海石化项目 SEPCO 的焊工培训与考核管理， 使参加项目施工的焊工根据适用的标准取 得相应资格证书，满足项目焊接施工的需要，确保合格的焊工从事相应的焊接工作。Scope 范围The procedure applied SEPCO welder train and test work in Steam&Power Project. 本程序适用于汽电联产项目 SEPCO 的焊工培训和考核工作。Definition 定义SEPCO 山 东 电 力 基 本 建 设 总 公 司 Shan

7、dong Electric Power Construction CorporationSEPCO1/2 山东电力建设一、二公司 SEPCO No.1/2 Construction Company .Weld Control Manual(WCM) 焊接控制手册( WCM )The WCM is the compilation of welding procedures, Weld heat treatment, non-destructive examination, positive material identification procedures, and Form 167 (or

8、Equivalent) Welding and NDE Matrix issued by SEPCO for project use to fulfill the requirements of the CSPC Nanhai Steam&Power Project.WCM 汇编了由 SEPCO 发布的焊接程序、焊接热处理程序、无损检测程序，材料光谱分析程 序以及焊接和无损检测一览表 167 (或类似表格) ，将 WCM 应用于项目中以落实 CSPC 南海汽电联产项目的要求。References 参考资料PR-8710-8100-0025 焊接程序 Welding ProgramPR-8710

9、-8100-0038 焊接控制 Welding ControlPR-8710-8100-0026 Rev 01Page 4 of 20Welder training and qualification procedurePR-8710-8100-0026 Rev 01Welder training and qualification procedurePage of 20ASME Standard Welding and Brazing Quanlification ASME 标准第卷焊接和 钎焊评定AWS D 1.1 Steel Construction Welding Regulation

10、AWS D 1.1 钢结构焊接规范WI-8710-8100-0003C 焊接材料控制 Welding Material ControlPR-8710-8100-0213 NDE 管理程序 NDE Management ProcedurePR-8710-8100-0215 焊接热处理程序 Welding Heat Treatmeant Procedure4.8 WI-8710-8100-0022 General Welding Standards (GWS)通用焊接标准 (GWS)ASME 第八卷 压力容器 ASME Section I Power Boilers.ASME 第一卷 动力锅炉 A

11、SME Section VIII Pressure Vessels.ASME Section V Non-destructive Examination . ASME第五卷 无损检测 DL5007-92 The Code Of Erection and Acceptance for Power Plant Constraction Welding Section电力建设施工及验收技术规范(焊接篇)DL/T822-2002The Code of The Welding Teat Treatment for Power Plant火力发电厂焊接热处理技术规程GB3323-87 GB3323-87

12、钢熔化焊对接接头射线照相和质量分级Responsibilities 职责SEPCO Construction ManagerSEPCO 施工经理SEPCO construction manager is responsible for implementing the welder testing program by sub-contractors on site.SEPCO 施工经理负责落实分包商现场进行焊工考试计划。SEPCO 一/二公司项目经理Project manager of SEPCO1/2Responsible for supvising and reviewing welde

13、r testing and qualification.SEPCO1/2 项目经理 负责监督与审核焊工考试和资格评定。Welder Examination Team 焊工考核小组Leader 领队：Reviewing welder qualification,PQR and WPS. Organizing weider examination. 审查焊工资格，审核工艺评定报告和焊接工艺规程，组织进行焊工考试。Welding engineer 焊接工程师：Constituting welder examination plan.Organizing examination at site.Be

14、responsible for discipline of examination room.Transacting welder card.Establishing and managering welder archives.制定焊工考试计划，组织现场考试，负责考场纪律，办理焊工证，建立管理焊工档案。NDE engineer NDE 工程师：Responsible for testing examination ing out testing report. 负责考试试件的检验，出具检验报告。SEPCO Field Welding EngineerSEPCO 现场焊接工程师Notifyin

15、g BSF a minimum of 48 hours in advance of any welder tests, giving the location and number of welders to be tested, including the applicable WPS. 在进行任何焊工测试之前至少 48 小时通知 BSF ，说明测试地点、要测试的焊工人数及适 用的 WPS 。Responsible for issuing the required welder certification in a timely manner, prior to the welder(s)

16、commencing work on permanent facilities. 负责焊工在永久设施上开始作业之前，及时颁发必需的焊工证书。CMD welding engineer from SEPCO1/2一、二公司施工部焊接工程师PR-8710-8100-0026 Rev 01Welder training and qualification procedurePage of 20PR-8710-8100-0026 Rev 01Page of 20Welder training and qualification procedureEntire responsible for all th

17、e welder training and test including welding equipment preparation 、 welding workpiece preparation 、theory and technical training guiding 、 testing workpiece machined 、 check examine 、 training result review and so on, and put up welder training record.全面负责所有焊工的培训和考核工作，包括焊接设备准备、焊件准备、理论和技能培训指 导、试件加工、

18、检查试验、培训结果评定等，并建立焊工培训 档案。Welding engineer from construction (or Erection)team 施工队或工程处焊接工程师Responsible for cooperating welder training and test management including selfs weldertraining plan、 welding material preparation 、 steel structure welder training and high pressure welder training commission an

19、d so on。各专业工程处负责配合做好焊工培训和考核管理工作，包括编制本单位焊工培训计划、准 备焊接材料、钢结构焊工的培训及高压焊工的培训委托等。Procedure 程序General 总则SEPCO1/2 have contractual responsibility for welder training programs. When a contractor deems that his welders have been properly trained for their intended work on the CSPC Nanhai Petrochemicals Project

20、 and have passed the tests given by the appropriate Chinese Labor Bureau, each welder and/or welding operator shall pass a welder qualification test conducted on site at the contractors test facility before being permitted to perform any welding on site.根据合同规定， SEPCO1/2 应负责执行焊工培训计划。如果承包商认为焊工已经得到了 CS

21、PC 南海石化项目有关作业的适当培训，且已经通过中国劳动局举行的相关考试，则在允 许焊工现场作业之前，每个焊工和 /或焊接操作员必须通过在承包商测试设施上现场举行的焊 工资格认定测试。After successful testing, welders will be required to attend a training class given by SEPCO to explain the basic project welding requirements. 测试通过后，要求焊工参加 SEPCO 为说明项目焊接基本要求举行的培训班。SEPCO1/2 welders are subjec

22、t to performance review at all times by the BSF LFWEor FWE. Whenever deemed appropriate or necessary due to unacceptable repair rates, a welder may be asked to re-perform qualification testing by BSF in the contractors welder testing facility at the contractors expense.SEPCO1/2 焊工将随时接受 BSF LFWE 或 FW

23、E 的表现评审。无论何时，由于不能接 受的返修率而认为合适或必要时，可能要求焊工重新进行 BSF 在承包商焊工测试设施 上要求的资格认定测试，测试费用由承包商承担。Qualification testing of SEPCO1/2 welders will be conducted under the supervision ofthe SEPCO welding engineer. Each Contractor shall ensure that each welder is properly trained and qualified for performance of welding

24、 on the designated CSPC Nanhai Petrochemicals contract.SEPCO1/2 焊工的资格认定测试由 SEPCO 焊接工程师监督执行。 各承包商应确保每个 焊工接受适当培训，并能胜任在指定的 CSPC 南海石化合同项下的焊接工作。Welder Training Work Progress 焊工培训工作流程SEPCO1/2 shall provide a list(s) of welder candidates to perform welding training on theCSPC Nanhai project.SEPCO1/2 应提供接受

25、CSPC 南海项目焊接培训的焊工名单。SEPCO1/2 shall provide their welder candidates with classroom training and practical shop demonstrations of the welding processes as they deem necessary. SEPCO1/2 are responsible to ensure that each welder has been tested by the appropriate Chinese Labor Bureau.SEPCO1/2 应根据需要，为报考焊

26、工提供课堂培训，并实际演示该项目的焊接方法。SEPCO1/2 应确保每个焊工均已通过中国劳动局举行的相关考试。PR-8710-8100-0026 Rev 01 Page of 20Welder training and qualification procedurePR-8710-8100-0026 Rev 01Welder training and qualification procedureWelding Engineer Department review every engineer departments training plan and thewelders qualifica

27、tion, and write site welder training plan and welder list about the training which will be approved by SEPCO1/2 project chief engineer. 焊接工程处审核各工程处的焊工培训计划和参加培训的焊工的资质，编制工地焊工培训计 划和参加培训的焊工名单，报一、二公司项目总工批准。In accordance with the approved training plan and the welder list,SEPCO1/2 arrangethe training incl

28、uding theory train and technical train.按照批准的焊工培训计划和参加培训的焊工名单，由 SEPCO1/2 统一安排培训，包括理论 培训和技能培训。Welder Testing Facility 焊工测试设备SEPCO1/2 shall provide an appropriate welding testing facility at-site. The facility shallbe suitable for testing welders to international Code standards, together with adequate

29、fume extraction, and a separate screened test booth for each welder.SEPCO1/2 应提供适当的现场焊接测试设施。设施应适合于对焊工进行符合国际法规标准 的测试，并可充分排烟，每个焊工应有独立的遮蔽测试间。The test facility shall be provided with safe and calibrated welding equipment for each ofthe intended welding processes, all welding equipment shall be maintaine

30、d in good working order at all times. Unsafe, uncalibrated, damaged, and/or unusable welding equipment shall be removed from the test facility. 对每种拟测试的焊接方法，测试设备均应安全可靠且已经过校准，所有焊接设备应始终保 持良好的工作状态。 不安全的、 未经校准的、 损坏的和 /或不能使用的焊接设备应停止使用。Each welding machine shall be provided with suitable cables and attachm

31、ents (holders,earth clamps, etc) that are in good safe working order, any found to be unsafe should be removed.每台焊接机器应具备状态良好的合适的电缆及附件 (保持器、 接地夹等)，应停止使用发现Page 9 of 20 的任何不安全的机器。Test facilities shall have suitable baking and holding ovens for the welding filler metalused. As a minimum filler metal sha

32、ll be treated in accordance with the manufacturers recommendations. 测试设施应具备适当的供焊接填充金属使用的烘焙炉与保持炉。至少应根据制造商的建议 方法处理填充金属。All welders shall be provided with suitable and safe hand tools (grinders, brushes, etc),and personnel protective equipment (PPE) for performing welding operations. 应向所有焊工提供进行焊接作业所需的合

33、适的安全手动工具(磨光机、刷子等)以及个人 安全保护器材 (PPE) 。6.4 Welder Qualification Work Progress 焊工资格认定流程When a contractor deems that his welder candidate(s) have demonstrated the ability during training to perform sound welds and/or have passed the appropriate Chinese Labor Bureau tests, SEPCO1/2 welding engineer should

34、 submit concerned welders training and test documents which include but not is limited to:如果 SEPCO1/2 认为其焊工候选人在培训期间表现出了优秀的焊接能力和 /或已通过中国 劳动局的相关测试， SEPCO1/2 焊接工程师需向 SEPCO 提交焊工培训及考核相关资料。 这些资料包括但不限于：Concerned testified documents about welder s qualification and approved examination on Chinese Labor Bure

35、au; 焊工焊接作业资格及通过中国劳动局测试相关的证明材料；WPS 、 PQR about the welder qualifying test;焊接测试相关的 WPS 、PQR ；Concerned testified documents about the site conditions according to examinationrequirements including: site equipment adjusting record 、 welding rod and material PR-8710-8100-0026 Rev 01Welder training and qu

36、alification procedurePR-8710-8100-0026 Rev 01Welder training and qualification procedurePage of 20testify documents 、 store and withdrawal record;现场符合测试要求的相关说明。包括：现场设备校准记录、焊条及焊材证明文件、存储 及领用记录；The appropriate control forms shall be in approved specification with the project WCM that is issued in accor

37、dance with SEPCO procedure PR-8710-8100-0025,Welding Program.根据 SEPCO 的 PR-8710-8100-0025 焊接程序发布的 WCM 中应有合适的控制表格。SEPCO shall notify BSF a minimum of 48 hours in advance of any welder tests, givingthe location and number of welders to be tested, including the applicable WPS.SEPCO 应在进行任何焊工测试之前至少 48 小时

38、通知 BSF ，说明测试地点、要测试的焊 工人数及适用的 WPS 。SEPCO1/2 shall test each welder employed on the CSPC Nanhai Steam&Power Projectin accordance with an approved Project Procedure/Specification.SEPCO1/2 应按照批准的项目程序 /规范测试 CSPC 南海汽电联产项目所用的每个焊工。SEPCO weld engineers; in together with counterparts from BSF, will take overa

39、ll reviews, including document, materials, and work piece, weld spot appearance. Non-destructive test, after the appearance inspection of welded work piece has been proved to be qualified, shall be applied.SEPCO 焊接工程师和 BSF 代表对焊接文件、 焊接材料、 试件细节、焊缝外观进行检查。 焊缝外观合格后，才能进行无损检验；Non-destructive test shall be

40、done in the selections of MT, PT, UT and RT etc. and non-destructive test must be implemented by those who are qualified through professional skill training and examination. 无损检验采用磁粉、着色、超声波、射线等方法，且必须由经过专业培训考核且取得相 应方法合格证的人员来完成。A welder is allowed a maximum of two attempts at a welding qualification.

41、If a welder isconsidered acceptable for re-testing he/she shall undergo a further agreed training period prior to a re-test. Following re-training the welder is only allowed one re-test, if the welder falls this re-test he/she shall not be allowed to work on the NanHai project. 一个焊工最多只允许尝试进行两次焊接资格认定

42、。如果认为某位焊工可进行再次测试，在 再次测试之前，这位焊工应参加经过协商的进一步培训。再次培训之后，仅允许焊工进行 一次再次测试，如果该焊工仍不能通过测试，则应禁止其在南海项目中工作。When the welder successfully passes the appropriate qualification test, he/she is required to attend a training class for explain the welding general work requirements of the CSPC Nanhai Petrochemicals Proje

43、ct.焊工成功通过相关资格认定测试后， 要求其参加说明 CSPC 南海石化项目通用焊接作业要 求举办的培训班。Following successful qualification, SEPCO shall issue each welder a personal ID Card,which shall bear a recent photograph of the welder and the welders unique ID number, together with the list of the relevant approved qualifications on the rever

44、se (second) side. The welder shall carry this ID Card at all times when working on the CSPC Nanhai Petrochemicals Project. SEPCO shall have a different numbering system from other contractors, and the unique welder identification number given to each welder shall not be re-issued to any other welder

45、 during the life of the CSPC NanHai project. 资格认定合格之后， SEPCO 应向每个焊工颁发个人识别卡，上面附有焊工最近的照片及唯 一的识别号，并在反面(另一面)说明相关的批准的资格认定清单。焊工在 CSPC 南海石 化项目工作期间，应始终佩戴此识别卡。 SEPCO 应采用不同于其他承包商的编号系统，在 整个 CSPC 南海项目期间，向每个焊工发放的唯一焊工识别号不得再向其他任何焊工发 放。The welder ID card No. used by SEPCO is numbered as: SEPCO- -W。The firstPage 12

46、of 20PR-8710-8100-0026 Rev 01Welder training and qualification procedurePage of 20PR-8710-8100-0026 Rev 01 Page of 20Welder training and qualification procedures project ID Number; the third group isgroup is SEPCO1/2; the second group is welder serial number, W is abbreviation of word Welder.SEPCO 使

47、用的焊工个人识别号编号为： SEPCO - -W 。第一组为 SEPCO1/2 ；第 二组为焊工的出入证号；第三组为流水号， W 为 Welder 的缩写。Prior to the commencement of any work on site, all welders, weldingoperators and/ortack welders shall be qualified to the applicable approved Contractor welder qualification standards. These standards for welding qualifica

48、tion shall be included in the project WCM. On process piping the first two production butt welds for each newly qualified welder shall be radiographed.所有焊工、焊接操作员和 /或点焊工在现场开始任何作业之前，应具备批准的相关的承包商 焊工资格认定标准资格。焊接资格认定的这些标准应囊括在项目 WCM 内。对于程序管道 系统，每个刚刚取得资格认定的焊工焊接的头两个对接焊缝应采用射线照相进行检查。Record 记录SEPCO1/2 shall mai

49、ntain test record lists on a daily basis for all welder qualifications,weekly qualification maintenance logs, welder sw eld reject records and any other records associated with the testing and qualification of welders,and shall issue all welder qualification certificates for SEPCO approval.SEPCO1/2

50、应每日保存所有焊工资格认定测试记录清单、每周资格认定维护记录、焊工的焊接 不合格记录以及与焊工测试和资格认定相关的任何其他记录，并发放经过 SEPCO 批准的所有 合格焊工资格认定证书。During the welder training, the teacher should fill in welder 焊工培训过程中，焊接教练要填写焊工操作技能培训记录表；Fill in welder technical evaluation sheet after completing qualification examination; 焊工完成资格认定测试后，要填写焊工技能评定表；Welding t

51、eacher should keep the newest welder qualification record including rejectsrates.焊接教练应保持最新的焊工资格认定记录，包含不合格率；SEPCO welder engineer should submit copy of welder qualification record weekly.SEPCO 焊接工程师每周向 BSF 提交焊工资格认定记录的副本。Attachments 附录Attachment A Welder operation technical training record附录 A 焊工操作技能培

52、训记录表Attachment B Welder technical evaluation sheet附录 B 焊工技能评定表Attachment C Flow chart附录 C 流程图Attachment DList of Welder Examination Team Members附录 D 焊工考核小组成员名单Attachment EWPS for welder training and skill appraisal附录 E 焊工考试用 WPSAttachment F Qualified Welder List附录 F 合格焊工名单Attachment A附录 AWelder oper

53、ation technical training record sheet焊工操作技能培训记录表培训负责人：培训教练：Name 姓名Welder No. 焊工代号Regulation规格Material 材料Welding technical 焊接工艺WeldIing rod焊条Position 试件位置WeldingProcedure 焊接程序WeldIing wire 焊丝Connection Style 接头型式Date 日期Workpiece No.试件编号TechnicalCondition工艺情况Result 结果Appearance Quality外观质量Result 结果Int

54、ernalQuality 内部质 量Result 结果Score 得分Training Charge: Training Coach:Attachment B附表 B: Attached Form B: 焊 工 技 能 评 定 表Welder Skill Appraisal Sheet项目编码Project Code:项目名称 Project Name:日期 Date:焊工姓名Welder Name:证号 Certificate No:钢印号Steel Stamp N：o考试类型Test Categor：y焊接工艺方法Weld Process:使用的WPS:母材 Material Base M

55、etal:厚度Thickness:手工或半自动变/素每种方法Manual or Semi-Automatic Welding Processes实际值 Measured Value评定范围Evaluated Scope衬垫pad（金属、焊缝金属等metal）填（ fill in“是yes”或or“否no”）ASME P-No. to P-No.P-No.P-No. to P-No.板 plate管 pipe （若是管,填直径write down diameter for pipe material）填充金属metal to pack:; 类别category填充金属metal to packF

56、-No工.（艺process #1工/ 艺process #2）熔化性嵌条molten packing rod （GTAW填）f i（ll in“是yes”或or“否no”）#1 工艺焊缝熔敷厚度molten weld thickness in #1 process#2 工艺焊缝熔敷厚度molten weld thickness in #2 process焊接位置welding location焊接方向（上坡焊/ 下坡焊） welding orientation （upward/downward）背面保护气（填“是”或“否）” back protective weld （yes or no）熔化极气体保护焊过渡形t式ransit disposal in weld with polarized liquefied gas protection钨极气体保护焊电流类/极型性current type in weld withtu ngsten gas protection /polarity其它结果other result类型type接受拒绝不适用 inapplicable位置外观检查: