gdr0塔筒焊接工艺审批程序

Rev:REQUIREMENTSDate: Pg.1of Approval Electronic:PDM批准流程 电子:PDM流ation文件类型DTD-DTD– 交付物 Thepresent ,itscontent,itsannexesand/oramendments(the“”)hasbeendrawnupbyGAMESACORPORACIÓN OLÓGICA,SA.(“Gamesa”)forinformationpurposesonly,andcontainsprivateand informationregardingGamesaanditssubsidiaries(the“”),directedexclusivelytoitsaddressee.Thereforeitmustnotbedisclosed,publishedordistributed,partiallyortotally,withoutthepriorwrittenconsentofGamesa,andinanycaseexpresslyindicatingthefactthatGamesaistheownerofalltheinlectualproperty.Allthecontentofthe,whetheritistexts,images,brands,trademarks,combinationofcoloursoranyotherelement,itsstructureanddesign,theselectionandwayofpresentingtheinformation,areprotectedbyinlectualandindustrialpropertyrightsownedbyGamesa,thattheaddresseeofthe mustrespect.Inparticular(notwithstandingthegeneralityobligation),theaddresseeshallnotreproduce(exceptforprivateuse),copy,transform,distributeorpublishtoanyotherthirdparty,anyoftheinformation,totallyorpartially. 公共 出出 DEFINITIONSAND ATION WELDINGMAP WPQR ATION RECORDOFWELDTEST SOFTHEWELDED REPORTSOFNONDESTRUCTIVE REPORTSOFLABORATORY WPS ATION WPSBEVELS TYPICAL LONGITUDINALWELDING TO CIRCUNFERENTIALWELDING TO /FLANGETO DOORFRAMEWELDING(DOORFRAMETO STEELINTERNALELEMENTSANDFILLETWELDSIN FULLPENETRATIONSTEELINTERNAL STAINLESSSTEELINTERNAL WELDING ANNEXA–WELDING ANNEXB–BEVEL ANNEXC-WELDINGSEQUENCE(CLARIFICATIONAND ismadeinEnglishand .IncaseofanydiscrepancybetweentheEnglishand theEnglishversionshallprevail. Rev:Date: PagePAGE2of第 TOWERWELDINGPROCEDURES 简 范 定义及缩略 参考文 需要的文 焊接图要 焊接工艺质量报告的要 需要的文 焊接测试记 焊样的合格无损检验报 测试报 焊接工艺规范要 需要的文 焊接工艺规范文 焊接坡口的要 附加说 典型焊 一般外壳内组件和角焊 全焊透钢板内部组 不锈钢内部组 焊缝修 附 本

Initialversion初始 Rev:Date: PagePAGE3of第 TOWERWELDINGPROCEDURES describesthemandatoryationthatmustbeprovidedbytheweldingtowersworkshoprtoGamesafortechnical

AllGamesa’stowerrsandallitsweldsperformed(structural,internalelementsandrepairs).

ThehomologationofatowerranditsweldsforaGamesaproductarelinkedbetweenthemandmustbeperformedtogether.

DEFINITIONSAND Towerr:/workshopinchargeoftowersectionmanufacturing(weldingprocess)

RWTRecordofWeld RWT:WPSWeldingProcedure WPS: WQC:Welder Thefollowing sareinvokedaspartofthisspecificationandmustbefulfilledtotheextentdefined.Unlessspecificallyover-ruledbytheinclusionofadate,oranissueletterorcode,thelatestissueshallalwaysapply.

的程度予以满足。除非另外说明日期或本号， Rev:Date: PagePAGE4of第 TOWERWELDINGPROCEDURESEN1011-Welding– mendationsforweldingofmetallicmaterials-Part1:GeneralguidanceforarcweldingENHotrolledproductsofstructuralENENMetallicproducts.Typesof ISO9606-Qualificationtestingofwelders-Fusionwelding-Part1:ISO15609-Specificationandqualificationofweldingproceduresformetallicmaterials–Weldingprocedurespecification–Part1:ArcweldingISO15614-Specificationandqualificationofweldingproceduresformetallicmaterials–Weldingproceduretest–Part1:ArcandgasweldingofsteelsandarcweldingofnickelandnickelATION ationrequiredtoeachworkshopforeachGamesatowerhomologationis:

WPSincludedinWelding WPQRrelatedto Bevelspreparation (ifisdifferenttoOPBEVELSGamesa ,whereaproposalisincluded,basedonGamesa’sWPS)

焊接坡口预处理(如果与文件建议的倒角处理方案不同，文件会根据的焊接工 ationmusthavetheGamesawrittenacceptancepreviouslytostartmanufacturing.IncaseoftheworkshoprwantstouseanewWPSinthemanufacturingdifferenttothosealreadyapproved,theWeldingMapmustbemodifiedandsenttoGamesa(alongwiththenewWPSand

须经过修改并送至(与新的焊接工艺规范和焊接 Rev:Date: PagePAGE5of第 TOWERWELDINGPROCEDURESWPQR)forstudyandnewWELDINGMAP TheWeldingMapisaordrawingtolinkeachweldedjointwithitsrelatedWPS.AsessentialsAllweldedjointsmustbeincluded(alsoWPSfor

Foreachjoint,WPScodeandrevisionmustbe

WeldingMap mustbesignedby

WPQR Procedureshall plishrequirementsofISOIfWPQR saremadeaccordingtoanotherstandard,beforetheacceptance/approval,Gamesawillreviewthatthe meetatleastalltherequirementsincludedinISO15614-1.Incaseofmissingtestsorinformationrelatedtopoint7.1,extratestswillberequiredtocarryoutandpresentuptocoverISOdemandsandcompletethe

在批准/确认前，需要确认此标准起码需满足ISO15614-17.1节所ISO标准要求，并完成此文件。ATION ForeachWPQR,minimum ationrequired

RECORDOFWELDTEST InformationshowninISO15614-1Annex consumablestradename,standard,heat/lotand straceability:Alsoincluding numberandsteelNDTandlaboratorytesttraceability:Alsoincludingreportnumbers.

Rev:Date: PagePAGE6of第 TOWERWELDINGPROCEDURES Steeltes.Eachshallincludeatleastmaterialsquality,standards,testresults,heat/lotandnumber.Chemicalandmechanicalpropertiesshallbecertified3.1perEN10204.TestmethodandtestvalueshavetocomplywithstatedinEN10025requirements(EN10088forstainlesssteel s(wire,flux,gas…),dependingonweldingmethodused.Eachshallincludeatleaststandards,testresults,lot/batchandnumber.

EN10204证明的化学和力学性能。测试方法和测试值应符合EN10025所述的要求(EN10088不书都应至少包括标准、、炉号/批号和合REPORTSOFNONDESTRUCTIVE Dependingonthejointandaccordingtotable1ofISO15614-1.Eachtestshallincludetheinspectionstandard(ifanotherinternalinspectionprocedureisused,itshallbealsosenttoreviewandapprove)andtestresults,aswellasanyotherrelevantcondition.

此检测工艺也应进行审核和批准)和，以REPORTSOFLABORATORY Dependingonthejointandaccordingtotable1ofISO15614-1.Eachtestshallincludetheinspectionstandard(ifanotherinternalinspectionprocedureisused,itshallbealsosenttoreviewandapprove)andtestresults,aswellasanyotherrelevantcondition.Incaseofhardnesstestisrequired,alltheindentationsincludedinpoint7.4.6ofISO15614-1shallbetaken.Otherwise,anewcompletetestwillberequired.Incaseofimpacttestisrequired,point7.4.5ofISO15614-1mustbefollowed.Toclarifyrequirements,foreachnotchlocationtheaveragevalueofthe3specimensshallmeetthespecificparentmaterialimpacttestrequirements.Inaddition:If1(of3)specimenvalueislowerthanparentmaterialspecificationimpacttestvalue,andisnotlessthan70%ofthat

此检测工艺也应进行审核和批准)和，以如果需要进行硬度测试，应对所有ISO15614-1ISO15614-17.4.5节所包含的规定。更明确的说，三个试样的3个试样中的一个值低于母材指标耐冲击测试值，但不低于其70%，测试合格。 Rev:Date: PagePAGE7of第 TOWERWELDINGPROCEDURESvalue,testisIfonly1value(of3)islowerthan70%,3additionalspecimensshallbetakenfromthesametestpiece.TestwillbeOKiftheaveragevalueofthesespecimenstogetherwiththeinitialresultsisnotlowerthantherequiredaverage.If2(of3)specimensvaluesarelowerthanparentmaterialspecificationimpacttestvalue,weldingproceduremustberepeatedcompley.

70%，需要从3个试样中的两个试样的测试值低于母WPS Procedureshall plishrequirementsofISOIfWPS saremadeaccordingtoanotherstandard,GamesawillreviewthatthemeetatleastalltherequirementsincludedinISO

会对其进行审核以确保其起码满足ISO15609-1的全ATION ForeachWPS InformationrequiredinISO15609- Consumablesdesignation,manufacturerandtradename.Weldingparameters:mustbesimilartoWPQRweldingparametersand plishpoint8.4.8ofISO15614-1( um,HeatInput±25%).SeeexampleinAnnexAofthis

热输入±25%)。见此文件的附件A.BEVELS ThispointisrequiredwhenbevelsarenotaccordingtoGamesadesign OPBEVELS.

BevelsmustbedesignedaccordingtobevelsdescribedinWPS sincludedintheWeldingMap.

Amandatoryrequirementistofulfillthe Rev:Date: PagePAGE8of第 TOWERWELDINGPROCEDURES(lengthandangle)oftransitionsincludedintheOPBEVELSGamesa .SeeexampleinAnnexBofthis

AllweldsmustbeperformedinthemanufacturingprocessaccordingtoinformationincludedinWPS s(sameconsumable,parameters,weldingsequence…).AllweldsperformedinatowersectionmusthaveitsWPSandrelatedWPQR,includingrepairs,weldsforauxiliarybrackets,overlays…

WeldersmustbequalifiedaccordingtoISO9606-1.Incaseofusingadifferentstandard,aproposalofWQC’sshallbesubmittedtoGamesaforpreviousacceptance.Gamesawillreviewthatthe meetsatleastalltherequirementsincludedinISO9606-1.ForweldingprocessesSMAW,FCAWandSAW,consumablesusedinproductionmustbethesametestedintheWPQR(designation,makeandtradename).WPQRweldingparametersshallbeexactparameters(notrange)andWPSparametersshallbearangeofparameters.Evenforthenumberofruns/beadsintheweldingsequence,dimensionsinthejointdesignsketch…SeeexampleinAnnexAofthis CalculateHeatInputaccordingtoEN1011-1(becarefulwiththethermalefficiencyfactor).SeeexampleinAnnexAofthis Frequentlymacrographsarenotclearenoughto schemesandphotocopies.WeldingHAZandsteeltesmustbeIncaseoftheWPQRprocedureincludesgougingprocess:IfinWPQRtheprocessinvolvesaheatmethod(arc-air),intheWPSthegougingprocessincludedcanbethesamemethodoranon-heatmethod(grinding).

ISO9606-1资格认证。如果采用不同的焊接标准，必须向提供焊接资质认证提案以供前验收。会审核此文件是否起码满足ISO9606-1所包括的全部要求。焊点设计图中的尺寸等也是如此。见本文附件A见本文附件A中的案例。有时候宏观不过清晰，无法进行分析。所有IfinWPQRtheprocessinvolvesanon-heatmethod(grinding),intheWPSmustbeincludedthesamemethod(grinding).

WPSandrealweldintowersmustbeincompliancewiththeweldingsequenceusedintheWPQR (seeclarificationinAnnex

附件C的澄清)。 Alltowerjointsshallbe LONGITUDINALWELDING(S Qualifythisjointasabuttjointwithfullpenetration(figure1ofISO15614-1).CIRCUNFERENTIALWELDING(S /FLANGETOS Qualifythisjointasabuttjointwithfullpenetration(figure1ofISO15614-1).DOORFRAMEWELDING(DOORFRAMETOS QualifythisjointasaT-jointwithfullpenetration(figure3ofISO15614-1)TjointtestaccordingtoISO15614-1table1,andinaddition:

此焊缝应满足全焊透对接焊缝的质量要求此焊缝应满足全焊透对接焊缝的质量要求此焊缝应满足全焊透T型焊缝的质量要求Impact (*)IfitisnotpossibletomakethesetestsfromTjointspecimen,makeanewweldingtrialasabuttjointwithsimilarweldingparameters(electricalparameters,consumables,gouging,bevels,temperatures…)andmaketestfromthere.TodefinethethicknessesapprovedbyGamesaforthisjoint,intheWPQRthetestpieceshouldhavethemostsimilardimensionstotheGamesajointdesignedindrawings.

(*)T型试样进行这些测试，应根据相似的按照对接焊缝制造新的焊接试件并进试。中的试件应该尽可能的接近焊缝设计图纸上的 Rev:Date: PagePAGE10of第 ，共 TOWERWELDINGPROCEDURESAccordingtotheexamplebelow,thedimensionsforthetestpieceshouldbe:

teforthesthickness→ teforthedoorframethickness Ifthesetedimensionsarenotpossible,theminimumdimensionsacceptedbyGamesaare:

Sminimumthickness→Ts≥85%ofrealsdimension→Ts≥0,85x30mm→Doorframeminimumthickness→Td≥2xTs→Td≥2x25,5→Td≥51mm(*)Incaseofaweldingtrialasabuttjointtocompletetestsisrequired,theminimumdimensionacceptedbyGamesawillbealsoTs≥85%ofrealsdimension→Ts≥0,85x30mm→Ts≥25,5mm

外壳最小厚度Ts85%Ts0,85x30mm→Ts≥25,5mm门框最小厚度Td2xTsTd2x25,5Td≥51mm的最小尺寸也是Ts≥85%实际外壳尺寸→Ts≥0,85x30mm→Ts≥25,5mm FILLETWELDSINGENERALQualifythisjointasafilletweld(figure3ofISO

Rev:Date: PagePAGE11of第 ，共 TOWERWELDINGPROCEDURESIftheinternalelementisapipe(notate),asathreadedinsertorsimilar,thisjointmustbequalifiedasafilletweldaccordingtoTable1ofISO15614-1,usingthefollowingconfigurationoftestpiece,takingcareoftherangeofqualificationofthediameters

FULLPENETRATIONSTEELINTERNALQualifythisjointasaT-jointwithfullpenetration(figure3ofISO15614-1).Ifbracketis≥12mmthickandmaterialhasanimpactpropertiesrequirement,Gamesawillstudyifadditionaltestsshouldberequired. Qualifythisjointasafilletweld(figure3ofISO

此焊缝应满足全焊透T型焊缝的质量要求WELDING Qualifythisjointasabuttjointwithfullpenetration(figure1ofISO15614-1),simulatingaweldingrepairinapreviousweldedjoint.Inaddition,itshouldbeThegougingdepth(t)shallcomprisethewholeroot(r),andthegougingwide(w2)shallcomprisethepreviousweldingbeadwide(w1).Insummary,t>randw2>w1.Repairthickness(t)usedforWPQRtrials,willbethedatausedtocalculatetherangeof

此焊缝应满足全焊透对接焊缝的质量要求见括整个旧焊缝宽度(w1)。概括起来就是，t>r且 Rev:Date: PagePAGE12of第 ，共 TOWERWELDINGPROCEDURESqualificationfortheteinthe(table5ofISO15614-1).Payspecialattentioninthechoiceofthethickness(t);seeexample.ThesamemethodincludedintheWPQRtoremovethewelding(arc-air,grinding…),mustbeusedduringtherepair. ationusedinthepreviouswelding(beforegouging)isalsorequiredaccordingtopoint7.1.TestspecimensshallbetakenfromtherepairedCommonly,morethanonerepairprocedureisneededduetotherearemanyvariables(weldingprocedure,multi-singlelayers,thicknesses,materials…). um2xt.Asanexample:Ifgougingdeept=15mm→RepairprocedureisapplicableonlyforbasematerialthicknessT≤30mm.

用范围时所采用的数据(ISO15614-15)。故特如果开槽深度t=15mm→只有当基材厚度T≤30mm时，才可以采用修补工艺。 Rev:Date: PagePAGE13of第 ，共 TOWERWELDINGPROCEDURESTable5-Rangeofqualificationforbuttweldsmaterialthicknessandwelddeposit5DimensionsinThicknessThicknessoftesttRangeofSingle0,7t~0,7t~0,5t(3min.)to1,3ta3~0,5t~0,5t~Not50~Inmuli-run Repair

Repair

Insingle-run Repair

Rev:Date: PagePAGE14of第 ，共 TOWERWELDINGPROCEDURESRepair

ANNEXAWELDING Asanexample,ourweldingrecordtesthasthefollowingweldingparameters:

( Typeof12121312141235123Tocalculatetheheatinput,foreachrunwemusttousetheEN1011-1standard(becarefulwiththethermalefficiencyfactor“k”):

为了计算热输入量，每道焊接都必须采用Run→Run→v0→kv8mRun→第2→=vkv1Run → 第5道 0

AfterHeatInputinWPQR iscalculated,heatinputrangeinWPS canbealsocalculated(HeatInputmustbeinsidetherange±25%atleast).

Rev:Date: PagePAGE15of第 ，共 TOWERWELDINGPROCEDURESWPSweldingparametersrangeof Typeof121213121N123Forsinglerun Run1Qmin→Qmin=0.75×Q=0.75×0.96=0.72kJ/mmRun1Qmax→Qmax=1.25×Q=1.25×0.96=1.20kJ/mmFormulti-runlayer(fromallruns,minimumQinWPSisusedtocalculateminimumQinWPQR,and umQinWPSisusedtocalculatethe umQinWPQR):RunNQmin→Qmin=0.75×Qmin(WPS)=0.753.65=2.74kJ/RunNQmax→Qmax=1.25×Qmax(WPS)=1.254.72=5.90kJ/Withitsinternalexperiencetheworkshopcanestimatethecurrent,voltageandtravelspeedranges,butalwaysbeinginsideHeatInputrange:

第1道焊缝最小热输入量QminQmin=0.75×Q=0.75×0.96=0.72kJ第1道焊缝最大热输入量QmaxQmax=1.25×Q=1.25×0.96=1.20kJ多道焊缝(对每一道焊缝，都用焊接工艺规范中的最小热输入量Q来计算焊接工艺质量报告中的最小热输入量Q，用焊接工艺规范中的最大热输入量Q来计算焊接工艺质量报告中的最大热输入量Q)。=0.75×Qmin(WPS)=0.75×3.65=/第N道焊缝的最大热输入量Qmax=1.25×Qmax(WPS)=1.25×4.72=/Run Qmin A (600×27)＋(460× 0.006≈2.74kJ/

N道焊

Q→→

(600×27)＋(460 0.006≈2.74kJ Run Qmax= A (840×34)＋(640× 0.006≈5.90kJ/

第N道 Q→ →

(840×34)＋(640 0.006≈5.90kJ Finally,eachsingleWPSbead’sheatinputvalueshallbeintorangeifitisbelow umcalculatedin

Rev:Date: PagePAGE16of第 ，共 TOWERWELDINGPROCEDURESWPQRandabovetheminimumcalculatedintheWPQReachweldingprocess.

ANNEXBBEVEL Itismandatorytoachievethesamesmoothtransitionbetweentoteswiththicknesseslargelydifferent,asthedesignedintheGamesaOPBEVEL Therefore,dimensionswithasterisk(*)mustbefulfill