冷箱内铝合金及管道焊接工艺要求standard

梅塞尔中国工程标准ProjectCodeofMesserChina铝合金及管道焊接工艺要求THESTANDARDOFWELDINGPROCEDUREOFALUMINIUMALLOYANDPIPELINES编制: 于文盛MadebyWenshengYuCheckedbyApprovedbyZhanglongDai

DateDateDateCodeofPractice 编号(No.)：COP-0405 版本(Version)：AProjectCodeProjectCodeofMesserChinaCOP0405A22of7COP0405APermittoWork03/30/13目的Purpose标准冷箱内铝合金及管道焊接〔TIG〕工艺操作技术要求及焊接作业指导书的规定。Tostandardizetheon-sitemanualofAluminiumAlloyandpipelineinCoolBox.焊前预备WeldingPreparation:,坡口加工外表应进展清理,并到达平坦光滑,无毛刺和飞边、垫板及焊丝进展清理。Theshapeandthesizeofthegrooveoftheweldingpiecesshallbefollowedthedesignedrulesandweldingoperativemanual.Thesurfaceofthegrooveprocessshallbecleaned,levelwithoutburrsandoverlaps,thewasherandwiresshallalsobecleaned.焊件组对中，焊接定位焊缝时，应承受与正式焊接一样的焊丝和焊接工艺并应由合格焊工施焊，定位焊缝的长度，间距和高度宜符合焊接作业指导书，正式焊接前应对定位焊缝进展检查，当觉察缺陷时，应准时处理。Theselectionofthewiresandweldingprocedureshallbethesameastheweldingoperatedbyqualifiedweldersintheprocessoftackweldingforfittinguptheweldingpieces.Thelength,spaceandheightofthetackweldingseamshallfollowtheweldingmanual,Thetackingweldingseamshallbeinspectedandthedefectsshallbedealtwithpriortothewelding.当焊缝反面需加垫板时，垫板材质应符合设计规定或与母材一样，开有容纳焊缝根部的沟槽。Whenthebackoftheweldingseamneedstopluswasher,thematerialsofthewasherwithslotsopenedintherootoftheweldingseamshallfollowthedesignedrulesorthesamenesstothebasematerials.管道的对接焊缝内壁应齐平，内壁错边量应符合下例规定：Thebuttjointsofthewalloftheweldingseamshallbeleveled:壁厚wallthickness

内壁错边量edgeerror≤5mm＞5mm

≤0.5mm≤0.1δ且≤2mm不等厚对接焊件组对时，薄件端面应位于厚件端面之内，当外表错边量超3mm或内壁2mm时，应按设计要求或焊接作业指导书规定对焊件进展加工。Thesideofthinnessshallbewithinthesideofthicknessintheprocessoffittingupthevariousbuttjointspieces,whenthesurfaceoftheedgeerrorisover3mmortheedgeerrorofwallthicknessismorethan2mm,Theprocedureofweldingpiecesshallbebasedonthedesignedrequirementsorweldingoperativemanuals.焊接工艺要求：TheRequirementsofWeldingProcedure焊丝选用应符合以下规定：Theselectionofwireshallfollowtheunder-mentionedrules:純铝焊接时，应选用純度与母材相近的焊丝；Theselectionofwireshallbesimilartothepurityofthebasematerialintheprocessofpurealuminiumwelding.铝镁合金焊接时，应选用含镁量等于或略高于母材的焊丝；Theselectionofwireshallbenotlessthanthecontentofmagnesiuminthebasematerialsintheprocessoftheweldingofaluminiumandmagnesiumalloy.铝锰合金焊接时，应选用与母材成分相近的焊丝或铝硅合金焊丝；Theselectionofaluminiumandsiliconalloywiresshallbesimilartotheingredientsofthebasematerialsintheprocessoftheweldingofaluminiumandmanganese.异种铝合金焊接时，应选用与抗拉强度高一侧的母材相近的焊丝；Theselectionofwireshallbesimilartothehighersideofthetensilestrengthofthebasematerialsintheprocessofweldingofdifferentaluminiumalloy.铝及铝合金焊接时，也可以用母材作填充金属；Thebasematerialscanbealsofilledinthemetalsintheprocessoftheweldingofaluminiumoraluminiumalloy.应符合〔GB/T10858〕的规定。否则应征得制造厂同意，并经焊接工艺评定合格。手工钨极氩弧焊应承受沟通电源。ThemanualGTAWshalladoptalternatingcurrent.焊接前焊件外表应保持枯燥，无特别要求时可不预热。Thesurfaceofweldingpiecesshallkeepdryingpriortothewelding;thepreheatingisnoneedtodowithoutspecificdemand.焊接前应在试板上试焊，当确认无气孔后再进展正式焊接。Thetestweldingshallbeheldonthetestpanelpriortothewelding;theweldingshallbeensuringporositywithoutexistencepriortothewelding.宜承受大电流快焊施焊法，焊丝的横向摇摆不宜超过其直径的3倍。Theexpressweldingwithpowerfulcurrentshallbetaken,thehorizontalswingofthewiresshallnotexcessthreetimesofitsdiameter.引弧宜在引弧板上进展，纵向焊缝宜在熄弧板上熄弧，引弧板和熄弧板的材料应与母材一样。Thearcburningshallbeheldonthearcburningwasher,thearcblowoutoftheverticalweldingseamshallbeheldonthearcblowoutboard,thematerialsofthewashersofarcburningandarcblowoutshallbethesamenesstothebasematerials.手工钨极氩弧焊的焊丝端部不应离开氩气保护区，焊丝与焊缝外表的夹角宜为15度，80-90度。TheendofthewiresbymanualGTAWshallnotbedepartedfromtheargonprotectivearea,theanglebetweenthewiresandthesurfaceofweldingseamshallbe15degrees,theanglebetweenweldingtorchandweldingseamshallbewithintherangeof80-90degrees.The多层焊时宜削减焊接层数，层间温度宜冷却至室温，且不应高于65度，层间的氧化铝等杂物应用机械方法清理干净。Theweldingpassesshallbereducedandthepasstemperatureshallbecooledtotheroomtemperatureofnotmorethan65degreesintheprocessofinterpasswelding.Thesundriessuchasaluminainthepassesetc.shallbecleanedbymechanicalprocess.5mm的立焊缝，宜承受两人双面同步氩弧焊工艺。TheprocedureofAAWonbothsidesbytwoweldersshallbetakenasthethicknessofverticalweldingseamismorethan5mm.当钨极氩弧焊前端消灭触钨现象时，应进展修整或更换钨极，当焊缝消灭夹钨必需处理干净前方可连续进展焊接。TheelectrodeoftungstenshallberepairedorchangedwhenthefrontsideoftheGTAWisappearedthephenomenaoftungsten-touch,theexistenceoftungstenintheweldingseamshouldbecleanedpriortothewelding.焊件应承受以下防止变形措施：TheProtectiveMeasuresofWeldingPiecesagainstDistortion:焊接挨次应对称进展，当从中心向外进展焊接时，具有大收缩量的焊缝宜先施焊，整条焊道应连续焊完；Theweldingordershallbeheldsymmetrically,whentheweldingisfromthecentertotheoutside,theweldingseamwithlargevolumeofconstrictionshallweldinadvance,theweldingbeadshallfinishweldingconsistently. 不等厚度对接焊件焊接时，应实行加强拘束措施，防止对应于焊缝中心线的应力不均匀；Theconstrainedmeasuresshallbetakenwhenthebuttjointofweldingwithasymmetricalthicknesssoastoprotectthestressofthecentrallineofweldingseamagainstbeingasymmetrical.焊件宜进展刚性固定或实行反变形方法，并应有收缩余量。Theweldingpiecesshalltakerigidfixationormethods againstdistortionandhavetheremainingofshrinking.钢铝接头的焊接：进展钢铝接头焊接时，应必需实行有效措施，严格掌握焊接线能量。焊接环境：WeldingCondition:定位焊及正式焊接不得在雨〔雪〕天或相对湿度80%以上的环境下进展。环境温度在5℃以下时冷箱内应有措施。Thetackwelding&weldingcannotbeprocessedunderthecircumstanceofrainydays,snowydaysandthehumidityisupperthan80%.Theicechestshallbetakenmeasureswhentheenvironmentaltemperatureisbelow5℃.焊接预热：PreheatWelding6ｍｍ时，应预热至～１００℃。当壁厚大于等于８ｍｍ时应预热～１５０℃。Thepreheattemperatureshallreach100℃intheconditionthatthedistancebetweentheuppertowerandthemaincoldwallisnotmorethan6mm.Thepreheattemperatureshallalsobereach100℃intheconditionthatthewallthicknessisnotmorethan8mm.焊接挨次：WeldingOrder依据定位焊后，正式焊接均承受两人同时双面横焊，δ≥８ｍｍ时复盖层可用单人焊接。特别留意：‘定位焊后塔体可能引起的垂直度及塔板水平度变化确定’，即利用焊后变形进一步矫正垂直度及水平度。Alltheweldingshallbetakenashorizontalweldingonbothsidesbytwoweldersaccordingtothetackwelding,whentheδisnotlessthan8mm,thecoveredpassescanbeusedbysinglewelding.SpecialAttention:‘Thecolumnmaycausethechangeofverticalityorthelevelofthetowerwasherinthecompletionoftackwelding.’Thedistortionafterweldingshallberectifiedabouttheverticalityandlevel.在冷箱内各容器管口接收前需要用干净的白布或塑料布扎口，以免油脂及污物进入，对冷凝蒸发器内施焊时，严禁火焰或电弧击伤容器及管道外表。工件焊接时，电缆搭铁〔二次线〕不允许随便乱搭在工件上，应做专用工具，不允许在管道上引弧。Inordertoavoidgreasesandfeculencesbeingentered,eachnozzleofvesselintheicechestshallbecleanedandbefastenedbycleancalicoandplasticcloth,thesurfaceofthevessel&pipelinesshallbeforbiddenhurtingbyflameandelectricarcintheprocessofweldinginthecondensativeevaporator.Thecablejointwithironofearthwiresisnotallowedtobebuiltontheworkpiecesatwillintheprocessofweldingworkpieces,thespecialinstrumentshallbemade,andthearcburningisnotallowableonthepipelines.现场铝合金塔塔体环焊缝的焊接Thecircularweldingofthecolumnofaluminiumalloytoweronsite担当塔体环焊缝焊接的焊工应按本标准规定要求经考试合格持证上岗。Theweldersofannularweldingofthetowershallpasstheexamandbecertificate-carriedaccordingwiththestandardregulation.环焊缝处横焊位置，焊工应按“双面横焊”要求进展操作技能的考试，考试用材的牌号，规格应与实际产品全都。Thepositionofhorizontalweldingintheannularweldingseam,theweldershallbepassedtheoperativeskillsexamineaccordingtotherequirementsofhorizontalweldingonbothsides.Thebrandandspecificationsofmaterialsshallbeidenticaltothefactualproducts.立装塔环焊缝焊接工艺：Theweldingprocedurefortheannularweldingseamofverticalinstallingtower:焊接方法：双人双面同时横焊，当壁厚≥10mm时，坡口侧承受单人单面横焊加复盖层；WeldingProcedure:Whenthewallthicknessisnotlessthan10mm,twoweldersweldonbothsidesatsametime.Otherwise,onesideofgrooveshalladoptthehorizontalweldingandaddcapping.预热温度：Preheattemperature:壁厚﹤10㎜时预热～100℃Wallthickness﹤10mm,Preheatis100℃壁厚≥10㎜时预热～150℃ Wallthickness≥10mm,Preheatis150℃留意事项Attention焊接环境：雨天或环境相对湿度≥90％时不得施焊。Weldingcondition:Theweldingisforbiddenunderthecircumstanceofrainydaysortherelativehumidityisnotlessthan90％.坡口加工实行机械方法，并确保组对，定位焊时有足够的，均匀的间隙。Theprocessofgrooveissuggestedtoadoptingmechanicproceduresandensurethefittingupwithenoughandsymmetricalclearanceintheprocessofwelding.塔环焊缝正式施焊开头后，中途焊接中断时间不得超过15Afterthebeginningannularweldingoftower,thestoptimeintheprocessofweldingshallnotbeover15minutes.进入塔内前应检查容器内含Ｎ22Thecontentofnitrogeninthevesselshallbeinspectedpriortoenterthetower.焊接时用于氧乙炔气焊枪预热时，应在塔外侧预热，并避开坡口区。Preheatingbyoxy-acetyleneweldingtorchintheprocessofweldingshallpreheatoutsideoftowerandavoidthegroovearea.双面双人同时横焊及单人单面复盖焊时应选择合理的焊接挨次，保证塔体的直垂度。Theselectionofweldingordershallbereasonableandensurethe verticalityoftowerinprocessofweldingbytwoweldersonbothsidesandcoverweldingononeside.应尽量设法缩短氩气管，为此可将氩气瓶放在接近施焊区域的平台上。Theargongascylindersshallbelaidonthe