洁净系统焊接规范

1、Technical Specification of Welding of Sanitary Piping 卫生管道焊接技术规范卫生管道焊接技术规范 编写编写 Prepared by 公司/部门 Company/Dept 签字 Signature 日期 Date 审核审核 Checked by 公司/部门 Company/Dept 签字 Signature 日期 Date 批准批准 Approved by 公司/部门 Company/Dept 签字 Signature 日期 Date CONTENT 目录目录 1.范围范围 RANGE.3 1.1 文件描述文件描述 Description of

2、 Document.3 1.2 文件版本文件版本 Version Handling .3 2.总述总述 SUMMARY.4 3.焊接焊接 WELDING.4 3.1 总要求总要求 General Requirements.4 3.2 材料材料 Material.5 3.3 焊接点准备和安装焊接点准备和安装 Welding Points Preparation and Fit-up.5 3.4 预加热温度预加热温度 Preheating Temperature .6 3.5 加热处理加热处理 Heat Treatment.6 3.6 电气特征电气特征 Electrical Characteris

3、tics.6 3.7 焊接过程焊接过程 Welding Procedure .6 3.8 程序控制设置程序控制设置 Program Control Settings .7 3.9 焊接维修焊接维修 Weld Repair.7 3.10 自动焊接程序自动焊接程序 Automatic Welding Program.7 3.11 文件文件 Documentation .7 3.12 无损检查无损检查 Non destructive Inspection.8 3.13 每日焊接样品每日焊接样品 Daily weld samples.8 4.制造和安装制造和安装 FABRICATION AND INS

4、TALLATION .10 4.1 范围范围 Scope.10 4.2 一致一致 Conformance .10 4.3 规格规格 Specifications.10 4.4 管道材料的存放和在位处理管道材料的存放和在位处理 Piping material storage and handling at site.10 4.5 鉴别鉴别 Identification.11 4.6 制造制造 Fabrication.11 4.7 设计、切割和安装设计、切割和安装 Design, cutting and fitting up.11 4.8 焊接过程和资格焊接过程和资格 Welding proced

5、ure and qualifications.11 4.9 安装安装 Installation.11 4.10 焊接点焊接点 Welding Points.12 4.11 法兰接点法兰接点 Flanged joints .12 4.12 卡箍卡箍接点接点 Tri-Clamps.12 4.13 管道的支架与穿透管道的支架与穿透 Support of Piping and penetration.12 4.14 管道的检查和测试管道的检查和测试 Inspection and testing of pipes.13 5.检查检查 INSPECTIONS.14 5.1 范围范围 Scope.14 5.

6、2 零件及焊接鉴别零件及焊接鉴别.14 5.3 焊接准备焊接准备 Weld preparation.14 5.6 验收验收 Acceptance.17 5.7 其它要求其它要求 Other requirements.17 5.8 焊缝的要求焊缝的要求 Requirements on Welding Seams.17 1.范围范围 RANGE 本文件属于上海意迪尔洁净系统工程有限公司内部文件，仅用于指导意迪尔公司所承担的 洁净系统工程的管道焊接，包括，但不局限以下项目：制药用水贮存和分配系统，配料系 统。 This document is the internal document for Sh

7、anghai Ideal Sanitary Engineering Co., Ltd, and is applicable for the project validation Ideal has undertaken, including but not only including the following: Manufacturing, storage and distribution system of water for pharmaceutical use, product manufacturing system, 1.1 文件描述文件描述 DESCRIPTION OF DOC

8、UMENT 本技术规范是对成都苑东药业有限公司工厂设施中，PW 和 WFI 系统以及混料罐系统的技 术要求进行明确。 The technical specification specifies the requirements regarding storage tanks and distribution loops in the PW and WFI System and Mixing Tank System in the Baxter Healthcare Co., Ltd Facility at Guangzhou China. 1.2 文件版本文件版本 VERSION HANDLIN

9、G VersionDateStatusChange A018-08-2010Quotation design 2.总述总述SUMMARY 该规范适用于清洁管道的焊接、制造和安装。 The specification applies for sanitary pipe welding, fabrication and installation. 尤其适用于 AISI 316L 不锈钢清洁管道的焊接。 In particular such specification is to be used for welding AISI316L sanitary stainless steel pipes

10、任何更改都必须得到用户的同意。 Any changes must be approved by the customer 任何与规定不符的地方都必须提交 IDEAL 检验。 Any deviation from specifications must be tested by IDEAL 在此规范范围内的焊接点必须符合 GMP 和清洁标准 3A。 The welding joints in the scope of this specification must accord with GMP and Sanitary Standard 3A. 规范中的制造商指的是 IDEAL 洁净系统工程有

11、限公司，它负责设备、工程制造和安装。 In the scope of this specification the term FABRICATOR refers to IDEAL Sanitary System Engineering Co., Ltd., who is in charge of pipe fabrication and installation. 所有者指的是客户或其代理。 The term OWNERrefers to CUSTOMER or his representative 焊接检查人员指的是负责检查焊接操作的设备所有者或客户代理人。 The term WELDING

12、 INSPECTOR refers to the Owner or Customer representative who is in charge of inspecting the welding operation and examinations 3.焊接焊接 WELDING 该规范包括了使用自动焊接机或手动 TIG 设备进行的不锈钢钨焊接。 This specification covers the stainless steel tungsten arc welding performed by automatic weld machine or manual TIG equipm

13、ent 术语管道包括所有的焊接零件。 The term PIPING includes all welding fittings 3.1 总要求总要求 GENERAL REQUIREMENTS 手动钨极焊接（TIG）必须用实际工作材料进行抽样检验。这些抽样必须与自动焊接一样 通过独立检验。 Manual TIG welding must be tested through sampling the actual working materials. The samples shall be independently inspected like automatic welding 自动焊接机

14、的操作者必须通过焊接测试。必须在普通尺寸的管道材料上进行焊接。 Automatic weld machine operator must pass welding examination which requires welding on normal sized pipes 附加的焊接不能损坏整个焊接。 Additional welding should not damage the whole welding 附加焊接一定要尽量降低温度以避免造成材料微粒部分的结构变化。 Additional welding should be performed under a low temperatu

15、re to avoid causing structural changes of the material particulates. 附加焊接不能穿透内表面。 Additional welding shant strike the inner wall 附加焊接结束后必须检查线性和裂缝。 Check the linearity and seam after the additional welding completed. 3.2 材料材料 MATERIAL 焊接材料应该符合清洁不锈钢管道的奥氏体焊接。 Welding material shall comply with Austenit

16、ic welding of sanitary stainless steel pipes. 所有管道和接口必须完全焊接穿透。 All pipes and joints shall have complete weld penetration 使用的焊接电极必须是涂 2%钍的平头钨电极。电极如果被污染就更换一个。 Electrode for welding shall be a pointed 2% thoriated tungsten electrode with a flat trip. Replace the electrode if it is contaminated. 在管道内部使用

17、焊接氩气，用于净化，最低纯度为 99.99%。其他混合气体用于客户的预 防性焊接。必须提供惰性气体以防止内部焊接表面的氧化。开始焊接前必须将所有氧气 驱逐出焊接区域。 Welding grade argon gas shall be used inside the pipe for purge and shall be of 99.99% minimum purity. Other gas mixture could be used with customers preventive welding approval. Inert gas should be provided to preve

18、nt oxidative attack to the inner weld surface. Before starting the welding all oxygen is purged from the welding area. 3.3 焊接点准备和安装焊接点准备和安装 WELDING POINTS PREPARATION AND FIT-UP 如果焊接表面是湿的就不能进行焊接。在恶劣天气，大风或盖反气流天气时不能进行外 部的焊接，除非有很好的保护措施。 No weld is carried out when surfaces are wet. No outside welding i

19、s carried out during inclement weather, or period of high wind or negative airflow unless under proper protection. 焊接点的两个表面必须是清洁的，圆滑平整的。粗端的焊接准备必须由机器进行。 The two surfaces of the joint are clean, circular and smooth. The butt welding preparation shall be carried out by machines. 机器进行的焊接准备使焊接端光滑，没有凹痕或其他

20、有害的不规则处。 The welding preparation carried out by machine enables the welded end smooth, free of notches or other harmful irregularities. 建议使用 G+F 或同等的设备进行切割和最后的准备。 It is recommended to carry out cutting-off and final preparation using a G+F or equivalent device 切割必须平整并且不引起管道的变形或损坏。用磨轮切割的管道必须进行清洗，应除去

21、研磨的粉尘。 Cut-off must be smooth without distortion or damage to the tube. The pipe cut-off by an abrasive wheel must be cleaned to remove the abrasive dust 任何情况下都不能使用碳钢切割工具。 Carbon steel cutting tools are not admitted in any circumstances. 焊接和准备、制造及安装用的工具应该是不锈钢或者是合格的合金钢，清洁无油脂、无 污染； 切割油不含硫，除非在焊接前将管道表面或

22、内部的油全部清洗干净。 Tools used for welding, preparation, fabrication and installation shall be stainless or approved alloy steel, clean, free of grease and other contamination. Sulfur is not contained in the cut-off oil, unless the grease on outer surfaces or in the pipe is totally wiped off before welding.

23、 用允许的溶液对所有点进行干燥。 Dry all welding points with approved solution 焊接设备必须由焊接检查员一起安装。他必须检查所有安装是否符合控制程序。他应该 在焊接记录上签字，使之有效。无论何时都不能在制造管道的过程推迟这一工作。 The welding equipment shall be set up with the company of welding inspector who inspects whether all the installation accord with controlling program and signs o

24、n the welding record to make it effect. This procedure shall not be delayed at any time while manufacturing the pipes. 每天工作开始前，每个操作者必须在光滑管道上进行焊接测试。这些零件将作为焊接检 查员的检查之用。每一个自动焊接机都必须进行这一试验。 Every welder should proceed with welding test on smooth pipes before starting daily work. These accessories are for

25、 inspections by welding inspector. Each automatic weld machine shall have this test. 3.4 预加热温度预加热温度 PREHEATING TEMPERATURE 焊接前材料的最低温度不能低于 100C，一般情况下不需要进行预加热。 The temperature shall be no less than 100C before welding. Preheating is unnecessary in common situations. 3.5 加热处理加热处理 HEAT TREATMENT 不需要进行焊接

26、后的热处理。 Post welding heat treatment is not required. 3.6 电气特征电气特征 ELECTRICAL CHARACTERISTICS 电流应该符合焊接表中的数据。 Current shall be as specified on the welding table 3.7 焊接过程焊接过程 WELDING PROCEDURE 焊接技术，如焊接过程，焊接程序设置，电极位置等，应该与焊接表中的要求一致 The welding technique, such as weld procedure, welding program settings, e

27、lectrode positioning etc., shall accord with the welding table 3.8 程序控制设置程序控制设置 PROGRAM CONTROL SETTINGS 程序设置应该符合标准的要求，允许 10%的误差。 Program setting shall accord with criteria with a deviation permission of 10% 3.9 焊接维修焊接维修 WELD REPAIR 在检查时，如果发现有不符点而且是可以进行修正的，就需要进行焊接维修。 Weld repair is needed if any cor

28、rectable defects are found at inspection. 第一次的焊接维修可能是在已经焊接的位置再焊接一次。 The first weld repair may be rewelding on the welded spot. 可以进行修改的错误包括焊接不够，排列不齐，焊接穿透不够或过多，有孔和穿出洞。 The correctable defects include not enough welding, misalignment, excessive or inadequate weld penetration, porosity and pin holes. 所有

29、焊接出裂缝的都必须扔掉并从加热区移出。 All welds with cracks shall be rejected and removed from the heating zone. 3.10 自动焊接程序自动焊接程序 AUTOMATIC WELDING PROGRAM 任何控制程序都定义了不同尺寸管道的焊接参数。管道自动焊接系统的焊接程序要符合 焊接操作者和检查者规定的程序。每个自动焊接机的焊接程序必须提交给焊接检查者。 生产和检查焊接时只能使用允许的焊接程序。 Each control program defines a set of parameters for different

30、 sizes of Piping. Welding programs of the automatic pipe welding system shall accord with the procedures defined by welder and welding inspector. Automatic weld machines welding procedure must be submitted to the welding inspector. Only approved welding procedures can be employed for fabrication and

31、 welding inspection 焊接样品必须按顺序编号（如 T1，T2 等）。焊接样必须可追溯，可进行独立检验。 Welding samples must be numbered in sequence (such as T1, T2). Welding samples must be traceable and may be independently inspected. 在制造过程中，每日的样品都可在位使用。 Daily samples can be used in place in the fabrication procedures. 自动管道焊接系统的标准应该符合焊接操作者

32、和检查者规定的要求。 Automatic pipe welding system specifications shall comply with the request for weld operator and weld inspector. 3.11 文件文件 DOCUMENTATION IDEAL 会对所有进行的焊接提供书面记录。焊接记录格式必须填满，而且必须包括： IDEAL will provide a written record concerning all welds. The weld record must be fully filled and contains: 系统

33、名称 System name 焊接号 Weld number 焊接者姓名 Welder name 机器规格 Machine specification 焊接日期 Welding date 焊接程序号 Welding program number 焊接操作者和检查者（如果有）的签字 Signature of welder and inspector (if any) 另外机器将对焊接过程打印出自动记录。这个焊接号应该填在焊接记录中。 In addition the machine will print out an automatic record concerning the welding

34、procedure. This welding number shall be filled on the weld record. 每个焊接点必须连续编号。所有焊接点将在等大的图上及相关的焊接报告中显示。 Each weld point shall be numbered in progressive way. All welding points will be shown on isometric sketches and relative welding report. 检查者应该有焊接检查清单，而实际的焊接应该与这些编号一致。 The inspector shall maintain

35、 a weld inspection check list and the actual weld shall accord with the numbers 在位工作和工作结束时等大的图会起到作用，并且会得到更新。 Isometric sketches will be available and updated during working in place and after finishing the work. 3.12 无损检查无损检查 NON DESTRUCTIVE INSPECTION 如果需要无损坏检查，就应该按照法定要求和合同规定进行。而且必须考虑由于这些控 制造成的时间延迟

36、。 Non destructive inspection shall comply with the legal request and contract if necessary. Time delay caused by these controls shall also be considered. 3.13 每日焊接样品每日焊接样品 DAILY WELD SAMPLES 每日焊接样品应该用机器焊接程序进行。所有焊接样品应该在 5G 或 2G 位置上进行并进 行检查。这些样品必须按顺序编号（如 P1，P2 等）。在制造过程中这些样品应该能用 于用户的在位使用。 Daily weld sa

37、mples are accomplished through machine welding programs. All welded samples shall be made at 5G or 2G position and shall be inspected. These samples must be numbered in sequence (such as P1, P2). All these samples should be available for in place customer using. 每日样品结果必须整理到自动焊接机检测报告中，该报告必须填满。 The da

38、ily sample results must be collected in the fully filled automatic welding machine test report. 4.制造和安装制造和安装 FABRICATION AND INSTALLATION 4.1 范围范围 SCOPE 这一部分和图的标准及参考代码应该与管道的制造和安装一致。 This section and drawing standard and codes referenced shall apply to the pipe fabrication and installation. 4.2 一致一致

39、CONFORMANCE 这一规定范围内的所有工作应该遵守这一规定或其它参考文件：没有事先提供书面许可， 不得做这一规定或其参考文件规定外的变化。每个更改的申请都必须标明位置、描述和 更改的原因。 All works within the scope of this specification shall be performed in accordance with this specification or other reference documents: no deviation shall be made from this specification or its referenc

40、e documents without the prior written approval. The applicable for each deviation shall completely and specifically define the location, the description, and the reason. 管线的尺寸和制造应符合管道图的整体尺寸，应由 IDEAL 负责。 Pipe dimension and fabrication shall conform to the overall dimension as shown on the piping draw

41、ing and under IDEAL responsibility. 4.3 规格规格 SPECIFICATIONS 这里指的规定、标准、法规等应该考虑这一规定。规定、标准、法规等应该是有效的最 新版本。 All specifications, standard, codes referred herein shall consider this part. Specifications, standards and codes must be of the latest edition. 所有规定中的要求与工程师的要求或设计图纸的矛盾应该在开始工作前按原则预以澄清。 All conflic

42、ts between the requirements of this specification and engineerings request or designing paper should be clarified according to principal before starting work. 4.4 管道材料的存放和在位处理管道材料的存放和在位处理 PIPING MATERIAL STORAGE AND HANDLING AT SITE 管道材料应该由其它人进行鉴别和检查。 Piping material shall be identified and inspecte

43、d by others. 应该仔细存放所有管道材料和制造前的零件，防止污染油脂、受潮等。避免任何凹陷、 划痕或其它物理损坏。 Carefully store all Piping materials and prefabricated accessories for prevention of grease contamination and moisture. Avoid any denting, scraping or any other physical damage. 所有不锈钢材料应该与其它材料分开检查和存放。存放区必须在室内并防止接触爆炸性 气体和变化的温度。 All stainl

44、ess steel material shall be checked and stored separately from other construction materials. The storage area must be located inside a building and protected from any corrosive atmosphere and changing temperature. 必须严格控制出入，从而防止物理损坏及丢失。只有需要制造时才能拿出来。 Strictly control the access in order to prevent phy

45、sical damage and lost. Dont take them out unless fabrication needs. 4.5 鉴别鉴别 IDENTIFICATION 应按使用的规格鉴别材料并按合适的鉴别方式存放及处理这些材料。 All materials will be identified in accordance with the applicable specification and be stored and processed through suitable identifying methods. 4.6 制造制造 FABRICATION 如果需要，制造必须

46、符合规定及安装要求。 Fabrication must comply with the specifications and install request if necessary. 4.7 设计、切割和安装设计、切割和安装 DESIGN, CUTTING AND FITTING UP 要按图纸的要求按尺寸正确切割管道。 Piping shall be cut accurately according to drawings. 4.8 焊接过程和资格焊接过程和资格 WELDING PROCEDURE AND QUALIFICATIONS IDEAL 应该出示文件以证明所有程序、焊接工和操作者

47、符合规定第二部分的要求。 IDEAL shall show documents to prove that all procedures, welders and operators have been qualified according to requirements described in part 2 of this specification. 所有焊接工都有 24 个月的工作经验或通过工厂的培训。 All welders shall have twenty-four months working experiences or have been trained at the f

48、actory. 如果需要，可以提供每个焊接工的最新的书面证明。 Provide latest written certificate for each welder if necessary. 焊接管理者应该在自动焊接机的程序、制造和问题处理上有一定的经验。 Weld manager must have certain experiences on procedures, fabrication and question resolving of automatic welding machine. 开始焊接前必须将焊接程序提交检查者。 Welding procedures shall be submitted to welding inspector for approval before starting the welding. 4.9 安装安装 INSTALLATION 不允许在管道