小口徑管道和儀表管焊接作業(yè)指導(dǎo)書.doc

CSPC Nanhai Petrochemicals ProjectSEPCO Electric Power Construction Corp.CSPC NANHAI PETROCHEMICALS PROJECT南 海 石 化 項 目Work Instruction For Small Bore Pipe and Instrument Pipe Welding小口徑管道和儀表管焊接作業(yè)指導(dǎo)書WORKING INSTRUCTION: WI-8710-8100-0069SEPCO Electric Power Construction Corporation山東電力基本建設(shè)總公司SEPCOREVDATEREASON FOR ISSUEBYCHKDREVIEWAPPRA26.FEB.2004Issued for ApprovalX.WZHAO S.LXIAO T.PTIAN G.HB20.MAY.2004Issued for ApprovalX.WZHAO S.LXIAO T.PTIAN G.H0027.MAY.2004Issued for use X.WZHAO S.LXIAO T.PTIAN G.H目 錄TABLE OF CONTENS1工程概況PROJECT GENERAL DESCRIPTION2編制依據(jù)REFERENCES3職責(zé)RESPONSIBILITIES4施工準(zhǔn)備PREPARATION FOR CONSTRUCTION5 資源配置RESOURCE ALLOCATION6施工工序和施工方法WORKING PROCEDURE AND METHOD7工作安全分析（JSA-8560-8101-0148）修改記錄Revision Information版次Ver.章節(jié)號Section No.主要修改內(nèi)容Description of main changesB2增加“PR-8710-8100-0218 焊縫跟蹤程序 Rev.00”Add the “PR-8710-8100-0218 Weld bead tracking procedure Rev.00”1工程概況PROJECT GENERAL DESCRIPTION1. 1小口徑管道指外徑小于80mm的管道，汽電聯(lián)產(chǎn)項目STG部分的小口徑管道主要有低碳鋼、合金鋼類、不銹鋼等材質(zhì)。 The small bore pipe means that the pipe of which the external diameter is less than 80mm, the small bore pipe for part of STG for S&P unit project mostly including low carbon steel, alloy steel, stainless steel and such material characteristic. 2 編制依據(jù) reference2.1相關(guān)設(shè)計圖紙及文件 Correlative design drawing and document 2.2 電力建設(shè)施工及驗收技術(shù)規(guī)范（火力發(fā)電廠焊接篇 DL5007-92）Construction and acceptance technique specification for electric power construction (Welding chapter for thermal power plant DL5007-92)2.3 火電施工質(zhì)量檢驗及評定標(biāo)準(zhǔn)（焊接篇96版） Quality inspection and assessment standard for thermal power construction（Welding chapter for edition of 96） 2.4 電力建設(shè)安全工作規(guī)程（火力發(fā)電廠部分2002版） Safety work regulations for electric power construction (part of thermal power plant for edition of 2002)2.5 電力建設(shè)安全健康與環(huán)境管理工作規(guī)定（2002版） Safety health and environmental management work stipulation for electric power construction (Edition of 2002) 2.6 PR-8710-8100-0026 焊工培訓(xùn)與考核 Welder Training and Examination Rev.002.7 PR-8710-8100-0223 焊接消耗品控制 Consumable stores control for welding Rev.00 2.8 PR-8710-8100-0055 測量和校驗設(shè)備Measuring and Test Equipment Rev.002.9 PR-8710-8100-0038 焊接控制Welding Control Rev.042.10 PR-8710-8100-0025 焊接程序WELDING PROGRAM Rev.002.11 PR-8710-8100-1001 通用焊接標(biāo)準(zhǔn)WELDING PROGRAM Rev.012.12 PR-8710-8100-0213 NDE管理程序NDE Management Rev.022.13 WI-8610-8100-0004C 氣體管理Gas Management Rev.002.14 PR-8710-8100-0215 焊接熱處理Welding Heat Treatment Rev.002. 15火力發(fā)電廠焊接熱處理技術(shù)規(guī)程（DL/T819-2002） Technique regulations of welding heat treatment for thermal power plant（DL/T819-2002） 3 職責(zé) responsibility3.1 焊工負責(zé)管道的焊接，并檢查自己所焊焊縫的外觀。 Welders are responsible for welding the pipe and inspecting the appearance of weld bead welded by self. 3.2 班組焊接質(zhì)檢（QC1）、工程處焊接質(zhì)檢(QC2)、公司級焊接質(zhì)檢(QC3)負責(zé)對焊工日常工作的監(jiān)督，并按比例對焊縫進行外觀檢查和驗收。 QC1, QC2 and QC3 are responsible for supervising the daily work of welder and inspecting and accepting the appearance of weld bead in proportion.3.3 焊接工程師負責(zé)焊工考試、焊工檔案管理、焊接程序、焊工資格認定測試、WPS 以及 PQR 資格認定記錄的現(xiàn)場準(zhǔn)備、發(fā)布并維持，并負責(zé)檢查、指導(dǎo)焊工和焊接質(zhì)檢的工作。 Weld engineer is responsible for the welder examination, welder files management, weld procedure, cognizance test for procedure qualification, site preparation, issuance and maintenance for qualification cognizance record of WPS and PQR, as well as for inspecting and directing welders and the work of welding quality control. 3.4 NDE工程師負責(zé)無損檢測程序準(zhǔn)備、發(fā)布和維持以及NDE檢測及填發(fā)NDE報告。 NDE engineer is responsible for the preparation, issuance and maintenance of NDE procedure and NDE detection and filling in and issuing the NDE report. 3.5基建總公司（以下簡稱SEPCO）焊接工程師負責(zé)施工協(xié)調(diào)和質(zhì)量驗收。 Weld engineer in Shangdong Electric Power Construction corporation (SEPCO for short) is responsible for the construction coordination and the quality acceptance.4施工準(zhǔn)備PREPARATION FOR CONSTRUCTION4.1焊接工藝規(guī)程（WPS）和焊接工藝評定(PQR)滿足現(xiàn)場焊接需要。 WPS and PQR meet the requirement of site welding.4.2具有相應(yīng)資質(zhì)的焊工和熱處理工。 Provide qualified welder and heat-treatment worker.4.3焊機、熱處理機、焊條烘干箱等工器具準(zhǔn)備齊全，并經(jīng)過校驗。Tools and instrument such as welding machine, heat-treatment machine, welding rod baking oven are all ready and they have been verified. 4.4使用的各種焊接材料齊全，具有相應(yīng)的合格證。 All kinds of used weld material are all ready, and have relative qualified certificates. 4.5現(xiàn)場焊接搭設(shè)好防風(fēng)、防雨設(shè)施，管道內(nèi)也不得有穿膛風(fēng)。 The windshield and rain-proof equipment for site welding has been set up, there is no draft inside the pipe. 4.6焊件在組裝前應(yīng)將焊口及附近母材內(nèi)、外壁的油、漆、垢、銹等清理干凈，直至發(fā)出金屬光澤。清理范圍如下：每側(cè)各為1015mm。 Clean up the oil, paint, dirty, rust which are in the weld bead and inside & outside the wall of base material thoroughly prior to assemble the weldment. The cleaning range is as follows: 1015mm for each side.4.7對接單面焊的局部錯口值不應(yīng)超過壁厚的10%，且不大于1mm。 Partial value of fissure of displacement of butt one side weld shouldnt be over 10% of thickness of wall, and no more than 1mm. 4.8每個項目開工前，安裝部門應(yīng)提前足夠的時間通知焊接隊開工的日期、系統(tǒng)、項目、管線號、圖紙?zhí)?、材質(zhì)、規(guī)格等，以便焊接隊有充足的準(zhǔn)備時間。 The erection department should inform the welding team in advance about the commencement date, system, item, pipeline number, drawing number, material characteristic, specification and so on before the commencement of each project, so as to make the welding team have enough time to prepare it. 4.9開工前，班長派出焊工到技術(shù)組接受技術(shù)和安全交底。 The team leader send welder to the technique group to receive the real intentions of technique and safety before commencement.4.10所使用的氬氣純度不低于99.99%。 The used purity of argon gas is no lower than 99.99%。4.11焊接不銹鋼管道時應(yīng)使用專用于不銹鋼的鋼絲刷、砂輪片、地線夾、記號筆等。 Use special steel wire brush, grinding wheel slice, earth wire nip, marking pen and so on when welding the stainless steel pipe. 4.12不銹鋼相對于其它常見鋼種具有熱膨脹系數(shù)大、導(dǎo)熱系數(shù)小的特點，在焊接過程中，如果熱輸入量過大，容易變形、嚴(yán)重氧化，甚至出現(xiàn)裂紋。因此，應(yīng)在開工前的培訓(xùn)中，對具有相應(yīng)資質(zhì)的焊工進行專門練習(xí)培訓(xùn)，采用小電流、快速焊的操作手法。 Compare with other types, the thermal expansion coefficient of stainless steel is greater, the thermal-conductivity coefficient is smaller, in course of welding, if the heat input is too big, it will be easy to distort, and be oxidated seriously, even it will be cracked. So the relevant qualified welder should be trained for special practice before commencement, employing the operating method of low current and rapid welding. 4.13坡口的制備應(yīng)以機械加工的方法進行。如使用火焰切割切制坡口，則應(yīng)將割口表面的氧化物、熔渣及飛濺物清理干凈，并將不平處修理平整。 The groove preparation should be done with the method of machinery process. If use the flame to cut the groove, the oxide of notch surface, sinter and splash object should be cleaned up, and make the accidented place level. 5 資源配置resource allocation5.1 主要施工機具如下The main construction machinery and tools are as follows：ZX7-400ST逆變焊機（contra-variant welder）15臺焊條烘干箱Baking oven of welding rod2臺焊條保溫筒 heat-insulated mould of welding rod15個電焊鉗Electrode holders10把氬弧焊槍Argon arc welding torch15把鋼絲刷（包括普通型和不銹鋼專用型）Steel wire brush (Including common type and special type for stainless steel) 20把記號筆（包括普通型和不銹鋼專用型）Sign pen (Including common type and special type for stainless steel)20只手電筒Flashlight20只測溫筆Color pencil20只砂輪片（包括普通型和不銹鋼專用型）Grinding wheel slice (Including common type and special type for stainless steel)200片5.2 人員配置：Personnel allocation：焊接工程師和質(zhì)檢員Welding engineer and QC inspector4人 安全員Safetyman1人焊工Welder15人6施工工序和施工方法WORKING PROCEDURE AND METHOD6.1焊前預(yù)熱 Preheating before welding 6.1.1焊接前按照預(yù)熱工作單規(guī)定的溫度預(yù)熱。Preheating piping by “preheat working sheet” before welding。6.1.2施焊過程中，層間溫度應(yīng)不低于規(guī)定的預(yù)熱溫度的下限，且不高于400。 The interlayer temperature should be no lower than the stated lower limit of preheating temperature, and no higher than 400 in course of welding. 6.1.3 小口徑管道可以采用火焰加熱預(yù)熱，用測溫筆測溫，達到溫度方可施焊。 Preheating the small bore pipe can employing the flame, measure the temperature with color pencil, the to weld it if it reaches the temperature. 6.2 焊接 Welding 6.2.1氬弧焊打底的焊層厚度應(yīng)3mm。 The thickness of welding layer rendered by argon arc welding should be less than or equal to 3mm。6.2.2當(dāng)使用鎢極氬弧焊焊接比較薄的管道時，應(yīng)盡量分2次而不是1次焊完。 Welding the thinner pipe with the electrode argon arc welding should divide into two times as soon as possible, not finish it only one time. 6.2.3焊接質(zhì)檢員應(yīng)巡視現(xiàn)場，監(jiān)督焊接全過程，檢查焊接質(zhì)量。 The weld QC inspector should patrol the site and supervise the whole course of welding, and also inspect the welding quality.6.2.4焊工焊完一個焊口后，應(yīng)打磨焊口表面和附近區(qū)域，清除飛濺和尖銳棱角等，并對焊口外觀進行目視自檢（visual test）。 Burnish the weld surface and the nearby area and clean out the splashing objects and acuminous edges and so on after welding a weld bead, also do the visual test to the appearance of welding bead.6.2.5支架管部焊接的要求（包括檢驗、預(yù)熱、熱處理）與焊縫相同，并按照相同的等級要求做NDE檢驗。 The requirement of support pipe welding (including inspection, preheating, heat treatment) is the same as the welding bead, and do the NDE test according to the same grade. 6.2.6 儀表管的焊接檢驗要求等同于小口徑管道。 The welding inspection requirement of instrument pipe is equal to that of the small bore pipe. 6.2.7開工前由班長將焊縫檢查記錄單交給有相應(yīng)資質(zhì)的焊工，焊工應(yīng)嚴(yán)格按照上面規(guī)定的WPS施焊。 The monitor will hand in the Inspection record for welding beadto the qualified welder before commencement, the welder should do the welding strictly according to the stated WPS .6.2.8直徑60mm以下的小口徑管道的焊接采用氬弧焊方法。The welding is employing the method of GTAW to the small bore pipe of which the outside diameter is less than 60mm.6.3 焊后熱處理(PWHT)6.3.1熱處理工人應(yīng)嚴(yán)格按照熱處理工作單規(guī)定的要求進行熱處理工作。The worker should perform PWHT according to the given parameter by “PWHT SHEET”.6.3.2 降溫過程中，溫度在300以下可不控制。 It can be out of controlled if the temperature is lower than 300 in course of dropping in temperature. 6.4 焊口的返修Patching of welding bead 6.4.1焊接缺陷超過標(biāo)準(zhǔn)時，可采取挖補方式返修。但同一位置上的挖補次數(shù)一般不得超過2次。 Patch it with the method of mending when the welding deficiency exceeds the standard. However, the mending time in the same position cant generally exceed two times.6.4.2 由焊接工程師制定焊接返修工藝，并由具有相應(yīng)資質(zhì)的焊工進行返修焊接，返修記錄應(yīng)與該焊口的焊接記錄存放在一起。 The welding engineer establishes the welding patching process, and the qualified welder do the patching welding, the patching record should be put together with the welding record of weld bead. 6.4.3需進行熱處理的焊接接頭，返修后應(yīng)重做熱處理。Do the heat treatment over again to welding joint which needs the heat treatment after patching. 6.5質(zhì)量檢驗 Quality inspection6.5.1每個焊口焊接完成后，焊工本人應(yīng)立即進行100%外觀自檢，然后由QC2、QC3按照規(guī)定的比例進行復(fù)檢， The welder should do the appearance test in person after welding each weld bead, then to check it again by QC2, QC3 according to the stated proportion.6.5.2原則上每天所完成的焊口在當(dāng)天晚上進行RT檢驗。 In principal, do the RT test at night on the same day. 6.6記錄Record 6.6.1焊工在對口點焊完成后，在焊縫記錄驗收單上相應(yīng)欄內(nèi)簽上名字；在每個焊口完成后在相應(yīng)欄內(nèi)簽上名字和日期。After spot welding the weld bead, the welder will sign it up in the relevant column of the Acceptance record list of welding bead; Sign the name and date in the relevant column after finishing each welding bead. 6.6.2在焊縫驗收記錄單上的全部焊口完成后，班長應(yīng)將其交給焊接工程師。The monitor should hand it in to the weld engineer after finishing all welding beads in the Acceptance record list of weld bead.6.6.3焊接工程師把焊縫驗收記錄單與相應(yīng)的NDE報告、熱處理記錄單、焊縫記錄圖放在一起保存，做為竣工資料。 The weld engineer should put the Acceptance record list of welding bead together with the NDE report, heat treatment record and welding map, regarding them as the completion information.6.6.4每個焊工取得資質(zhì)后最初焊接的焊口要在記錄單上注明。The first batch weld should be remarked on the Acceptance record list of welding bead after qualification.6.7不銹鋼類管道焊接 Weld the stainless steel pipe 6.7.1不銹鋼相對于其它常見鋼種具有熱膨脹系數(shù)大、導(dǎo)熱系數(shù)小的特點，在焊接過程中，如果熱輸入量過大，容易變形、嚴(yán)重氧化，甚至出現(xiàn)裂紋。焊接不銹鋼管道時，要求移動速度快、電流小、填絲量少。 Comparing with other common steel type, the stainless steel has the characteristic of greater thermal-expansion coefficient and smaller thermal-conductivity coefficient, in course of welding, if the heat input is too big, it will be easy to distort, and be oxidated seriously, even it will be cracked. When welding the stainless steel pipe, the moving speed should be rapid, the current should be low, and the filler content should be small。6.7.2為防止根層氧化或過燒，焊接時內(nèi)壁充氬氣保護。 The inner wall should be filled the argon gas for protection when welding in order to prevent the root layer from oxidating or being burnt. 6.7.3焊接2層以上，才可以去掉充氬氣。 Dont stop filling argon gas until the welding reaches two layers above. 6.7.4使用不銹鋼專用的鋼絲刷、砂輪片、地線夾。 Use the special steel wire brush, grinding wheel slice, earth wire nip which are for stainless steel. 7附件: AttachmentJSA-8560-8101-0148 Small Bore Pipe and Instrument Pipe Welding Job Safety Analysis小口徑管道和儀表管焊接工作安全風(fēng)險分析4f28631bd0926bc9d73185689c55da94.pdf Page 19 of 19附件Attachment JSA-8560-8101-0148 Small Bore Pipe and Instrument Pipe Welding Job Safety Analysis小口徑管道和儀表管焊接工作安全風(fēng)險分析 JOB SAFETY ANALYSIS工作安全分析 Date（日期 ）：26 JAN 2004 Job Title工作名稱: Small Bore Pipe and Instrument Pipe Welding Job Safety Analysis小口徑管道和儀表管焊接工作安全風(fēng)險分析LOCATION地點：Erection Site安裝現(xiàn)場JSA No JSA編號: JSA-8560-8101-0148DEPARTMENT部門WET1焊接隊SUPERVISOR主管人 : TITLE OF PERSON WHO DOES JOB工作執(zhí)行人職務(wù):PREPARED BY 編制： REVIEWED BY 審查: APPROVED BY 批準(zhǔn)：Environmental Conditions環(huán)境條件Inside內(nèi)部 Outside 外部 Cold 冷 Heat 熱 Wet 濕 Dust 灰塵 Vapors/Mist 水汽 Noise 噪音 Vibration 震動 Other 其它 Heavy Rain 大雨P(guān)rimary Job Functions & Position 基本工作行動Lifting 舉重 Grasping 抓取 Pushing 推 Sitting 座 Reaching 延伸 Bending 彎曲 Kneeling 跪Standing 直立 Pulling 拖 Squatting 蹲 Other 其它SEQUENCE OF BASIC JOB STEPS工作步驟POTENTIAL HAZARD潛在危險風(fēng)險評估RAM （H 、M、L）RECOMMENDED ACTIONOR PROCEDURE 控制行動措施ACTION BY 執(zhí)行人DATE DUE完成日期REMARK備注Wire arrangement電線的布置Contact with electricity or electric discharge觸電MElectricians should put on personal protective equipment;電工人員應(yīng)穿戴個人勞動用品；The insulation of wires is good and the naked part with power should have protection measures.用電線路應(yīng)絕緣良好，裸露帶電部分應(yīng)有防護措施Slip, trip or fall on same level滑倒 絆倒或墜落LCheck the ladder used for laying wires and have slip prevention measures;電線布置使用的梯子，應(yīng)進行檢查，并有防滑措施Exposure to fire火災(zāi)MStrictly forbid wires hanging on the brake directly and plugging into socket directly;嚴(yán)禁將電線直接勾掛在閘刀上或直接插入插座內(nèi)使用Injury by hand tool傳遞工具傷害MDuring wires laying, fall-prevention-rope should be used in passing and using small tools overhead.布線過程中，高空傳遞、使用小型工具應(yīng)系好防墜繩Welding work焊接施工Slip, trip or fall on same level滑倒 絆倒或墜落Injure by fall of ground地面跌倒傷害MLook at the road during walking ,gazing around is forbidden; dont be nervous during working.提高工作警惕性，走路時要看腳下，不能東張西望，工作時不要緊張Contact with hot surface or substance 燒傷燙傷MHeat insulation measure shall be taken for welding preheat; welding operator shall wear specified working clothes; warning board such as “Danger: High Temperature!” shall be hung in high temperature area.焊接預(yù)熱時，應(yīng)采取隔熱措施；焊工穿專用工作服，在高溫區(qū)域懸掛“高溫危險”等警示牌。Sunstroke中暑MKeep air ventilation and prepare for sunstroke-prevention articles.保持現(xiàn)場空氣暢通，配備必要的防止中暑的物品Contact with electricity or electric discharge觸電MInspect whether there is any naked part on the wires; equip each welding machine with circuit breaker. Working platform and welding machine must have reliable earthing.施工前仔細檢查電焊線有無裸漏漏電現(xiàn)象，所有電焊機加裝漏電保護器，工作平臺必須接地可靠，焊機接地正確Explosion 爆炸Exposure to fire火災(zāi)MWelding lead shall be kept away from heat source, and must not contact with wire rope, rotating machine; moreover, it must not be set on oxygen cylinder or acetylene cylinder. There mustnt be flammable or explosive objects around welding area. Firefighting equipment shall be equipped on site and shall be monitored by specified personnel if necessary.禁止將電焊導(dǎo)線靠近熱源、接觸鋼絲繩、轉(zhuǎn)動機械或?qū)⑵浯钤O(shè)在氧氣瓶、乙炔瓶上,禁止在易燃易爆區(qū)域施焊，現(xiàn)場配備消防器材，必要時派專人進行監(jiān)護。Methods should be used to prevent spark from splashing when sth. Flammable such as paint is nearby. Welders should close the welding machines and check work site to find if survival spark is in the vicinity when welding is over and before weldersleaving.當(dāng)附近有油漆等易燃物時，應(yīng)當(dāng)有防止火花飛濺的措施。當(dāng)焊工離開現(xiàn)場之前，應(yīng)關(guān)閉焊機并檢查是否有殘存的火星。Aloft work高空作業(yè)Fall of person from height 高空墜落Hhighrise operator shall wear individual protecting appliance and safety harness , anchor them securely;高空作業(yè)人員應(yīng)穿戴好個人保護用品，并扎安全帶，其應(yīng)懸掛在上方牢固可靠處；Walk slowly, no running at height;高空行走時要緩慢，不能跑；Do not stand outside the handrail while working or use the handrail to lift something;不得站在欄桿外作業(yè)或憑借欄桿起吊物件；Injury by hand tool傳遞工具傷害MFall-prevention-rope shall be fastened correctly during handing small tools;傳遞小型工具時應(yīng)系好防墜繩；Slip, trip or fall on same level滑倒 絆倒或墜落HLook at the road during walking ,gazing around is forbidden;走路時要看腳下，不能東張西望；Hollow, pit near working area sha