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1、Title: Piping Welding Procedure题目：管道焊接标准操作程序STANDARD OPERATION PROCEDURE标准操作规程Code编号Version 版本Page页码Issue Date 放行日期Effective Date生效日期Review Date复审日期 Review and Approval审核和批准Name名字Title 职位Signature 签名Date 日期Written by 编写Reviewed by审核Approved by 批准Issued by放行Revision History修订历史Version版本Revision Histo
2、ry修订历史Written by/Date编写/日期Approved by/Date批准/日期1.0首次发布1.Purpose目的Standard pipe welding operation.规范管道焊接操作。2.Scope范围Applicable to pipe welding operation of undertake project.适用于公司承接项目的管道焊接操作。3.Terms and Definitions术语和定义 Adopt terminologies and definitions set fouth in GB/T19000-2008 idt ISO90002005,
3、Quality management systemFundamentals and vocabulary.本程序采用GB/T19000-2008 idt ISO90002005质量管理体系 基础和术语中的术语和定义。4.Responsibilities职责4.1.Endoscopy examination is carried out by welder.焊接者负责对管道焊接进行内窥镜检查。4.2.Report of endosopy examine is reviewed by site manager.现场经理负责对内窥镜检查报告进行审核和确认。5.Procedure/Requiremen
4、ts程序/要求5.1.Regulations 编制依据1） 中国国家标准GB 20801-2006: 压力管道规范- 工业管道2） 电力建设施工及验收技术规范（管道篇）DL5031-943） 工业金属管道施工及验收规范GB50235-974） 电力建设施工及验收技术规范（焊接篇）DL5007-925.2.General requirements总体要求 5.2.1.Manual Tungsten Inert Gas (TIG) welders and orbital welders using these procedure shall be qualified by making coupo
5、n test welds using actual job material. These coupons shall be subject to the same Independent examination as the automatic welds.采用这些程序的手动TIG焊接工和自动轨道焊工，将用实际工作材料作焊接试样测试以确认合格。这些焊接试样和自动焊接试样进行同样的独立检验。5.2.2.Automatic welding machine operators shall be qualified by making acceptable test welds on sample
6、materials. The welds shall be made on the prevalent job size tube material. 自动焊接机的操作人员将用样品材料做焊接测试以确认其资格。焊接测试应该选用项目常用的管材尺寸材料。5.2.3.Tack welding of the components must avoid deleterious effect on the complete weld.组件的定位点焊必须避免对完全焊接的不良影响。5.2.4.Tack should be as light as possible to reduce over heat that
7、 might cause structural changes to the granular composition of the material.定位点焊应该尽可能的轻，以降低过热而导致材料的内部结构变化。5.2.5.Tacks should not penetrate the inner surfaces.定位点焊不应焊透内表面。5.2.6.After the tack welding completion its necessary to check the alignment and gap.定位点焊完成后，需要检查线定位焊接的对准性和缝隙。5.3.Materials材料 5.3.
8、1.The material to be welded shall comply with the URS.用于焊接的材料须符合URS要求的技术规格。5.3.2.All tubing and fittings shall have complete weld penetration.所有管道和配件须完全焊透。5.3.3.Welding electrode to be used shall be a pointed 2% thoriated tungsten electrode with a flat tip.采用的焊接电极为2%涂钍平头钨焊电极。5.3.4.The electrode shal
9、l be replaced if contaminated.焊接电极如有污染须更换。5.3.5.Welding grade argon gas shall be use inside the pipe for back-up purge and shall be 99.99%minimum purity.焊接管道内部保护氩气的最低纯度为99.99%。5.3.6.Argon gas (99.99%) back-up has to be provided to prevent oxidative attack of the inner weld surface. Before starting t
10、he welding all oxygen is purged from the welding area.焊接过程中必须要通入99.99%氩气进行保护，以防止焊接的内表面被氧化。在开始焊接前，吹走焊接区域的所有氧气。5.4.Weld焊接 5.4.1.Preparation准备5.4.1.1.No weld is carried out when surfaces to be welded are wet. No outside welding is carried cut during inclement weather or during periods of high wind or n
11、egative atmospheric agent unless the work is properly protected. 当焊接表面潮湿时，不得进行任何焊接。除非有适当的保护措施，在严酷气候或风速高或不良大气条件下不得进行室外焊接。5.4.1.2.It is essential that the two surfaces of the joint are clean, circular and squared.焊接接头两端面的清洁，圆整和平直是重要的。5.4.1.3.The machining method of base metal preparation shall leave t
12、he weld end with smooth surfaces, free from notches or other harmful irregularities.金属加工方法应确保焊接端表面光滑，无划痕或其它有害的不规则形状。5.4.1.4.It is recommended to carry out the cut-off and final preparation using a G+F equipment or equivalent.建议采用G+F或同类设备来处理切割和最终处理。5.4.1.5.Cut-off must be squared and not cause any di
13、stortion or damage to the tubing. The pipe cut-off by an abrasive wheel must be cleaned to remove the abrasive dust.切割必须平直和不会造成管件变形或损坏。砂轮切割的管件端面必须清洁以除去磨屑。5.4.1.6.Carbon steel cutting tools are not admitted in any circumstance,碳钢切割工具在任何情况下都不得使用。5.4.1.7.Tools used for weld joint and preparation, fabri
14、cation and installation, shall be stainless of approved alloy steel, cleaned free of oil, grease and other contamination residuals before they are used.用于焊接端面的处理、装配和安装工具，在使用前须检查是否是没有生锈的认可合金钢，清洁无油脂，和无其它污染残留物。5.4.1.8.Non sulphur based cutting oil may be used, provided all traces of such oil are comple
15、tely removed from both the interior and exterior surfaces on the tubing prior to welding.不得使用硫基切割油，除非在焊接前管件的内外表面都被彻底清除所有残留油渍。5.4.1.9.The welding equipment shall be set up together with WELDING INSPECTOR.需与焊接检查员一起设定焊接设备。The inspector will check that all settings comply with the master program.此检查员将检查
16、所有设置是否符合主程序。5.4.1.10.At the start of each day, each operator shall make acceptable test welds on plain tubing, These pieces shall be identified and made available to the welding inspector. Test shall be made for each automatic welding machine.每天的开始时，每个操作人员要作焊接测试。这些焊样将编号，并呈交给焊接检查员。每台自动焊接机都需做测试。5.4.1.
17、11.One red smple is needed if the orbital welding machine stops for more than eight hours. One welding test is needed if the argon is used out and has to replace new bottles.当自动焊机停机超过8个小时，需做焊样，并用红色笔标示。当一瓶氩气用完,需要换新瓶时,应作焊接测试。5.4.2.Preheating temperature预热温度5.4.2.1.The minimum base material temperature
18、 shall not be less than 10 0 C prior to welding. In general, no preheating shall be required.在焊接材料的温度不得低于10C。一般来说，不需要预热。5.4.3.Electrical characteristics供电5.4.3.1.Current shall be as specified on the applicable welding schedule.电流应与注明在相应的焊接表相符。5.4.4.Welding procedure焊接程序5.4.4.1.The welding technique,
19、 such as weld sequence, welding program settings, electrode positioning etc., shall be as shown in the applicable welding schedule焊接工艺，如焊接次序，焊接程序设置，焊极位置等，都将与相应的焊接表相符。5.4.5.Weld repair焊接修补5.4.5.1.A weld repair is required when, through inspection, it is determined that an unacceptable defect exists a
20、nd that the defect is correctable. The first repair may be a re-weld over one existing.经检查，如发现不符合标准的缺陷并且此缺陷是可修复的，有必要进行修复焊接。最可能的修复是在已有的焊接上进行再焊接。5.4.5.2.The allowable defects which may be repaired include poor fit up, misalignment, excessive or inadequate weld penetration, porosity and pin holes.可做修补的
21、缺陷包括不佳的准备，不良线性，过量或不适当的焊接穿透，多孔性和沙眼。5.4.5.3.All welds with cracks shall be rejected and removed together with the heat affected zone.所有有裂纹的焊接将被视为不合格，并须与受热区一起去除。5.4.6.Automatic welding program自动焊接程序5.4.6.1.Any master program defined a set of parameters for different size of tubing to be welded.所有主程序都规定
22、了不同尺寸管件焊接的一组参数。5.4.6.2.Welding programs of the automated tube welding system shall be in accordance with the procedures to be defined by the welding operator together with the inspector.自动管道焊接系统的焊接程序都须符合焊接操作员与检查员一起制定的程序。5.4.6.3.Production and test welds shall be made only using approved welding prog
23、rams.正式和测试焊接需采用已认可的焊接程序。5.4.6.4.Welding samples must be numbered in sequence (ex.: T1, T2, etc.). Welding samples, with complete traceability, are subject to independent laboratory examination.焊接样品必须按顺序编号(如T1，T2等)。焊接样品，具备完全的可追朔性，将备独立机构检验。5.4.6.5.All daily samples will be available in site to the own
24、er, during all the construction period在整个施工阶段，所有每天的现场样品将留予业主。.5.4.6.6.Calibration of the automated tube welding system shall be in accordance with the procedures to be defined by the welding operator together with the inspector.。自动管道焊接系统的校正都须符合焊接操作员与检查员一起制定的程序5.4.7.Documentation文档5.4.7.1.a written l
25、og on all welds carried out on the system will be provided (see attachment ). The weld log forms, that must be fully filled, will minimally contain :将提供此系统所有焊接记录报告(见附件)。此焊接记录报告表格，必须完全填写，最少包含：a. system name系统名称 b. weld number焊接号 c. welder name焊接工姓名 d. machine identification设备e. welding date焊接日期 f. we
26、lding program number焊接程序编号 g. welding operator ( and in addition inspector, if any ) signature焊接操作工(如有，还加上检查员)签名5.4.7.2.Isometrics sketches (showing installed elevations for proper sloping, dimensions and lengths, all weld numbers) will be available during site activity and will be updated ( “ as-bu
27、ilt” issue ) at the end of job.透视简图 (标示相应的坡度，尺寸和长度，所有焊点编号)将在整个施工期间使用并且更新，在工程完成生成竣工图。5.4.8.Non destructive examination非破坏性检查5.4.8.1.Every weld should be checked by visual and/or boroscopic way (both internal and external)，if visual and boroscope are impossible, NDT(RT) is needed.每一焊缝应通过目测或内窥镜进行检查(内外表
28、面)，当内窥镜和目测不可能检查到时,需要进行非破坏性检查。5.4.8.2.Non destructive examination, when required by the applicable by the applicable code or contract specification, shall be performed in accordance with the code rules of contract specification. The time delay due to these controls must be considered.当相应的条例或合同规格要求时，非
29、破坏性检查将在符合条例或合同规格下进行。须考虑到因此而造成的时间延误。5.4.9.Weld daily samples每日焊接样品5.4.9.1.Weld daily samples shall be made using the machine welding programs. These samples must be numbered in sequence. All of those will be available to the owner in site during all the construction period.每日焊接样品应采用设备焊接程序。这些样品必须按顺序编号
30、。所有这些焊接样品将在整个施工期间提供给业主。5.4.9.2.The daily samples results must be collected in the Automatic Welding Machine Test Report that must be fully filled,每日样品结果必须收集在完全填写的自动焊接设备测试报告中。5.5.Inspection检查5.5.1.Weld preparation焊接准备5.5.1.1.Tube section verification :管道截面确认 Tube ends are removed any possible contami
31、nation from the cut off.要去掉管道端口切割产生的任何可能之污物。5.5.1.2.Cleaning verification清洁确认 Components are cleaned with approved solvent.用认可的溶剂清洁配件。The cleaned and prepared ends should not come into contact with the skin prior to welding.在焊接前，已清洁和准备好的端口不得接触皮肤。No visible foreign material is acceptable at the weld
32、ends of the components. This includes lint from cleaning cloths.在部件的端口不得有可目见的异物，此包括清洁布的纤维。Tungsten electrode must be clean and uncontaminated.钨焊极必须清洁和无污染。5.5.1.3.Joint fit-up接口准备 The tungsten electrode shall be centered on the joint.钨焊极应置于焊点中央。5.5.1.4.Weld machine settings焊机设置 Parameters shall be se
33、t in accordance with appropriate welding schedule as shown in the welding procedure.参数的设置应按焊接程序中相应的焊接表进行。5.5.2.Weld inspection焊接检验Every sample weld and all production welds shall be visually inspected on the interior, If the weld has correctable defects, a second weld pass may be made to try to corr
34、ect them before the spool is removed from the welding machine . If the rewelding does not remove the defect, the weld shall be rejected and not mounted.每个焊接样品和所有装配焊都要目检管道内侧。如焊接有可修复的缺陷，在焊接部件拆离焊机前进行第二次焊接以修复缺陷(见表一)。如果重新焊接未修复缺陷，则此焊接视为不合格并不得装配。TABLE I 表一ABDefects for which rewelding may be attempted须进行重新
35、焊接的缺陷Defects to be rejected : Cut out required together with its heat affected zone ( brown color ): 不合格的缺陷：须与受热区(棕色)一起切除：1. incomplete penetration未焊透 2. porosity多孔 3. pin hole 沙眼 4. cold lap 冷隔 5. excessive penetration 过度穿透( 0.4 mm )6. misalignment未对准( 0.4 mm )6. misalignment未对准( 0.55 mm) All autom
36、atic welds will be controlled as follows:所有自动焊接按如下控制：For each daily sample a weld carried out with the same welding program will be chosen. The check will be done with endoscopy examination will be carried out. 对每日样品，用选定的焊接程序完成一个焊接，进行内窥镜检验。For all executed automatic welds, a welding machine print ou
37、t with welding parameters will be annexed to the report. 对于所有完成的自动焊接，含有焊接参数的焊机打印报告将附在报告中。At least 10% of executed automatic welds, endoscopy examination will be carried out.至少10%的自动焊接，进行内窥镜检验。All the manual weldings will be endoscopy examined.所有手工焊接要进行内窥镜检验。6.Index of Attachments附录索引Attachment附录Code编号Title名称1QMS-SOP-SP-03-F01Welding Report of Sample Welds焊样的焊接报告2QMS-SOP-SP-03-F02Welding Report焊接报告7.References引用文件Not applicable.不适用。8.Revision History修改历史8.1.This is the first version.这是此文件的首次正式发布。