碳钢管道焊接工艺

Proposal on Carbon Steel Pipe Welding

碳钢管道焊接工艺

1 Technical description 技术特征

1.1 Pipe material and size: 20# seamless steel pipe

材质、规格： 20#无缝钢管 1.2 Work medium： water

工作介质： 水

1.3 Designed pressure：4㎏/㎝2

设计压力： 4㎏/㎝2 1.4 Work pressure：4㎏/㎝2

工作压力：4㎏/㎝2

1.5 Test pressure：6㎏/㎝2

试验压力：6㎏/㎝2

2 Related documents to this proposal：

本工艺编制依据：

2.1 Technical specification of F06B

F06B技术文件

2.2 GB50236-98《Field Equipment and Industrial Pipe Welding Work Execution and Acceptance Code》

国标GB50236-98《现场设备、工业管道焊接工程施工及验收规》 2.3

GB50235-97《Industrial Metal Pipe Works Construction and

Acceptance Code》

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国标GB50235-97《工业金属管道工程施工及验收规》

2.4 CEFOC Welding Technical Appraisal Report : HG3，HG2002-1 本公司焊接工艺评定报告：HG3，HG2002-1 3 Welder焊工

3.1 Welder should be certified in passing the Welding Examination of Boiler Pressure Container and Pressure Pipe。 焊工应具有“锅炉压力容器压力管道焊工考试规则”规定的焊工考试合格证。

3.2 Welder should pass the qualification test by GB50236-98 Code to obtain work permit of the Contractor before starting the welding work of this project.

焊工进入现场后，应按GB50236-98规定，先进行焊接实际操作考试合格。经总包方认可发证后，方能承担本项目的焊接工作。 3.3 This technical proposal should be complied to during the welding work of this project

焊工承担本项目的焊接工作中，应切实执行本焊接工艺。 4 Welding work inspection 焊接检验

4.1 Welding inspector should be fully acquainted with the F06B technical specification and both the international standards and this proposal

焊接检验人员应F06B技术文件及相关国标和本工艺。

4.2 Inspect the pipe materials and welding materials in

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accordance with the relevant rules and sign the acceptance form。

对管材焊材按规定进行检验、填表验收。

4.3 Supervise the work of welder and help him to correct any defects in work. To ensure the welding work quality, the inspector is powered to stop the work of any serious offender or those who refuse to correct defects in work。

对焊工是否执行本工艺进行全面监督检查,对违反者进行教育帮助得以改正。对严重违反者或教育不改者有权令其停止焊接工作。以确保焊接质量。

4.4 Perform the inspection of welded work in line with Article 7 of this proposal

做好本工艺第7条“焊接后检查和管理工作”。

4.5 Coordinate with the representatives of Contractor and Supervisor to participate the inspection

邀请和欢迎总包或监理方检验人员进行检查。 5 Preparation work before welding： 焊前准备：

5 .1 The pipe materials and welding materials are checked to be qualified products

管材焊材必须具有符合规定的合格证明，并与实物核对无误。 5.2 Pipe material and size: 20# seamless steel pipe

管材型号为20#无缝钢管，规格为 DN50至DN250

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5.3 Welding materials 焊材

5.3.1 Argon welding wire model and size: CO2 wire, ∮2.5mm ∮2.0mm

氩弧焊焊丝型号规格：CO2保护焊焊丝，∮2.5mm ∮2.0mm 5.3.2 Welding rod model and size: J422 ∮3.2mm ∮2.5mm

电焊条规格型号规格：J422 ∮3.2mm ∮2.5mm 5.3.3 Ce tungsten pole model and size: WCe-20∮2.0mm

铈钨极型号规格：WCe-20∮2.0mm 5.3.4 Argon purity: 99.99％。

氩气纯度为99.99％。

5.4 Welding parts preparation 焊件准备

5.4.1 The positioning of welding point should comply to GB50235-97 and GB50236-98。

焊接口的分布位置必须符合国标GB50235-97和GB50236-98规的规定。

5.4.2 The positioning of welding point should comply to GB50235-97 and GB50236-98。 管道为V型坡口，对接接头、组对应符合图1要求： - . -考试资料- - --

Note: The clearance of 3.5～4mm is for welding. When making

spot welding, the clearance should be bigger 注：间隙3.5～4mm为焊接时的数据，组对点固焊时，应适当大于此数据，以补收缩。

图1.焊口组对数据

5.4.3 The groove of welding parts should be processed by grinding machine and cleaned within 10mm of both inside and outside surface from any oil, dust and burr

焊件坡口应用机械或磨光机加工。焊口组对前应将坡口及其外表面10mm围的油、垢、毛刺等清理干净。

5.4.4 Penetration welding must be applied in spot weld and 4 spots with 5mm of each should be welded on pipe with diameter ≤150mm and 6 spots with 5mm of each should be welded on pipe with diameter ＞150mm.

点固焊，根部必须焊透。不得有焊接缺陷。管径≤150mm为4点，每点长度为5mm。管径＞150mm为6点，每点长度为5mm。 5.4.5 The connection of pipe should keep straight in axel and if necessary, make measurement as the flowing chart from 200mm to the center of welding point. The differential allowance is 1mm to pipe with diameter ＜100mm and 2mm to pipe with diameter ≥100mm. The differential allowance to the full length of pipe should be within 10mm and if exceeding that rate, cold correction

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should be applied instead of hot correction.。 管子组对焊口时应保持其轴线平直。在不得以时，距焊口中心200mm处测量平直度如图2所示，管径＜100mm时允许偏差为1mm；管径≥100mm时允许偏差为2mm，但全长允许偏差均不大于10mm。万一超差时，只能用冷矫正，严禁加热矫正。 图 2 管道对口平直度 5.4.6 The pipes inside wall should keep smooth when making pipes joint. The differential allowance should be within 10% of the thickness of pipe wall. The non penetrated welding as A of the following chart is not allowed.

管道组对应壁齐平，万不得以时，错边量不宜超过壁厚10％，且大于2mm。焊接时不准有图3a之未焊透。 A non penetration B penetration - . -考试资料- - --

a 未焊透 b 焊透

图 3 焊件错边焊口

5.4.7 No pressure joint of pipes

管道连接时，不得用强力组对焊口。 6 Welding： 焊接

6.1 The welding equipment must be functioning well.

焊接设备性能完好.例如:交流弧焊机应有适当的空载电压;焊接电流调节灵活。氩弧焊机必须具备非接触引弧、提前送气、迟后关气和焊接电流衰减下破功能。

6.2 Welding method and parameter：

焊接方法及焊接工艺参数： 6.2.1

When

pipe

diameter

≤

50,

use

gas

welding(oxygen-acetylene welding)with the parameter as the following table:

管径≤50mm采用气焊（氧气乙炔焊接），焊接工艺如下： When pipe wall thickness>3mm,groove must to be made, and the groove angle is 650 ，there must not be layer of oxide on the surface of groove.

 当管材壁厚>3mm时，需倒焊接坡口，坡口角度为650，坡口表面不得有氧化层；

When pipe wall thickness≤3mm, the space between the two parts should be 2.5-3mm.

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 当管材壁厚≤3mm时焊接管材对口出留出２.５至３mm的焊接缝隙。

The material of weld wire is H08Mn2Si,the diameter of weld wire should be 2.5mm.

 焊丝材料牌号为Ｈ０８Ｍn２Ｓi，焊丝直径为２.５mm。 There should be 2 passes or 3 passes according to the thickness of the pipe wall.

 根据管材的壁厚分别为２遍或３遍成活。

The layer of oxide must be removed before the next pass.  每进行下一遍焊接实施前，需用钢丝刷将上一遍焊接表面的氧化层刷去。

6.2.2 When 50mm＜pipe diameter≤133mm, use argon weld for prime welding and arc weld for cover welding. Refer to the following table:

50mm＜管径≤133mm采用氩弧焊打底，焊条电弧焊盖面。焊接工艺参数如表2：

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Welding layer焊接层次 Welding material焊材 Size Model型号 规格 (mm) Electricity 电特性 Weld current焊接 nozzle size 喷嘴 Argon consume (L/Minute)焊枪 用氩量 (升/分) Power电源 Polarity极性 口径 电流 (A) (mm) DC 直1 H08Mn2Si ∮2.5 流 DC 直流 2 J422 ∮2.5 AC 交Positive正接 Positive正接 80-100 ∮8 8 55-70 —— 流 —— —— 6.2.3管径＞133mm采用氩弧焊接打底，焊条电流焊盖面。焊接工艺参数如表3

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Welding layer焊接Welding materia焊材 Electricity 电特性 Polarity极性 Positive正接 negative反接 Weld current焊接 电流 (A) nozzle size 喷嘴 口径 (mm) Argon consume (L/Minute)焊枪 用氩量 (升/分) 8 Size PowerModel型号 规格 层次 电源 (mm) DC 1 H08Mn2Si ∮2.5 直流 DC直2 J422 ∮3.2 流 AC 交流 90-105 ∮8 90-115 —— —— —— 6.3 When pipe diameter＞133mm, use argon weld for prime welding and arc weld for cover welding. Refer to the following table:

阿斯线要接紧在近焊接点，不论氩弧焊还是焊条电弧焊，都必须在坡口引弧。防止焊件电弧击伤。

6.4 fter the argon prime welding, the welded seam must be cleaned by steel brush and be checked of its quality. Then cover welding by arc weld.

第一层氩弧焊打底焊缝焊完后，必须用钢丝刷将焊缝表面刷干净。检查合格后，再用焊条电弧焊焊接第二层（盖面层）

6.5 Upon completion of welding, make cleaning of welded seam surface, marking the welder No. on pipe and sign the welding

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record for quality inspector to perform checking

焊口焊接完毕后，应清除焊渣及飞溅物。将焊缝表面刷干净进行自检合格后。做好焊工钢印号标记。填写焊接记录。交检验员检验确认。

6.6 Quality requirement to welded seam：

对焊缝的质量要求：

6.6.1 The seam surface should not have: crack, air hole, dregs or non penetration welding The inner surface of seam should be fully penetration welded

焊缝表面不得有：裂纹、气孔、夹渣、未焊透。咬边深度≤0.5

δ，且≤0.5 mm连续长度≤100mm，且两侧咬边总长≤10％焊缝全

长。

焊缝表面为全焊透。

6.6.2 The height of outer surface of seam is 0-3mm（0-4mm to overhead welding）and uniform. The outer surface width of seam is（δ-1）×1.2＋clearance width＋0.5-2.5×2。

焊缝外表面高度0-3mm（仰焊可放宽到0-4mm）应力求均匀。焊缝外表宽度（δ-1）×1.2＋间隙宽度＋0.5-2.5×2。 7 Welding inspection 焊接后检查和管理工作。

7.1 Quality inspector would conduct the following checking of the welded work：

焊工焊完焊口后。检验员应及时进行检查：

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7.1.1 Check the outer surface quality of welded seam in accordance with the requirement in 6.6 above

按本工艺6.6条要求检查焊缝外表质量。 7.1.2 Check the mark made by the welder

检查焊工标记钢印号。

7.1.3 Check the welding record, put the serial No. of welded joint and inspection result on the record and sign it

检查焊接记录，编上焊口流水号并签字认可。

7.1.4 Label at a remarkable place 30mm from the welded joint the serial No. of welded joint. This No. should be in compliance with that on the welded joint, welding record and drawing.

在距焊口30mm显眼处，标记上焊口流水号。并在图纸上同样位置标记焊口流水号。使每个焊口的流水号在焊接记录焊口实物及图纸上完全一致。利于追踪。

7.1.5 Coordinate with the representatives from Contractor and Supervisor for the welded seam quality inspection and acceptance.

邀请总包和监理方检验人员，检查认可焊缝质量。

7.1.6 Ask welder to make repair welding of the unqualified work found in inspection. To any serious defects that are beyond repair, the quality inspector is required to submit report on the cause and make suggestions on the correction measures so as to ensure the

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repair quality.

对检查不合格的焊口应督促焊工清除焊接缺陷。按原工艺要求进行补焊。对有严重缺陷不合格或经补焊仍不合格的应向有关人员报告。分析原因，制定修补措施后进行修补。确保焊缝修补合格。

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