二氧化碳气体保护焊接方案中英文+28129.docx
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二氧化碳气体保护焊接方案中英文+28129
Content
1.Projectoverview工程概况 1
2.Fabricationreference编制依据 1
3.Constructionfeatures施工特点 1
4.Constructionpreparation施工准备 1
4.1.Preparationbeforewelding焊前准备 1
4.2.Constructionworkingconditionspreparation施工作业条件准备 2
5.Constructionprocess施工工艺 2
5.1.Wedlingprocess焊接工艺 2
5.2.Rootcleannessprocess清根工艺 3
6.Constructionattentions施工注意事项 4
7.Safetyhousekeeping安全文明施工 4
7.1.Safetyassurancemeasures安全保证措施 4
7.2.Housekeeping文明施工 4
1.Projectoverview工程概况
Completed,inordertoefficientlyshelflifefortheengineeringcharacteristicsoflargediametercarbonsteelpipelineweldingtasks,withcarbondioxidegasshieldedweldingthebassoonweldwhenneeded.
针对本工程的碳钢管线直径大的特点,为了高效保质完成焊接任务,焊接大管焊缝时需要用二氧化碳气体进行保护焊接。
2.Fabricationreference编制依据
1、Theconstructioncontractandtheownersoftheprojectconstructionplans
本工程施工合同及业主提供的本工程施工图;
2、Theprojectsaudited,approvedtheconstructionorganizationdesign";
本工程经审核、批准的《施工组织设计》;
3、《Thecarbondioxidegasshieldedweldingwire》GB8110—2008
《二氧化碳气体保护焊用焊丝》GB8110—2008
4、《Specificationforweldingofsteelstructurebuildings》JGJ81—2002
《建筑钢结构焊接技术规程》JGJ81—2002
5、《Gaswelding,manualarcweldingandgas-shieldedarcweldingweldgroovebasicformandsize》GB985.1-2008.
《气焊、手工电弧焊及气体保护焊焊缝坡口的基本形式与尺寸》GB985.1-2008.
6、《Codeforacceptanceofconstructionqualityofsteelstructures》GB50205—2001
《钢结构工程施工质量验收规范》GB50205—2001
3.Constructionfeatures施工特点
1、Weldappearance,weldmoldingnolongerpolished,uniformweldgeometry.焊缝成型美观,焊缝焊接成型后无需再打磨处理,焊缝几何尺寸均匀一致。
2、Lessweldspatter,flux-coredarcstabilizeradded,stablearcburningdropletwasdropwiseevenexcessivewhenweldingspatterfewsmallparticlesandsplashing,coolingfaster,easiertoclear.
焊接飞溅少,药芯焊丝在其中加入了稳弧剂,电弧燃烧稳定,熔滴呈滴状均匀过度,故焊接时飞溅很少,且飞溅颗粒细小,冷却速度快,清除较容易。
3、Weldshrinkagedeformationissmall,duetotheweldingheatinputfocus,smallheat-affectedzone,weldshrinkagedeformationissmall,smallweldingresidualstress.
焊缝收缩变形小,由于其焊接热量输入集中,热影响区小,因此焊接收缩变形小,焊接残余应力小。
4、Highweldingefficiency,highcurrentdensityfilamentsautomaticwelding,determineitshighermeltingfillspeed,therebygeneratingahighweldingspeed,andtheautomaticweldingprocessandeliminatestheneedforfrequentreplacementofthemanualweldingelectrodetime.
焊接效率高,细丝自动焊的高电流密度,决定了其较高的熔填速度,从而产生较高的焊接速度,且自动焊过程省去了手工焊中频繁更换焊条的时间。
4.Constructionpreparation施工准备
4.1.Preparationbeforewelding焊前准备
1.Weldinggroove焊接坡口:
(1)TheweldgrooveofaV-shapedgroove.
焊缝坡口为V型坡口。
(2)Theweldinggrooveshallbesmooth,nocracks,delamination,slagandotherdefectsdimensionsconformtothepatternprovisions.
焊接坡口应平整,不得有裂纹、分层、夹渣等缺陷,尺寸符合图样规定。
(3)Surfaceofthegrooveandoneachsideof50mmbeforeweldingwater,rust,oil,productresidueandotherharmfulimpuritiesintheweldingshouldbecleaned.
坡口表面及两侧各50mm焊前应将水、铁锈、油污、积渣和其它有害于焊接的杂质清除干净。
(4)Weldgroupgapshouldbe3±1mm.
焊缝组对间隙宜为3±1mm.
2、Weldingmaterial焊接材料:
CO2gasshieldedweldingtoφ1.2ER70S-6wire,toprotectthegasusingCO2.
CO2气体保护焊采用φ1.2的ER70S-6焊丝,保护气体采用CO2。
3、Weldingwiremanagement焊丝管理:
(1)StartingweldingwiremusthavefactorycertificateofchemicalcompositionandmechanicalpropertieswithinthewarrantybookmustcomplywiththerelevantprovisionsoftheState.
施焊中的焊丝,必须具有出厂合格证书,质保书内的化学成份及机械性能必须符合国家有关规定。
(2)Wireintotheboxpackaging,theofficialshallnotbeopenedbeforeweldingtopreventmoistureintheair.
焊丝成盒包装,正式施焊前不得拆封,以免在空气中受潮。
(3)Theweldingmaterialdesignatedpersonsresponsibleforthesafekeeping,disbursementandrecovery.
焊接材料设专人负责保管、发放和回收。
(4)Theweldingconsumableslibrarymustbekeptdry,relativehumiditylessthan60%ofthecoffersofnotlessthan10°Ctemperature.
焊材库必须保持干燥,相对湿度不大于60%,库房内的温度不低于10℃。
4、Weldercertificate焊工资格:
TheweldermustholdacertificateissuedbytheBureauofLaborBoilerandPressureVesselwelders,eligibleprojectsareasfollows:
焊工必须持有劳动局颁发的锅炉压力容器焊工考试合格证,合格项目如下:
(1)Automaticgasshieldedwelding:
RZ2-5、RZ2-6、RZ2-7、RZ2-8.
气体保护自动焊:
RZ2-5、RZ2-6、RZ2-7、RZ2-8.
(2)Semiautomaticgasshieldedwelding:
Rb2-5、Rb2-6、Rb2-7、Rb2-8.
气体保护半自动焊:
Rb2-5、Rb2-6、Rb2-7、Rb2-8.
(3)Weldercertificationinweldingsteelsshould16MnR.
焊工合格证中施焊钢种应为16MnR.
5、Weldingequipment焊接设备:
GasprotectweldingshalladoptDC-400power、LN-9GMAwirefeedingmachineandBug-oautocar.
气体保护焊选用DC-400电源、LN-9GMA送丝机及Bug-o自动小车。
4.2.Constructionworkingconditionpreparation施工作业条件准备
1、Theweldingenvironmentinanyofthefollowingconditionsmustadopteffectiveprotectivemeasures,otherwisestopwelding:
焊接环境出现下列任一情况时,必须采用有效防护措施,否则停止焊接:
(1)Windspeedmorethan8m/s;
风速大于8m/s;
(2)Relativehumiditymorethan90%;
相对湿度大于90%;
(3)Rainandsnow雨天及雪天;
(4)Environmenttemperatureunder-5℃.
环境温度在-5℃以下。
2、Theweldingenvironmentinanyofthefollowingconditionsmustadopteffectiveprotectivemeasures,otherwisestopwelding:
施焊应在坡口内引弧,禁止在非焊接部位引弧。
3、Groundcable,weldingclamp,weldingtorchmustbeagoodcontact.
地线、电缆线、焊钳、焊枪必须接触良好。
4、Theweldedconstructionsituationshouldbesomeoneresponsiblefortherecordtheambienttemperatureandweldedconstructionrecords.
焊接施工情况应有专人负责记录环境温度及焊接施工记录。
5.Constructionprocess施工工艺
5.1.Weldingprocess焊接工艺
1、Weldedconstructionmustbestrictlyinaccordancewiththeweldingprocessandweldingprocedures.
焊接施工必须严格按照焊接工艺和焊接程序进行。
2、Allbuttweldweldingweldwidthoneachsideovertheedgeofthegroove2mmappropriate.
施焊时全部对接焊缝的焊缝宽度以每边超过坡口边缘2mm为宜。
3、CO2gasshieldedweldinglargerpipeline,twoweldermustbesymmetrical,andkeeppace.
CO2气体保护焊焊接较大管线时,两台焊机必须对称进行,且保持同步。
4、Weldingprocessparameter:
asshowninthefollowingtable
焊接工艺参数:
如下表所示
Table1Typicalofdifferentdiameterwireshortcircuittransferweldingparameters
表1不同直径焊丝典型的短路过渡焊接工艺参数
Weldingwirediameter
焊丝直径mm
0.8
1.2
1.6
Weldingcurrent
焊接电流A
100-110
120-135
140-180
Arcandvoltage
电弧电压V
18
19
20
Table2Thelowerlimitvalueandthearcvoltagerangeinthecurrenttransitionofthefineparticlesofthedifferentdiameterwire
表2不同直径焊丝细颗粒过渡的电流下限值及电弧电压范围
Weldingwirediameter
焊丝直径(mm)
1.2
1.6
2.0
3.0
4.0
Weldingcurrent
焊接电流(A)
300
400
500
650
750
Arcandvoltage
电弧电压(V)
34-45
Table31.6weldingwireCO2semi-automaticsweldingcommonlyusedprocessparameters
表3 1.6焊丝CO2半自动焊常用工艺参数
Droplettransfermode
熔滴过渡形式
Weldingcurrent
焊接电流A
Arcandvoltage电弧电压V
Gas-flowrate
气体流量(L/min)
Applicationscope
适用范围
Shortcircuitingtransfer
短路过渡
160
22
15-20
Allpositionwelding
全位置焊
Fineparticletransition细颗粒过渡
400
39
20
Flatwelding
平焊
5、Multilayerwelding,eachweldarcstartingpointshouldturnstaggermorethan50mm,theterminalshouldcraterfill,ifany,thecraterdefectswithgrindingwheelclear.
多层焊时,每层焊道引弧点应依次错开50mm以上,终端应将弧坑填满,如有弧坑缺陷,应用砂轮清除。
6、Girthweldjointsmustbestaggeredandthelongitudinalweld,theweldjointtobepolished.
环焊缝焊接时,接头必须和纵焊缝错开,焊缝接头要打磨。
7、Eachweldingseammonolayershallasfaraspossibleoncefinishedwelding.
每条焊缝单层应尽可能一次焊完。
8、WeldingofweldingseamT-shapedcross-siteshalllongitudinalweldingseamweldingtothegirthgroovewithinthegrooveofthecircularseamweldingmeat,thenpolishedclean,inordertoremovethedefectsoftheweldterminal.
焊缝丁字交叉部位的焊接应将纵缝焊到环缝坡口内,然后将环缝坡口内的焊肉打磨干净,以去除焊缝终端缺陷。
5.2.Rootcleannessprocess清根工艺
1、Backseamforrootcleanness,shallbeusedtheanglegrindertocleanupmaynotusecarbonarcgougingandflamecutting.
焊缝背面如需清根,应采用角磨机进行清理,不得使用碳弧气刨和气割。
2、Therootcleannessexcessofdepositedmetalshallberemoved.
清根应将多余的熔敷金属清除掉。
3、Afterrootcleanness,theshapeofthegroove,thewidthshallbeconsistent,rootcleannessdepthshallbeappropriate,andbecompletelyridoftherootsofdefects,andifnecessary,rootcleanness,theinspectionofgroovesurfacepenetrantshallqualifiedbeforewelding.
清根后的坡口形状、宽窄应一致,清根深度应适当,并完全清除根部缺陷,如有必要清根后坡口表面经渗透探伤合格后方可施焊。
6.Constructionattentions施工注意事项
1、Weldingoperationsshallstrictlyenforcetheweldingprocedure,tostrengtheninter-layerCleaner.
焊接操作时应严格执行焊接工艺规程,加强层间除渣。
2、AweldingmachineshalluseaCO2gascylindertoensurethesupplyofCO2.
一台焊机宜使用一只CO2气瓶,以保证CO2供应。
3、StrictcontrolCO2watercontent.NewrefillableCO2cylindersshallbeinvertedcylinders24h,priortousetoopenthevalve,whichletgoofstagnantwater,shallbereplacedwithanewbottlewhenthebottlepressureislessthan2.0Mpa.
严格控制CO2含水量。
新充装的CO2气瓶宜将气瓶倒置24h,使用前打开阀门,放去其中的积水,当瓶内压力小于2.0Mpa时,应更换新瓶。
4、Whentheringseamandlongitudinalseamweldatwelding,weldingoperationshouldbeparticularlycareful.Excessweldthemeatendofthelongitudinalseamplanningtorespondtothesurfaceforgrindingcarefully,inordertoachieveasmooth,continuous,easygirthweld.