熔盐储罐焊接施工方案修改.docx
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熔盐储罐焊接施工方案修改
1.工程概况2
1.ProjectSummary2
2编制依据3
2CompilationBasis3
3施工准备4
3ConstructionPreparation4
4焊前准备9
4WeldPreparation9
5施工工序13
5Constructionprocess13
6熔盐罐底板组对焊接14
6Assemblyweldingfortankbottomplate14
7熔盐储罐壁板的焊接21
7Weldingoftankshell21
8拱顶的焊接26
8Weldingofvault26
9焊缝的修补27
9Repairweld27
10焊接检验28
10Weldinginspection28
11质量保证措施33
11Qualityassurancemeasures33
12HSE保证措施41
12HSEAssuranceMeasures41
13工机具及人力资源63
13Machines&Tools,andHumanResources63
1.工程概况
1.ProjectSummary
本工程为2台20000m³拱顶冷、热熔盐储罐新建工程,工程所在地位于青海省德令哈市西出口太阳能发电基地内,工程内容包括储罐罐主体制作、安装、防腐、及相关检测。
Thisworkisfortwosetsof20000m³vaulthotmeltsaltstoragetanknewproject,theprojectislocatedinsolarenergybaseofwestexitofDelinghaCity,Qinghaiprovince,andtheprojectcontentsincludefabrication,installation,anti-corrosion,andrelevantinspectionofthemainbodyofthestoragetank.
储罐结构形式为拱顶固定顶,共由五带壁板组成,壁板材质为Sa-516Gr.70N,壁板厚度从下到上依次为42mm、34mm、25mm、16mm、10mm。
Thestoragetankstructureisfixedarchroofwhichisconstitutedwithfiveshellplates.ThematerialofshellplateisSa-516Gr.70N,thethicknessofshellplatefromuptodowninsequenceis42mm,34mm,25mm,16mmand10mmrespectively.
2编制依据
2CompilationBasis
2.1中广核德令哈50MW光热项目热传储热系统施工图
2.1ConstructionPlanofCGN-Delingha50MWSolarThermalPowerGenerationProjectHeatTransmissionandHeatAccumulationSystem
2.2合同、招标文件;
2.2Contract,biddingdocument;
2.3Q/JH121.11.004-92《安全技术操作规程》
2.3Q/JH121.11.004-92SafetyTechnicalOperationProcess
2.4GB50128-2014《立式圆筒形钢制焊接储罐施工及验收规范》
2.4GB50128-2014VerticalCylindricalSteelStorageTankWeldingConstructionandAcceptanceSpecification
2.5SH/T3530-2011《石油化工立式圆筒形钢制储罐施工工艺标准》
2.5SH/T3530-2011TechnicalStandardforConstructionVerticalCylindricalSteelStorageTanksforPetrochemicalIndustry
2.6GB50341-2003《立式圆筒形钢制焊接油罐设计规范》
2.6GB50341-2003CodeforDesignofVerticalCylindricalWeldedSteelOilTanks
2.7GB/T709-2006《热轧钢板和钢带的尺寸、外形、重量及其允许偏差》
2.7GB/T709-2006Dimension,Shape,WeightandTolerancesforHot-rolledSteelPlatesandSheets
2.8NB/T47014-2011《承压设备焊接工艺评定》
2.8NB/T47014-2011Weldingprocedurequalificationforpressureequipment
2.9NB/T47015-2011《压力容器焊接规程》
2.9NB/T47015-2011WeldingspecificationforPressureVessels
2.10GB/T985-1998《气焊、手工电弧焊及气体保护焊焊缝坡口基本形式与尺寸》
2.10GB/T985-1998Basicformsandsizesofweldgroovesforgasweldingmanualarcweldingandgas-Shieldedarcweldind
2.11GB/T986-1998《埋弧焊焊缝坡口的基本形式与尺寸》
2.11GB/T986-1998Basicformsandsizesofweldgroovesforsubmergedarcwelding
2.12JB/T4730-2005《承压设备无损检测》
2.12JB/T4730-2005NondestructiveTestingofPressureEquipments
3施工准备
3ConstructionPreparation
3.1焊工考试
3.1WelderExamination
3.1.1所有参加熔盐罐制作安装工程的焊工必须经过严格的审核和正规的岗前培训,持证上岗,对从事埋弧焊、气体保护焊和手工焊的焊工,应按GB50236-2011《现场设备、工艺管道焊接工程施工规范》焊工考核的有关规定进行考试。
3.1.1Allwelderswhowilltakeparticipationinthemanufactureandinstallationofthehotmeltingsalttankmustreceivestrictreviewingandregulatedpre-jobtrainingandobtaincertificatesbeforebeingappointedthepost.Thewelderswhotakeparticipationinthesubmergedwelding,gasshieldedweldingandmanualweldingshouldtakeexaminationasperrelevantregulationsforassessmentofweldersinFieldEquipment,GB50236-2011ProcessPipelineWeldingConstructionSpecification.
3.1.2对于首次施焊SA-516Gr.70N钢板的焊工,必须考试合格,才允许进行相应的焊接工作。
3.1.2ThewelderwhofirstweldsSA-516Gr.70Nsteelplatemusttaketheexaminationandthenbeappointedtoconducttheweldingworkafterexaminationqualification.
3.1.3根据现场情况,在正式开工前,完成焊工考试情况。
按焊工实际焊接类型分别进行考试。
考试合格后,方可进行焊接操作。
3.1.3Accordingtofieldsituation,thewelderexaminationshouldbecompletedbeforeformalstartingoftheconstruction.Theexaminationshouldbepreparedinlinewiththeactualweldingtyperespectivelywhichwillbeperformedbythewelder.Theexaminationqualifiedwelderwillbeawardedwithwelderqualificationcertificateandwillbeappointedthepostinlinewithcertificate.Noweldingjobforwelderwhofailedtobeawardedwithwelderqualificationcertificate.
3.1.4焊接工作进行前,焊接技术员要对所有焊工进行焊接技术交底,让焊工熟知焊接工艺方案,熟练掌握所焊部位的材质种类和所采用的工艺方法,如坡口形式、焊材选用、焊接电压电流调节、焊接速度控制等,让焊工了解焊接应力与焊接缺陷的危害与预防措施。
3.1.4Beforewelding,theweldingtechnicianshoulddelivertechnicaldetailsdisclosuretoallwelderstomakeeachwelderbefamiliarwiththeweldingtechnologyplan,toperfectlymasterthematerialsclassificationandapplicabletechnologyfortheweldingparts,suchasgrooveshape,weldingmaterialsselection,regulationofweldingvoltageandcurrent,andweldingspeedcontrol,inordertomaketheweldersunderstandthehazardsandpreventionmeasuresofweldingstressandweldingdefects.
3.2焊接设备
3.2Weldingdevice
直流电焊机、CO2气体保护焊焊机、埋弧自动平(角)焊机等。
焊接设备的电流表、电压表、等仪表、仪器以及规范参数调节装置应定期进行检验。
上述表、计装置失灵时,不得进行焊接。
手工电弧焊、氩弧焊焊机必须集中放置在离焊接区较近的焊机棚内;自动焊根据现场需要进行放置,放置焊接设备的场地必须保持通风良好、干燥、维修方便。
Weldingequipment:
DCwelder,CO2gasshieldedweldingmachine,automaticsubmergedarcflatfilletwelder,etc.Ammeter,voltmeter,andotherspecificationparameteradjustingdevicesshallbeinspectedperiodically.Whentheaforesaidmeterandmeteringdevicefailtofunction,weldingshallnotbeperformed.SMAWandGTAWweldermustbecollectivelyplacedintheweldmachineshed,nearbytheweldzone,theautomaticweldmachinetobeplacedaccordingtothesiteneeds.Theweldmachinesshedmustbekeptwellventilated,dryandeasymaintaining.
3.3焊接材料
Weldingmaterials:
焊接材料应具有产品质量证明文件,符合现行国家标准的规定,且实物与证明书上的批号相符,外观检查时,焊条的药皮不得有受潮、脱落或明显的裂纹;焊丝在使用前应清除其表面的油污、锈蚀等;埋弧自动焊丝、焊剂必须放在干燥处妥善保管;低氢型焊材需按照批次、规格不同,分别取样送有资质试验室进行熔敷金属的扩散氢含量检测,扩散氢含量以不超过4mg/100g为合格。
Weldingmaterialsshallhavecertificateofqualificationandshallmeetthestipulationsofthecurrentnationalstandard,andlotnumberonthematerialpackageshallconformtothecertificate;Electrodeshallbefreeofmoisture,fallingorapparentcrackduringvisualinspection;Weldingwireshallbefreeofoilstain,ruststainandsoonpriortousage;Submergedautomaticarcweldingwireandfluxshallkeepinadryplaceproperly;
焊接材料入库前检查其装箱单,出厂质量证明书等文件,检查焊材包装等情况及核对标识后方可入库。
焊材入库后应根据焊材种类、型号、批号分类存放,存放焊材的库房应干燥、退风,库内温度应大于50℃,相对湿度不大于60%;焊材应放在焊材架上,离开地面和墙壁的距离不小于300mm,应安放湿度计并做好记录。
Beforereceivingweldingmaterials,itisrequiredtocheckitspackinglist,leave-factoryqualitycertificateandotherdocuments,weldingmaterialpackages,andidentifications.Whentheweldingmaterialisreceived,itshallbestoredasperitscategory,type,andbatchnumberrespectively,andtheweldingmaterialstorageroomshallbedry,ventilated,roomtemperatureshallbelargerthan50C,relativehumidityshallnotbelargerthan60%;weldingmaterialsshallbeputontheweldingmaterialsupport,itsdistancetothegroundandwallshallnotbelessthan300mm,andhumiditymetershallbeinstalledanditsreadingshallbewellrecorded.
焊接材料设专人保管,掌握焊材库的温度、湿度状况及焊材库存量、出库量,并必须设去湿剂。
Weldingmaterialsshallbekeptbedesignatedperson,temperature,humidity,inventory,distributionamountoftheweldingmaterialstorageroomshallbemastered,andthede-wettingagentshallbeused.
焊条和焊剂烘干设专职烘干员,并按厂家说明书要求进行烘烤,如无规定按下表要求烘烤。
在使及过程中保持干燥,焊条烘干数量要有计划,根据工程的进展情况,适量的进行烘干。
烘干时,要经常打开通风孔并打开风扇,驱除潮气,焊条、焊剂放进或取出时,干燥箱内温度不得低于200℃;烘干合格后的焊条放入恒温箱内。
焊工取焊条时,必须携带焊条筒,随用随领。
同一焊条筒内不准放入两种不同规格的焊条,以免用错。
当湿度为80%-90%时,使用时间不超过2小时。
湿度小于80%时,使用时间不超过4小时,超过这些时间,应按规定重新烘干,焊条再烘干的次数,一般不超过2次。
烘干焊条要使用远红外线式焊条烘干箱和保温箱,箱内不得烘干除焊条、焊剂以外的物品,干湿温度计要定期校验。
焊条烘干员应及时做好《焊条烘干记录》、《焊材发放记录》、《焊材库温湿度记录》,记录时写全焊材的使用部位、材料名称、牌号、批号等内容。
对于回收的焊条,应分类存放,重新烘干,不得与未使用的焊条混放。
Thedesignatedpersonshallbearrangedtoneresponsiblefordryingelectrodeandflux,anditshallbedriedaspertheinstructionofthemanufacturer,ifnostipulationismade,belowtableshallbefollowed.Duringusageprocess,itisrequiredtokeepdry,theelectrodeshallbedriedasperthescheduledquantity,anddryingoperationshallbeproperlymadeaspertheprojectprogress.Duringdryingprocess,ventshallbeopenedandfanshallbeusedfrequentlytoremovemoisture;whenelectrodeandfluxareused,temperatureinthedryershallnotbelessthan200℃;Afteritisdriedthoroughly,theelectrodeshallbeputintothermostat.Whentheweldingoperatortakesouttheelectrode,quivermustbecarriedforplacingtheelectrode.Thesamequivershallnotbeplacedwithelectrodeofdifferentspecificationsoastoavoidmisapplication.Whenthehumidityis80%-90%,usagetimeshallnotbemorethantwohours.Whenthehumidityislessthan80%,theusagetimeshallnotbemorethanfourhours,otherwise,itshallbedriedagain,butthedryingtimesfortheelectrodeshallnotbemoretwiceingeneral.Itisrequiredtousefar-infraredelectrodedryingovenandincubatortodrytheelectrode,besideelectrodeandweldingflux,nootherarticleisallowedtobedriedintheoven,anddryandwetbulbthermometershallbecalibratedperiodically.TheelectrodedryingresponsiblepersonshallmakeElectrodeBakingRecord,ElectrodeIssueRecord,andTemperatureandHumidityRecordofWeldingMaterialStorage.Applicationposition,vendorname,brandno.,andfurnacenumberoftheweldingmaterialshallberecordedclearly.Therecoveredelectrodeshallbestoredasperitsclassificationanddriedagain,anditisforbiddentoputitwiththeunusedelectrodetogether.
药皮受潮、脱落或有明显裂纹的焊条不得使用,焊丝在使用前应清除表面的油污、锈蚀等。
Ifthecoatingismoisture,dropped,orsignificantcrackexists,theelectrodeisnotallowedtouse;priortoapplicationofweldingwire,grease,rust,andotherdefectsshallberemovedfromitssurface.
4焊前准备
4WeldPreparation
4.1坡口形式
4.1GrooveType
项目
间隙
形式
角度
备注
边缘板对接
内端12~14mm
外端8~10mm
加垫板
50°
中幅板对接及收缩缝
6mm
加垫板
40°
大角缝
2mm
/
内侧45°外侧50°
罐壁环焊缝
间隙2±1mm
/
内侧45°外侧45°
罐壁纵焊缝
3mm
/
5