30000立方油罐焊接施工技术措施english.docx
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30000立方油罐焊接施工技术措施english
1.ProjectOutline
1.1Projectbriefintroduction
TheSudanKhartoumRefineryisinvestedandconstructedbySudanEnergyDepartmentandCNPCanditscrawoilprocessingcapabilityis250×104t/a.Therefinerypossesses9unitsandtheirmatchingstorage,transportationandutilityengineeringandrelevantauxiliaryandlivingfacilities.TheprojectbelongstooneoftheexpansionprojectofKhartoumRefinery.Thecrudeoilcamefromoilpipelineoutsidetheplanttobestoredinthe4×30000m3tanksaftermeasuringandtransporteddirectlybyfeedingpumptotheDelayCokingplantasrawresource.
Thefour4×30000m3storageoiltankserectedbyourCompanyhavebigdiameter（theinternaldiameteris46m）andthethicknessofplatesisvary（5-24mm）,inthiscase,wecompiledthistechnicalmeasuretoensuretheweldingqualityandthesemeasuresshouldbestrictlyexecutedduringtheconstructionprocess.
1.2Characteristicsoftheproject
1.2.1Theworkloadofweldingofthetanksislargeandconcentratingtherebydeformationiseasytotakeplace.
1.2.2ThespeedofthewindinnorthSudanisveryhigh（maximumspeedis38.5m/sandtheaveragespeedis3.9m/s）andthiswillincreasethedifficultyofwelding.
1.2.3Theconstructiondurationisveryshotandthequalityrequirementisstrict.
1.3Compilingbasis
1.3.1Designdrawings
1.3.2GBJ128-90《ConstructionAndAcceptanceSpecificationForVerticalDrumWeldingSteelOilTanks》
1.3.3JB4708-2000《WPSForSteelPressureVessels》
2.WeldingProcedure
WeldingProcedureisshowedindrawing1.
3.Weldingmethods
3.1Preparationpriortowelding
3.1.1Prepareforweldingprocedureassess.ThepracticalweldingprocedureassesssuchasP01、P02、P03、P04、P13、P14、P136etctheCompanypossessedwillmeettheprojectdemand.
3.1.2Prepareforqualificationsofwelders.Thewelderswhotakepartintheconstructionactivitiesshouldpasstheexaminationwhichisexecutedaccordingto《ExaminationRegulationsForWeldersWorkingOnBoilersAndPressureVessels》.
3.1.3Confirmingofweldingmethods.Tothematerialssuchas16MnRandQ235-AF,handarcweldingwillbeused.
3.1.4TheweldingmachinewillbeZX5-400SiliconRectifierwelderandZX7-400Reverser.
3.1.5Theelectrodewillbeusedisshowedinthefollowingform
Typeofbasematerials
Typeofweldingconsumable
ArcWelding
Remarks
16MnR
E5015（J507）
16MnR+Q235-AF
E5015（J507）
Q235-AF
E4303（J422）
3.1.6Storage,dryingandissueofelectrodes
3.1.6.1Theweldingconsumableistobekeptbyspecialpersonnel.Thetemperatureoftheelectrodestorehousewillbekeptabove5℃andthehumidityshouldbelessthan60%andgoodventilation.Thestorehousekeepershouldrecordthetemperatureandhumidityineverymorning,noonandafternoonandwritedownthe《InspectionRecordsForSurroundingConditionsOfTheElectrodesStorehouse》
3.1.6.2Allthematerialsenteringstorehouseshouldpossessqualitycertificateconfirmedbymaterialsengineerandputupbytheirsorts.Theelectrodesshouldbe300mmawayfromthegroundorwalltoensuregoodventilation.
3.1.6.3Checktheelectrodesonebyoneforpropertypesandsizesafteropenthepackage.Checkcarefully,alltheelectrodeswhichcoatingisfallenorbadlyrustedorcoreeccentricityareforbiddentobeused.
3.1.6.4Electrodeswillbedriedinaccordancewiththespecificationrequirement.Ifthereisnospecification,dryelectrodesinaccordancewiththefollowingform:
DryingparametersForm3.1.6.4
Species
Temperature（℃）
Duration（h）
Validperiodofusing（h）
Timesofdrying
Keepingtemperature（℃）
E4303
100-150
0.5-1
8
≤3
20-50
E5015
350-400
1-2
4
≤2
100-150
3.1.6.5Thequantityofdyingelectrodeswillbeadequatewithpracticaluseofthedaytopreventre-drying.Theelectrodesafterdyingshouldbestoredintheboxwithconstanttemperatureof100～150℃andtakethemonlyitistobeused.Theelectrodesshouldbebroughttojobsiteinthethermosandreturntothedyingroomandre-dryingagainwhentheelectrodesexceedthepermittedtime.
3.1.6.6Thekeepershouldwritedownthedryingrecordsindetailssuchasspecies,sites,quantity,batchNo.andtimesofdrying.
3.1.6.7TheconstructingteamshandtheirtakingIDintheelectrodeskeeper16hourspriortotaketheelectrodesinaccordancewiththepracticalquantitytheworkneedsandcannottakemorethan3kgforonetime.Theelectrodeonlycanbeusedin4hours.
3.2Beveling
3.2.1Thegrooveswillbemadebygascuttingandremovetheburrsandslagoftheirsurfaceandtwosidesbygrindingwheels.
3.2.2Therequirementsoftypesanddimensionsofgroovesareshowedinthefollowingform
TherequirementsoftypesanddimensionsofgroovesForm3.2.2
Capacityoftank
Weldingposition
Materials
Thicknessofplates（mm）
Typesofbeveling
Angleofgrooves
（°）
Roofface（mm）
Gaps
（mm）
Remarks
30000m3
Annularplates
16MnR
10
V
0
6
Grindingafterwelding
Longitudinaljointsofthefirstcircleshells
16MnR
24
X
60±5
2±1
2±1
Longitudinaljointsofthesecondcircleshells
16MnR
22
X
60±5
2±1
2±1
Longitudinaljointsofthethirdcircleshells
16MnR
20
X
60±5
2±1
2±1
Longitudinaljointsofthefourthcircleshells
16MnR
18
X
60±5
2±1
2±1
Longitudinaljointsofthefifthcircleshells
16MnR
15
X
60±5
2±1
2±1
Longitudinaljointsofthesixthcircleshells
16MnR
12
X
60±5
2±1
2±1
Longitudinaljointsoftheseventhcircleshells
16MnR
10
V
60±5
2±1
2±1
Longitudinaljointsoftheeighthcircleshells
16MnR
8
V
60±5
2±1
2±1
Longitudinaljointsoftheninthcircleshells
Q235AF
8
V
60±5
2±1
2±1
Longitudinaljointsofthetenthcircleshells
Q235AF
8
V
60±5
2±1
2±1
Circularweldsfromthefirsttothefifthcircles
16MnR
24／22/20/18/15/12
K
50
2
2
Circularweldsfromthesixthtotheninthcircles
16MnR/Q235AF
12／10／8
V
50
2
2
3.3Weldingprocedureandrequirement
3.3.1Priortowelding,cleanthebevelingfacesinthescopeof20mmandremovetherust,sand,dirtygreaseandwateretcinthearea.
3.3.2Theweldingoffixingweldandclippersarethesameasthenormalwelding.ThelengthofeachfixingweldisQ235-A≥50mm,16MnR≥80mm.Checktheweldcarefullyandremoveitpriortonormalweldingifthereisanydefect.
3.3.3Arcstartingandendingshouldbecarriedoutinsidethegrooveorweldingbeadandthenstartthearcbackward.Full-fillthepitpriortoendingarcandjointoflayersshouldstagger50mm.
3.3.4Totheplatestheirthicknessare≥6mm,thelapfilletshouldbeweldedtwiceattheleast.
3.3.5Tothebuttjointsofthetwo-sidewelding,roofcleaningshouldbecarriedoutpriortoweld.Whenadoptcarbonarctocarrytotheroofcleaning,theplanechannelshouldbetrimmedandthecarbonlayershouldbegrindedoffaftertheroofcleaning.
3.3.6Taketheefficientmeasurestoprotecttheweldinginthefollowingconditions.
aRain;
bHandweldandthewindspeedexceeds8m/s;
3.3.7Weldingofthebottoms
3.3.7.1Theweldingofthebottomplatesaccordingtothefollowingorder:
alongtheexternaledge200mm-350mmofannularplates→theotherweldsofthebottomplatesexcludingtheshrinkingweld→thecircularfilletbetweenthebottomsandshells→thebuttweldsleftoftheannularplates→theshrinkingweldsbetweentheannularplatesandbottomplates.
3.3.7.2Tothefirstbuttweldofthebowannularplate,thewelderswillbearrangedequallyandweldsymmetrically.
3.3.7.3Theweldingofthebottomplates
a、Accordingtotheprincipleoftheshortweldpriortothelongone,therootbeanshouldbecarriedoutbythemethodofweldingbackwardinsectionsorjumpwelding.
b、Weldthejointsafterintervalofthem.Tothelongwelds,theweldingshouldbecarriedoutfromthecentertothesidesandweldinsections.Removeallofthespotsoftheweldsnexttoitbeforeweldingandaddaclamptothewelds.Ifthedeformationoccurs,theweldingshouldbecarriedoutfromthearchtothesides.
3.3.3.3.4Theweldingofthecircularfilletjointbetweenthebottomsandtheshells
a、Spotweldtheannularfilletjointafterthecompletionofthelongitudinaljointweldinganditsharmlessexaminationasacceptable.Completethelongitudinaljointofthelowerendoftheshellbeforetheannularfilletjointstarttoweld.
b、Accordingtotheorderofoutsidepriortotheinside,arrangeseveralpairsofweldersequallyandweldinsectionsalongthesamedirection.Tothefirstlayerofthejoint,theweldingshouldbecarriedoutbackwardinsectionsorjumpweld.
3.3.7.5Weldingoftheshrinkingjointsofthebottom
a、Weldtheshrinkingjointsafterthecompletionofthefilletjointsbetweenthebottomandtheshell.
b、Removethetemporaryclampsandsundriesbeforespotweldandthenweldfromcentertosides.Thefirstseamshouldbejumpweldinthesamedirectionandthesecondseamshouldbecontinuousweldinthereversedirection.
3.3.8Weldingoftheshell
a、Afterthecompletionoftheoutsideoftheseam,cleantherootbyacarbon-arcplaneorgrindingwheelandthencarriedouttheinsidewelding.
b、Theweldingofthelongitudinaljointshouldbeinaccordancewiththeprincipleofoutsidepriortoinside.Setareinforcingplatebeforeweldinganditcannotberemoveduntilthecompletionoftheinsiderootcleaning.Theinsideweldingshouldbecarriedoutaftertheannularjointtobespotweld.
c、Tothecircularjoint,arrangetheweldersequallyandshouldbetwo“synchronization”inweldinglayersandweldingdirections,anditcannotbeweldseverallayersinthesameposition.
d、TotheT-shapedjoint,itmustbestrictlycontrolfrompartdeforma
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