丙烯晴焊接方案(中英文)

26万吨/年丙烯睛装置焊接方案工程焊接Projectweld一概况General26万吨／年丙烯腈装置，工艺管道11800延长米，折合243867吋／口，需现场制作的（除焚烧炉外）储罐11台，最大7000米最小300米。涉及焊接的材质现已知有10种。（除焚烧炉）分别是：Q235A、Q235B、15CrMo、CS、20、316L、316、304L、304、304SS。不锈钢焊接占的比例较大，焊接工作量主要集中在工程的中后期，加强管理，提高管道预制比例，严格工艺纪律，实现SECCO提出的一次焊接合格率96％，正点、高质量地建好丙烯腈装置。ShanghaiSECCO900,000T∕AethaneProjectand260,000T∕AANinstallation,processpiping11,800extendmeter,reduced243,867DB,requeststoragetank11stationswhicharemanufacturedinsite(exceptforburninginstallation),thebiggeststoragetankis7000cubicmeter,thesmallestis300cubicmeter.Materialswhichhavebeenknowrefertoweldthebiggesthave10types.(exceptforburninginstallation)Theyare:Q235A,Q235B,15CrMo,CS20,316L,316,304L,304,304SS.SSweld’sproportionisratherbig,weldamountofworkmainlyfocusonthemiddle-backdateofproject,reinforcemanagement,enhancetheproportionofpipingprefabrication,strictlystrengthenprocessdiscipline,realizeonceweldpercentofpass96%whichisbySECCO,completeANinstallationwellandhighquanlity.二编制依据Orgernizationbase.5国家及行业标准规范。Standardandspecificationofcountryandcraft.6《锅炉压力容器压力管道焊工考试与管理规则》国质检总局.“Weldexaminationandmanagementrulesofboiler,pressureresselsandpressurepipling“qualityinspectiondepartmentofChina.7《钢制压力容器焊接工艺评定》JB4708－2000WeldprocessassessmentofsteelpressureresselsJB4708-2000.8《石油化工工程焊接工艺评定》SHJ509－88（可能有新版）weldprocessassessmentofpetrochemicalprojectSHJ509-88(mayhavenewversion)9《钢制压力容器焊接规程》JB／T4709－2000WeldruleofsteelpressurevesselsJB/T4709-2000.101)《石油化工立式圆筒形钢制储罐施工工艺标准》SH／T3530－2001ProcessstandardofconstructionofpetrochemicalverticalcylindershapesteelstoragetanksSH/T3530-20012)《现场设备、工业管道焊接工程施工及验收规范》GB50236-98WeldprojectconstructionandacceptancecriterionofequipmentsinsiteandindustrypipingGB50236-98.3)《工艺金属管道工程施工及验收规范》GB50235-97ProcessmetalpipingprojectconstructionandacceptancecirterionGB50235-974)《钢结构工程施工及验收规范》GB50205-2002SteelstructionprojectconstructionandacceptancecriterionGB50205-20025)《石油化工剧毒、易燃介质管道工程及验收规范》SH3501-2001PetrochemicalstrongpoisonandinflammablemediumpipingprojectandacceptancecriterionSH3501-20016)《石油化工异种钢焊接规程》SH3526-92WeldruleofpetrochemicaldifferentsteelSH3526-927)《石油化工工程铬钼耐热钢管待焊接技术规程》Waitingweldtechnicalruleofpetrochemicalprojectchromemolybdenhead-resistantsteelpipeSH520-918)《石化化工工程高温管道焊接规程》SH3523-92WeldruleofpetrochemicalprojecthightemperaturepipingSH3523-929)《焊接用钢丝》GB1300-77SteelwireusedinweldGB1300-7710)《碳钢焊条》GB5117-85CSweldingrodGB5117-8511)《不锈钢焊条》GB983-85SSweldingrodGB983-8512)《低合金钢焊条》GB5118-85LowalloysteelweldingrodGB5118-8513)《焊条质量管理规程》JB3323-83QualitymanagementruleofweldingrodJB3323-8314)《焊缝符号表示法》GB324-88WeldingseamsignexpressionmethodGB324-88三工程中钢材及其焊接Steelmaterialandweldinproject.1低碳钢的焊接LawCS.weld丙烯腈装置中CS、20、Q235A、Q235B属低碳钢系列。应含碳量较少（≤0.25％），其它合金元素添加很少，因而焊接性良好，焊前一般不需预热。塑性较好，焊接接头产生裂纹的倾向小，适应各种位置施焊。工程中低碳钢材料主要用于钢结构、给排水、一般介质的管道及容器。材料厚度δ4～22，最大管径D1820mm。20＃管子，δ19、δ22两种壁厚是否需要预热和热处理按设计要求。Suchas:CS,20,Q235AQ235BtheybelongtolowCSseriesinANinstallation.Amongofthem,amountofcarbonislow(≤0.25%)andotheralloyfactorsareverylittletoo,sotheirweldingperformanceisbetterandpre-heatisnotnecessarybeforeweld.Plasticityisbetterisbetter,cracktendencyfromweldingjointislittle,theyadoptweldineveryposition.Inconstruction,lowCSmaterialismainlyusedinsteelstructure,feed-drainwater,normalmediumpipingandvessel.Materialthicknessisfromδ4to22,biggestpipingdiameterisD1820mm.δ19andδ22fromclass20pipe,istheirwall-thicknessperformtopreheatandheat-treatmentisperformedaccordingtothedesignrequirement.四种材料的具体焊接规范见表1。Detailedweldcriterionoffourmaterialsincludeinfollowingtableone.215CrMo钢的焊接Weldof15CrMosteel.15CrMo钢属珠光体耐热钢,是一铬钼为主要原料的低合金钢（珠光体＋铁素体）。它的高温强度和高温抗氧化性较好，装置中主要用于供热系统。焊接铬钼耐热钢时，焊材选用要保证焊缝金属的化学成分，最大限度地接近被焊钢材的化学成分。15CrMosteelbelongtoperliteheat-resistantsteelandislowalloysteelanditsmainmaterialischromeandmolybder(perliteferrite).Itsstrengthandantioxidationpropertiesinhightemperaturearebetter,itisusedinfeedheatsystemininstallation.Whenweldchromemolybderheat-resistantsteel.Weldmaterialmustassurechemicalelementsofweldingseammetalandmaximunclosetothechemicalelementsofbeingweldedsteelmaterial.1）、坡口加工及检查Workingandinspectionofgroove.管子切割及坡口加工宜采用机械方法，当采用氧－乙炔火焰切割时，应清除熔渣、氧化皮，并将表面凹凸不平处打磨平整。坡口加工后应进行外观检查，坡口表面不得有裂纹、分层等缺陷。若设计要求对坡口表面进行无损探伤时，应执行JB4730标准，探伤范围为坡口及其两侧各20mm处。Pipcuttingandgrooveworkingshalladoptmechanicalmethod.Whenadoptoxygen-ethyneflamecutting,cleanoutslag,oxideskinandmaketherugositysurfacescourlevel.Performtoinspectappearanceafterworkinggroove,surfaceofgrooveshallnothavefaultofcrackandlayerect.IfNDTforisrequiredbydesign,shouldperformstandardJB4730,therangeofcrackdetectionisintheplacezoomofgrooveandit’sbothsides.2）、预热Preheat焊接接头易产生冷裂纹倾向和再热裂纹倾向，为了避免产生上述现象，焊接时一般都要求焊前预热。15CrMo焊前预热温度若设计无要求，δ≥10mm时，t150℃。Weldjointiseasytoworkcrackandre-crack,inordertoavoidthephenamenon,normallyrequesttopreheatbeforeweld.Ifthepreheattemperatureto15CrMohavenotrequirementindesign,whenδ≥10mm时，t150℃。3）、焊后缓冷Slowcoolingafterweld焊后缓冷是焊接这类钢必须严格遵守的原则，即使在炎热的夏天也必须做到。一般是焊后立即用石棉布覆盖焊缝及近缝区。Slowcoolingistherulescompliedwithbyweldsteel,itisalsodoneinhotsummer.Themethodisthatimmediatelycoverweldingseamandcloseseamare