Mock-Up-Testing

扬子石化—巴斯夫项目管子管板焊接模拟实验第1页共6页MockUpTestProcedureofT-TSJointForBASF-YPCProjectPage1of61、概述General1.1本试验程序的目的是确保我厂能够按照要求完成管子－管板焊接。Itistheobjectiveofspecimenweldingpriortocommencementoffabricationtoenablethemanufacturertoverifythatwearecapableofperformingthetubeweld-ininconformitywiththerequirements.1.2本试验程序应按照E-S-MC和GB151-1999执行。TheprocedureshallbeaccordingtoE-S-MCandGB151-19992、管子－管板焊接试样Tubetotubesheetweldingsample2.1管板tube-sheet材料material厚度thickness(mm)孔径diameterofholesfrom/to(mm)孔桥宽度webwidth(mm)SA2403163023.2515.0024.252.2管子tube材料material尺寸dimensionsfrom/to(mm)管子数量numberoftubesSA249TP316Φ23×3102.3接头形式Weldpreparation管子管板接头形式按E-S-MC表5.1的1.10.1设计，如下图1。（X=2mm）Designofthetubetotube-sheetjointshallbeaccordingtotable5.1(code1.10.1)ofE-S-MC,asshowedinfigure1.Fig.1Designofthetubetotube-sheetjoint2.4管子布置Tubesheetlayoutwithtubespacing管板孔布置见下图2.Thearrangementofthetube-sheetholesisshowedinfigure2.Fig.2Thearrangementofthetube-sheetholes扬子石化—巴斯夫项目管子管板焊接模拟实验第2页共6页MockUpTestProcedureofT-TSJointForBASF-YPCProjectPage2of63、焊前准备Preparationbeforewelding3.1在开始焊接前，必须用丙酮以及干净的布块去除管子管板管孔以及周围焊接区域的油、污等杂质。Thetubes,thetube-sheetholesandtheirtheweldingareamustbecleanupwithacetoneandclothmakesureremovingalloils,rustandotherforeignsubstance.3.2焊接前应对所有管子管板做好相应标记。Allthetubeandthetube-sheetholeshallbemarkedbeforewelding.4、焊接Welding4.1预焊接工艺指导书（P-WPS）见附件1（包括点焊工艺参数）P-WPSseestheattachment1(includingthespotweldingprocedureparameter)4.2焊接记录WeldingRecord4.2.1管子固定型式typeoffasteningforthetubes每个焊接接头都应用氩弧焊进行点焊固定。点焊图见下图3。Everytubetotube-sheetjointshellbefastenedwithGTAWthroughtackwelding.Andthetackweldinglocationseesfigure3.4.2.2管子管板焊接tubetotube-sheetwelding4.2.2.1根部焊道起弧点位于6点钟位置。Thestartoftherootpassisonthepositionof6o’clock.4.2.2.2手工钨极气体保护焊采用立向上焊接FormanualGTAwelding,theVerticaluppositionshouldbeused.4.2.2.3收弧点必须越过起弧点（两倍于焊道宽度的距离）。上部焊道必须全部覆盖根部焊道。起弧点和连续焊道的收弧点须错开。Therearendofthebeadmustcoverthefrontendofthebead(length=twotimesthebeadwidth).therootpassmustbefullycoveredbythesubsequentpass.Thefrontendofthebeadandtherearendofthebeadofsuccessivepassesshallbeoffset.4.2.2.4管子管板焊接采用三道焊接，每一道均采用手工氩弧焊。第一道不填丝，第二、三道填丝。第一道、第三道焊接起弧位置均在6点钟方向，第二道起弧可在6点钟至12点钟之间位置。焊接方向均为向上。具体焊接图见见下图4，焊接工艺参数记录如下：Tubetotube-sheetweldingshallbe3layers,andeverylayerusesGTAW.Thefirstlayerisself-fluxing,andthesecondandthethirdonesshallusefillermetal.Arcingstartingpositionofthefirstandthethirdlayershallbeon6O’clock.Thesecondoneshallbetween6O’clockand12O’clock.Andweldingdirectionisfromdowntoup.Thedetailweldingseesfigure4below,theweldingprocedureparameterisasfollowing:点焊位置229630点焊位置1.3第二层起弧点第三层起弧点第一层起弧点.4扬子石化—巴斯夫项目管子管板焊接模拟实验第3页共6页MockUpTestProcedureofT-TSJointForBASF-YPCProjectPage3of6焊层WeldLayer焊接方法Process焊材FillerMetal极性Polar.焊接参数WeldingParameters焊剂/气体FluxorGas气流量FlowRate(l/min.)钨极直径TungstenDiameter(mm)许可范围Permittedrange牌号Grade规格SizeI(A)U(V)V(m/h)1GTAW//DC(+)1001212Ar9Φ3I：90-130A2GTAWER316Φ2.0DC(+)1001212Ar9Φ33GTAWER316Φ2.0DC(+)1001212Ar9Φ3最小预热温度PreheatTemp.MinMin.30℃,Max.65℃最大层间温度Inter-passTemp.Max.180℃焊后保温HoldTemp.Post-welding是Yes否No方法Method:NA.焊后消氢HydrogenTreatmentNA℃NA小时hours方法Method:NA.焊工姓名及钢印号WelderNameandStamp鲁军民Y02葛小青12.5、试件焊接的检测Testingofspecimenwelding5.1所有的管子－管板接头须按照DINEN970要求对管子－管板接头进行车间宏观目测检查，并记录检查结果，评判标准及结果列于表1。Alltube-to-tubesheetjointsshallconductanddocumentshopinspectionswithvisualinspectiontoDINEN970onalltube-to-tubesheetjoints.CriteriaforevaluationandtheresultaregiveninTable1.5.2对完成的试件焊接实施表面表面裂纹检测（PT）检测，评判标准及结果列于表1。Finishedspecimenweldingworkshallundergosurfacecracktesting（PT）testing.CriteriaforevaluationandtheresultaregiveninTable1.5.3所有的管子－管板接头须按照DINEN1435-B级标准接受射线检测。为方便射线检测，管板厚度须加工至6－8毫米厚。须按照图5所示方法进行射线检测。检测报告见附件2。Alltube-to-tubesheetjointsshallundergoradiographictestingtoDINEN1435,ClassB.Fortesting,thetubesheetshallbemachinedtoathicknessof6mmto8mmmaximum.ThesetupshallbechosenasshowninFig.5.Theexaminationresultseestheattachment2.5.4此外，试件沿A-A和B-B截面切开（参考图2），对每个截面实施宏观金相检查。每一个宏观金相截面上的管子－管板焊接接头须被评价，焊肉厚度须被测量，评价和测量结果见表2。Furthermore,thetestpieceshallbedividedintheplanesA-AandB-B(refertoFig.2)andametallographicmacrosectionshallbeproducedineachcase.Alltube-to-tubesheetweldingcapturedinthemacrosectionsshallbeevaluatedandtheweldthicknessdeterminedreferstoTable2.5.5射线检测和宏观金相检验的接受标准列于表2。TheevaluationcriteriaforradiographictestingandmacrosectionsaregiveninTable2.rRadiationsource辐射源fX-Rayfilm底片wWallthicknesscompensator(e.g.steelcylinderofidenticalthickness,orthinleadsheet)补偿块（钢棒或薄铅版）Figure5:Setupforradiographictesting射线检测模型W扬子石化—巴斯夫项目管子管板焊接模拟实验第4页共6页MockUpTestProcedureofT-TSJointForBASF-YPCProjectPage4of6表1：宏观目测检查和表面裂纹检测评价标准EvaluationcriteriaforvisualtestingandsurfacecracktestingNo.ImperfectionDescription缺陷描述ReferenceNo.toDINENISO6520-1NotesIllustrations图示Limitsforimperfections可接受的缺陷尺寸结果Result1Crack裂纹100AlltypesofcracksRissarten任何类型的裂纹Notacceptable不接受acceptable2Surfacepore表面气孔2017-Notacceptable不接受acceptableSolidinclusionsintheweldmetaluptothesurface表面夹杂6003Melted-throughtubewall焊穿600OnlyforCode1.10.2,1.10.10+1.10.12Table5.1仅对表5.1中1.10.2、10和12项Notacceptable不接受acceptable4WeldprojectionOverlap焊瘤60