熔盐储罐焊接施工方案.docx

目录

1.工程概况 2
1.Project Summary 2
2 编制依据 2
2 Compilation Basis 2
3 施工准备 4
3 Construction Preparation 4
4 焊前准备 8
4 Weld Preparation 8
5 施工工序 11
5 Construction process 11
6 熔盐罐底板组对焊接 12
6 Assembly welding for tank bottom plate 12
7 熔盐储罐壁板的焊接 17
7 Welding of tank shell 17
8 拱顶的焊接 21
8 Welding of vault 21
9焊缝的修补 22
9 Repair weld 22
10焊接检验 23
10 Welding inspection 23
11 质量保证措施 27
11Quality assurance measures 27
12 HSE保证措施 35
12 HSE Assurance Measures 35
13工机具及人力资源 53
13 Machines & Tools, and Human Resources 53

1.工程概况
1.Project Summary
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。
This work is for two sets of 20000m³ vault hot melt salt storage tank new project, the project is located in solar energy base of west exit of Delingha City, Qinghai province, and the project contents include fabrication, installation, anti-corrosion, and relevant inspection of the main body of the storage tank.
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-516 Gr.70 N，壁板厚度从下到上依次为42mm、34mm、25mm、16mm、10mm。
The storage tank structure is fixed arch roof which is constituted with five shell plates. The material of shell plate is Sa-516 Gr.70 N， the thickness of shell plate from up to down in sequence is 42mm, 34mm, 25mm, 16mm and 10mm respectively.
2 编制依据
2 Compilation Basis
2.1 中广核德令哈50MW光热项目热传储热系统施工图
2.1 Construction Plan of CGN-Delingha 50MW Solar Thermal Power Generation Project Heat Transmission and Heat Accumulation System
2.2 合同、招标文件；
2.2 Contract, bidding document;
2.3 Q/JH121.11.004-92《安全技术操作规程》
2.3 Q/JH121.11.004-92 Safety Technical Operation Process
2.4 GB50128－2014《立式圆筒形钢制焊接储罐施工及验收规范》
2.4 GB50128-2014 Vertical Cylindrical Steel Storage Tank Welding Construction and Acceptance Specification
2.5 SH/T3530-2011《石油化工立式圆筒形钢制储罐施工工艺标准》
2.5 SH/T3530-2011 Technical Standard for Construction Vertical Cylindrical Steel Storage Tanks for Petrochemical Industry
2.6 GB50341-2003《立式圆筒形钢制焊接油罐设计规范》
2.6 GB50341-2003 Code for Design of Vertical Cylindrical Welded Steel Oil Tanks
2.7 GB/T709-2006《热轧钢板和钢带的尺寸、外形、重量及其允许偏差》
2.7 GB/T709-2006 Dimension, Shape, Weight and Tolerances for Hot-rolled Steel Plates and Sheets
2.8 NB/T47014-2011《承压设备焊接工艺评定》
2.8 NB/T47014-2011 Welding procedure qualification for pressure equipment
2.9 NB/T47015-2011 《压力容器焊接规程》
2.9 NB/T47015-2011 Welding specification for Pressure Vessels
2.10 GB/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》
2.10 GB/T985-1998 Basic forms and sizes of weld grooves for gas welding manual arc welding and gas-Shielded arc weldind
2.11 GB/T986-1998《埋弧焊焊缝坡口的基本形式与尺寸》
2.11 GB/T986-1998 Basic forms and sizes of weld grooves for submerged arc welding
2.12 JB/T4730-2005《承压设备无损检测》
2.12 JB/T4730-2005 Nondestructive Testing of Pressure Equipments
3 施工准备
3 Construction Preparation
3.1 焊工考试
3.1 Welder Examination
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。
3.1.1 All welders who will take participation in the manufacture and installation of the hot melting salt tank must receive strict reviewing and regulated pre-job training and obtain certificates before being appointed the post. The welders who take participation in the submerged welding, gas shielded welding and manual welding should take examination as per relevant regulations for assessment of welders in Field Equipment, GB50236-2011 Process Pipeline Welding Construction Specification.
3.1.2 对于首次施焊SA-516 Gr.70 N钢板的焊工，必须考试合格，才允许进行相应的焊接工作。
3.1.2 The welder who first welds SA-516 Gr.70 N steel plate must take the examination and then be appointed to conduct the welding work after examination qualification.
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。
3.1.3 According to field situation, the welder examination should be completed before formal starting of the construction. The examination should be prepared in line with the actual welding type respectively which will be performed by the welder. The examination qualified welder will be awarded with welder qualification certificate and will be appointed the post in line with certificate. No welding job for welder who failed to be awarded with welder qualification certificate.
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。
3.1.4 Before welding, the welding technician should deliver technical details disclosure to all welders to make each welder be familiar with the welding technology plan, to perfectly master the materials classification and applicable technology for the welding parts, such as groove shape, welding materials selection, regulation of welding voltage and current, and welding speed control, in order to make the welders understand the hazards and prevention measures of welding stress and welding defects.
3.2焊接设备
3.2 Welding device
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。
Welding equipment: DC welder, CO2gas shielded welding machine, automatic submerged arc flat fillet welder, etc. Ammeter, voltmeter, and other specification parameter adjusting devices shall be inspected periodically. When the aforesaid meter and metering device fail to function, welding shall not be performed. SMAW and GTAW welder must be collectively placed in the weld machine shed, near by the weld zone, the automatic weld machine to be placed according to the site needs. The weld machines shed must be kept well ventilated, dry and easy maintaining.
3.3焊接材料
Welding materials:
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。
Welding materials shall have certificate of qualification and shall meet the stipulations of the current national standard, and lot number on the material package shall conform to the certificate; Electrode shall be free of moisture, falling or apparent crack during visual inspection; Welding wire shall be free of oil stain, rust stain and so on prior to usage; Submerged automatic arc welding wire and flux shall keep in a dry place properly;
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。
Before receiving welding materials, it is required to check its packing list, leave-factory quality certificate and other documents, welding material packages, and identifications. When the welding material is received, it shall be stored as per its category, type, and batch number respectively, and the welding material storage room shall be dry, ventilated, room temperature shall be larger than 50C, relative humidity shall not be larger than 60%; welding materials shall be put on the welding material support, its distance to the ground and wall shall not be less than 300mm, and humidity meter shall be installed and its reading shall be well recorded.
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。
Welding materials shall be kept be designated person, temperature, humidity, inventory, distribution amount of the welding material storage room shall be mastered, and the de-wetting agent shall be used.
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。
The designated person shall be arranged to ne responsible for drying electrode and flux, and it shall be dried as per the instruction of the manufacturer, if no stipulation is made, below table shall be followed. During usage process, it is required to keep dry, the electrode shall be dried as per the scheduled quantity, and drying operation shall be properly made as per the project progress. During drying process, vent shall be opened and fan shall be used frequently to remove moisture; when electrode and flux are used, temperature in the dryer shall not be less than 200℃; After it is dried thoroughly, the electrode shall be put into thermostat. When the welding operator takes out the electrode, quiver must be carried for placing the electrode. The same quiver shall not be placed with electrode of different specification so as to avoid misapplication. When the humidity is 80%-90%, usage time shall not be more than two hours. When the humidity is less than 80%, the usage time shall not be more than four hours, otherwise, it shall be dried again, but the drying times for the electrode shall not be more twice in general. It is required to use far-infrared electrode drying oven and incubator to dry the electrode, beside electrode and welding flux, no other article is allowed to be dried in the oven, and dry and wet bulb thermometer shall be calibrated periodically. The electrode drying responsible person shall make Electrode Baking Record, Electrode Issue Record, and Temperature and Humidity Record of Welding Material Storage. Application position, vendor name, brand no., and furnace number of the welding material shall be recorded clearly. The recovered electrode shall be stored as per its classification and dried again, and it is forbidden to put it with the unused electrode together.
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。
If the coating is moisture, dropped, or significant crack exists, the electrode is not allowed to use; prior to application of welding wire, grease, rust, and other defects shall be removed from its surface.
4 焊前准备
4 Weld Preparation
4.1 坡口形式
4.1 Groove Type
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
/
50°-60°

4.2熔盐罐各部位焊接方法
4.2Welding various parts of molten salt tanks
序号
No.
焊接部位
Welding parts
焊接方法
Welding method
所用焊材
Welding consumables
1
熔盐罐底板
Molten salt tank bottom
气保焊+埋弧自动焊
GMAW+SAW
ER50-6+H10Mn2
2
熔盐罐壁板立缝
Molten salt tank wall standing seam
气电立焊
EGW
AT-YJEG50A
3
熔盐罐壁板环缝（外侧）
Molten salt tank wall ring seam
熔盐罐壁板环缝（内侧）
Molten salt tank wall ring seam
埋弧自动焊
SAW
手工电弧焊
SMAW
H10Mn2

J507
4
熔盐罐大角焊缝
Bighorn weld molten salt tank
焊条电弧焊+埋弧自动焊
GTAW+SAW
J507+H10Mn2
5
熔盐罐拱顶板
Molten salt tank top plate
手工电弧焊
GTAW
J507
4.3焊接注意事项
4.3 Welding attenation
4.3.1设计图纸中除注明者外，其余角焊缝的焊脚高度均等于两相焊件中较薄件的厚度，且须为连续焊。
4.3.1Unless otherwise noted in the design drawing, other fillet weld's weld joint height shall be equal to the thinner part of the two welded parts, and continuous welding is required.
4.3.2凡参加储罐焊接的电焊工必须经劳动部门的考试合格并有相应项目和位置焊工担任。
4.3.2Welders who engaged in the storage tank welding must pass the examination of the labor department, and the welding work shall be performed by the welder with corresponding project and position.
4.3.3定位焊应由合格焊工施焊，焊接工艺要求与正式焊接相同。引弧和熄弧不应在母材或完成的焊道上，正式焊接前应将定位焊缝两端修磨成缓坡，保证接头的质量，定位焊长度不小于50mm。
4.3.3Tack-welding shall be performed by the qualified welder, and the welding process requirements shall be identical to formal welding requirements. Run-on tab and run-off tab shall not be applied in parent material or the completed weld pass, prior to formal welding, it is required to trim and grind both ends of the tack weld into slow slope so as to ensure the joint quality, and the tack weld length shall not be less than 50mm.
4.3.4焊缝组装前应清除坡口表面及两侧各20mm范围内的泥沙、铁锈、水分和油污，并充分干燥，露出金属光泽。
4.3.4Prior to assembling weld, bevel surface and 20mm of both sides shall be free of sediment, rust, water, and grease, it shall be fully dried, and it is required to have the metallic luster.
4.3.5焊接中应保证焊道始端和终端质量，始端采用后退起弧法，终端应填满弧坑，多层焊的接头应错开。
4.3.5It is required to ensure starting and finishing end of each weld pass are qualified, the starting end adopts backward arc striking method, the finishing end shall have the crater filled fully, and joint of multilayer welding shall be staggered.
4.3.6双面焊的焊缝背面焊接前，当采用碳弧气刨清根时，应修整刨槽并磨除渗碳层。所有角接及T型接头焊缝，至少焊两遍完成，接头错开，圆滑过渡；板厚大于或等于6mm的搭接角焊缝，至少焊两遍。
4.3.6All corner joint and T joint welds shall be welded at least twice, joints shall be staggered and rounded off; if the plate thickness is larger than or equal to 6mm lapped fillet weld, it shall be welded twice at least.
4.3.7焊接环境出现下列情况之一时，必须采取有效防护措施，否则禁止施焊。
4.3.7If one of following welding condition occurs, effective preventive measures shall be taken, otherwise, it is forbidden to execute welding.
a．手工电弧焊时风速大于8m/s；
b．气体保护焊时风速大于2m/s；
c．大气相对湿度大于85%；
d．雨、雪、大雾环境。
a.When manual arc welding is performed, wind speed is larger than8m/s;
b.When gas shielded welding is made, wind speed is larger than2m/s;
c.Relative humidity of atmosphere is larger than85%;
d.Rain, snow, and fog occur.
4.3.8如出现上述现象时，应针对各条采取以下措施：搭设防风、防雨棚，对初始焊道100mm内加热，保持焊道干燥；以上措施必须满足此条要求，否则不得施焊。
4.3.8If the above phenomena occur, following measures shall be taken correspondingly: set up wind proofing and rain proofing shed, heat the initial welding pass within 100mm, and keep the welding pass dry; the aforesaid measures must satisfy this requirement; otherwise, execution of welding is not allowed.
5 施工工序
5 Construction process
划线
铺设垫板
铺设中幅板
焊接中幅板
基础验收

焊接边缘板外侧300mm
铺设边缘板

组装、焊接其余四带壁板
组焊罐顶
焊接纵缝
组装第五带壁板

伸缩缝、龟甲缝焊接
大角缝组对、焊接
环焊缝、立焊缝检测
中幅板真空试验

Weld center plate
Laying center plate
Mount liner plate
Scribe

Mount edge plate
Weld edge plate outside 300mm

Fit-up and weld other four shell plate
Weld longitudinal seam
Assemble and weld tank top
Fit-up the 5th with shell plate

Center plate vacuum test
Weld expansion joint and tortoise shell seam
Assemble and weld big fillet weld
Inspect circumferential weld and vertical weld

6 熔盐罐底板组对焊接
6 Assembly welding for tank bottom plate
罐底由中幅板和边缘板组成，罐底板焊缝均采用对接焊。基础验收合格后,确定方位画出中心线，得出中点、画出垫板、边缘板安装位置线，其中边缘板安装铺设按设计直径和基础坡度长度外加收缩余量来确定半径。边缘板之间铺设间隙外侧为8-10mm，内侧为12-14mm。
Tank bottom is composed of center plate and edge plate, the tank bottom plates are all butt welded, before laying the bottom plates, its lower surface should be painted with anti-corrosion coatings, leaving 50mm range of the edge. After foundation inspection & acceptance, the position shall be determined to draw the center line, so as to find the midpoint, draw the mounting position lines of backing board and edge plate, wherein the radius of edge plate mounting and laying is determined as the design diameter and foundation slope length plus shrinkage allowance. The laying gap of edge plates is 6mm of outside and 8mm of inside.
6.1 罐底边缘板焊接
6.1 Weld tank bottom plate
6.1.1弧形边缘板的对接焊采用手工焊。先焊其外侧300mm焊缝，打底焊后进行渗透检查，以第二层开始每层错开50～70mm，焊接完成后上部磨平。为控制焊接引起的角变形，将坡口处用夹具向上提起6～8mm。
6.1.1Manual welding is applied for the butt welding of curved edge pla