PLTU KALIMANTAN SELATAN 2*6MW
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
20G材质锅炉压力管道焊接方案
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
1. 编制目的 Purpose
本工程锅炉为济南锅炉厂制造，安装于印度尼西亚南加里曼丹省。
The boiler in this project is manufactured by JINAN Boiler group co.ltd, and installed in Province of South Kalimantan, Indonesia.
在本项目，焊接材料为中国ATLANTIC制造供货、焊接设备为ZX7-400逆变氩弧焊机、电源采用柴油发电机、焊工使用印度尼西亚当地人员，焊接标准采用ASME标准。 为了保证施工质量，统一施工工艺，特制定此施工程序。
In this project, the welding material is manufactured by ATLANTIC CHINA, the welding equipment ZX-700 inverter arc welding machine. The power is supplied by diesel generator, and welders are local. ASME standardization is applied to all welding work. 2. 编制依据 Basis
2.1 已经取得当地政府认可及PLN现场管理部的同意的WPS(PQR)施工工艺卡。 WPS (PQR) which is approved by local government or PLN site management. 2.2 NWPCI上报的《检查试验的工作指导》（WI for Inspection and Test Procedure）No.
NW-ITP-QM-0003
WI for Inspection and Test Procedure (No. NW-ITP-QM-0003) submitted by NWPCI 2.3 济南锅炉厂图纸资料及设备使用说明书
Drawings and document form JINAN Boiler Group Co.ltd. 3. 适用范围 Scope
#3锅炉及#4锅炉受热面部分，见下表
The following table shows boiler pressure part of #3 & #4 boiler 序号 名称 规格 焊接方式 No Item Spec. Welding method 1 水冷部分 Water wall 1.1 水冷壁管子 全氩弧焊 φ60*5 Water wall tube Argon arc welding 1.2 氩弧焊打底、电焊盖面，需要热处理 下降管 φ377*25 Argon arc welding as base, electrical welding as Downcomer cover, PWHT needed 1.3 分散下降管 氩弧焊打底、电焊盖面 Distributed φ133*10 Argon arc welding as base, electrical welding as downcomer cover 1.4 氩弧焊打底、电焊盖面 水冷引出管 φ133*10 Argon arc welding as base, electrical welding as Water guiding tube cover 2 过热器部分 Superheater 2.1 炉顶及后包覆 φ38*4 全氩弧焊 PT.NORTHWEST POWER CONSTRUCTION INDONESIA
PLTU KALIMANTAN SELATAN 2*6MW
2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 4 4.1 4.2 WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART Boiler top & rear Argon arc welding steam Cooled Wall 侧包覆 全氩弧焊 Side steam cooled φ42*4.5 Argon arc welding wall 低温过热器 全氩弧焊 φ38*4 Cold superheater Argon arc welding 连接管系 氩弧焊打底、电焊盖面 Connection piping φ133*10 Argon arc welding as base, electrical welding as work cover 连接管系 氩弧焊打底、电焊盖面 Connection piping φ133*12 Argon arc welding as base, electrical welding as work cover 连接管系 全氩弧焊 Connection piping φ28*4 Argon arc welding work 省煤器部分 Economizer 省煤器管子 全氩弧焊 φ32*4 Economizer pipes Argon arc welding 连接管系 氩弧焊打底、电焊盖面 Connection piping φ89*11 Argon arc welding as base, electrical welding as work cover 氩弧焊打底、电焊盖面 管接头 φ108*10 Argon arc welding as base, electrical welding as Tube end cover 接口 氩弧焊打底、电焊盖面，需要热处理 φ219*20 Joints 管路部分 Pipeline 氩弧焊打底、电焊盖面 管子 φ89*7 Argon arc welding as base, electrical welding as Pipe cover 管接头 全氩弧焊 φ28*4 Pipe joints Argon arc welding 4.具备现场焊接的条件
Conditions needed for welding work at site
4.1 RT、UT实验室 RT、UT lab
4.1.1在本项目，NWPCI将与印度尼西亚具有资质的单位进行合作，来完成RT、UT等实验室的工作。具体
的合作模式如下：
In this project, NWPCI will cooperate with qualified Indonesian organization to finish lab work of RT, UT
and so on. The details are as following:
PT.NORTHWEST POWER CONSTRUCTION INDONESIA
PLTU KALIMANTAN SELATAN 2*6MW
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
4.1.2 NWPCI提供实验室所有设备（该设备由中国制造，2007年曾在印度尼西亚MEALUBOL项目使用过）、
材料以及现场实验室，该合作单位提供有资质的操作和管理人员，并负责出具合格的报告。
NWPCI will supply all equipments, which is made in China and once used in MEALUBOL project 2007, as
well as material and lab. The cooperating organization supply qualified operating and management staff, and make reports.
4.1.3该实验室建成后将在WIKA及PLN等相关单位的帮助下，取得当地政府部门的在本项目的运营许可。 Under the help of WIKA and PLN, the lab will get permit in local government. 4.2 焊工上岗前的焊接培训 Welding training before working
4.2.1在本项目，所有压力部件焊接，全部使用印度尼西亚当地并具有相应资质的合格焊工(持有当地政府颁
发的合格证书)
In this project, the welding of all pressure parts should be performed by qualified welders of Indonesia, who
hold certification from local government.
4.2.2现场搭建现场培训场地，该场地模拟本现场实际施工条件，即所有培训的设备、电源、焊接材料、环
境等完全与将来实际施工一致。
Build training room at site, which simulate actual condition of this project, namely the equipments, power,
welding material, and environment should consistent with actual site condition.
4.2.3焊工到达现场，首先进行WPS技术交底，然后进行焊接练习，熟悉后，每个焊工焊接一个标准6G试
件，该试件须经现场质量部门检查验收，表面合格后交现场试验室进行RT或UT检测合格后，即表示该焊工通过了现场培训考试，该焊工将由WIKA质量部门统一登记、制作并发放本项目焊工上岗证，焊工持证上岗工作。
After arriving on site, the welders should teach-know-how about WPS, then exercise welding. After that,
every welder should weld one 6G standard sample, and take it for inspection and acceptance in QC department for visual inspection and RT/UT test. Qualified welder will be registered in WIKA QC department and get a work permit, with which he can do welding work on site.
4.2.4对于不合格的焊工，允许其再次重复4.2.3，如果两次考试不合格，将取消该焊工参加本项目资格。 Unqualified welders could repeat 4.2.3 once more. If not qualified again, he can not weld on this site.
4.3 焊接前的工序交接
Hand over procedure before welding
4.3.1钳工负责对口、其质量按安装程序要求进行，完成后交焊接专业进行焊前检查验收。
Under installation procedure, the fitter is responsible for fit-up, then hand over to welding principle for inspection.
4.3.2焊工依据焊接程序，对每一个焊口进行编号，按照WPS的技术要求，对每一个焊口进行焊前检查，
主要检查焊口坡口及对口间隙是否满足WPS要求，如超出标准，需要技术协商解决方案。
According to welding procedure, the welder should mark a sequence for every welding joint, and perform pre-welding inspection, which mainly to check whether the clearance of the fit-up satisfy WPS requirement. If not, a technical coordination is needed to solve the problem. 4.3.3双方在检查验收记录上签字确认，完成工序交接。
Both parties should sign on inspection and acceptance record, so as to fulfill procedure hand over.
4.4 通用要求 General requirement
4.4.1焊接场所应采取有效的防雨、防风等措施。
PT.NORTHWEST POWER CONSTRUCTION INDONESIA
PLTU KALIMANTAN SELATAN 2*6MW
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
The welding location should apply proper whether proof measures. 4.4.2焊接场所有足够的施工照明。 Adequate illumination in welding location.
4.3.3焊口局部间隙过大时,应设法修整到规定尺寸,严禁在间隙内加填塞物。
When partial clearance of welding joint is large, it should be managed to adjusted to qualified dimension. Forbid to fill up the clearance with other matters.
4.3.4焊接组装时应将待焊工件垫置牢固,以防止在焊接过程中产生变形和附加应力。
When assembling welding parts, firmly pillow the parts, so as to avoid any distortion and stress during welding. 4.3.5禁止用强力对口和热膨胀法对口,以防引起附加应力。
It is forbidden to fit-up by strong strength and heat expansion, so as to avoid additional stress.
4.3.6本工程采用手工电弧焊，严禁在被焊工件表面引燃电弧,试验电流或随意焊接临时支撑物。
In this project, manual arc welding is applied. So it is forbidden to light up arc, test current or weld temporary support on the surface of welding parts.
4.3.7点固焊时,其焊接材料,工艺应与正式施焊时相同。
The welding material & specification for tack welding should consistent with formal welding. 4.3.8施焊时，应短弧操作，以防产生气孔。
During welding, apply short arc, so as to avoid any blisters. 4.3.9不得对焊接接头进行加热校正。
Do not rectify or adjust the welding joint by heat.
4.5 焊接材料 welding material
本项目依照WPS要求，对于20G材质的焊接材料要求如下表：
According to WPS, the requirement of welding 20G material should as follows: No. Welding method GTAW Material requirement 1 氩气：选用印尼当地生产的氩气，合格证见附件. Argon is supplied by local company, see attachment for qualify certification. 2 焊丝：采用中国ATLANTIC生产的CHG56牌号焊丝，合格证见附件. The welding wire is CHG56 of Chinese ATLANTIC co.ltd, see attachment for qualify certification. 1 氩气：选用印尼当地生产的氩气，合格证见附件. Argon is supplied by local company, see attachment for qualify certification. 2 焊丝：采用中国ATLANTIC生产的CHG56牌号焊丝，合格证见附件. The welding wire is CHG56 of Chinese ATLANTIC co.ltd, see attachment for qualify certification. 3 焊条：采用中国ATLANTIC生产的CHE507牌号焊条，合格证见附件. The electrode is CHE507 of Chinese ATLANTIC co.ltd, see attachment for qualify certification GTAW backing,welding cover surface
PT.NORTHWEST POWER CONSTRUCTION INDONESIA
PLTU KALIMANTAN SELATAN 2*6MW
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
4.6 作业所需工器具
Equipment and tools needed for welding No 1 2 3 4 5 6 Item No 7 8 9 10 11 Item 焊接检验尺 welding calliper 角向磨光机angle grinder 钢丝刷 steel brush 氩气皮带 argon cable 电焊面罩 welding mask ZX-700 inverter arc welding machine 手电筒flashlight 电焊线 welding cable 电焊钳 welding torch 氩气表 argon meter 氩弧焊枪 argon arc soldering gun
5工作流程及相关文件 flow chart and relative documents
5.1工作流程Flow chart
PT.NORTHWEST POWER CONSTRUCTION INDONESIA
PLTU KALIMANTAN SELATAN 2*6MW
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
机械准备 Equipment preparation WPS approval 焊前培训考试 Test before welding 人力动员 Manpower mobilization 焊前准备 Preparation 焊前检查验收 Pre-welding inspection&acceptance 重新处理 Rework NO YES 焊接 Welding 质量检查及无损检测 QC inspection and NDT NO YES YE 验收合格 Acceptance
6 组织机构及人力资源Organization and Manpower
PT.NORTHWEST POWER CONSTRUCTION INDONESIA
PLTU KALIMANTAN SELATAN 2*6MW
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
现场经理 Site manager 陈富安Chen Fuan 焊接负责人 Welding superintendent 邢建钢Xing Jiangang 7. 焊接计划 Welding schedule
见项目安装计划
Refer to project erection schedule 8 安全环境 Safety and Environment
8.1 进入施工现场戴好安全帽,高空作业扎好安全带。
Wear a safety helm when entering the site, and fasten a safety belt when doing construction work at high altitude. 8.2 脚手架搭设应牢固可靠。 Scaffolding should be firmly built.
8.3 闭合电焊机刀闸应戴干燥手套,身体侧对刀闸及开关。
Wear a dry glove close the brake of welding machine, and the body should not face to brake and switch. 8.4 一、二次线严禁裸露,发现裸露应请专业人员停电处理。
The primary and secondary wire is not allow to expose in the air. If found any exposed wire, ask special personnel to cut off power and deal with the wire.
NDT supervisor PWHT supervisor Boiler welding supervisor ESP welding supervisor Radioactive assessor 2 Ultrasonic assessor 2 Spectrum assessor 2 PWHT worker 2 HPwelder 10 LP welder 8 PLwelder 8
PT.NORTHWEST POWER CONSTRUCTION INDONESIA
PLTU KALIMANTAN SELATAN 2*6MW
WELDING PROCEDURE FOR 20G MATERIAL OF BOILER PRESSURE PART
8.5 电焊机出现故障时,应在停电状态下检修。
If any failure appears in the welding machine, it should be repaired under condition of power off. 8.6 高空作业时,严禁乱扔工器具及焊条（丝）,焊条（丝）头应及时回收。
When doing work at high altitude, it is forbidden to throw tools and electrode rod/wire . The wasted electrode rod/wire should be collected together.
8.7 施焊过程中应注意做好防护，预防烫伤事故发生。 During welding, apply protection measures to avoid empyrosis.
因篇幅问题不能全部显示，请点此查看更多更全内容