焊材管理控制程序

CONTENTS 目录

1.0 – PURPOSE 目的

2.0 – SCOPE 范围

3.0 – RESPONSIBILITY 职责

4.0 – PROCEDURE 程序

4.1 – General 概述

4.2 -- Receiving Inspection 验收

4.3 – Storage 存储

4.4 -- Baking and Holding 烘烤与保温

4.5 -- Re-Baking / Drying 再烘烤/干燥

4.6 – Consumable Issuance 焊材发送

4.7 -- Return of Unused Welding Consumable 未用焊材返还

5.0 -- REFERENCED DOCUMENTS 参考文件

1.0 – PURPOSE 目的

The purpose of establishing this procedure is to administrative and technical control of receiving, storage, baking, issuance and return of welding consumables used for structural and piping welding in TOWER YOKE project.

本程序文件在行政和技术方面，对焊材的验收、存储、烘烤、发料和焊材返

送进行控制。本程序文件管理的焊材用于单点系泊项目。

2.0 – SCOPE 范围

This procedure only applies to the TOWER YOKE project.

本程序文件仅适用于单点系泊项目。

3.0 – RESPONSIBILITY 职责

3.1 -- Welding Engineer is responsible for 焊接工程师负责:

? Preparation and revision of this procedure 本程序文件的准备与修订

? Determine the procurement requirement and usage 规定采购要求与使用方法

? Preparation of Issuance List in relation to the applicable approved WPS for the guidance of the Welding Material Issue Room Keeper

按已批准的适用的WPS，准备相关的发货清单，作为焊材发放室管理员的发

放指导。

3.2 -- QC Dept is responsible for QC部门负责:

? Implementation of this procedure 执行本程序文件

3.3 -- Procurement & Construction Dept is responsible for 采购和施工部门负责:

? Establish the storage conditions and the in-process flow to facilitate the implementation of this procedure

建立存储条件在整个工艺流程中以促进该程序文件的执行。

3.4 -- Welding Material Issue Room Keeper is responsible for：焊接材发放室管理

员负责:

? Storage, baking, holding, issuance and return of the welding consumables

焊材的存储、烘烤、保温、发放及返还

3.5 -- Production department is responsible for 生产部门负责:

? Performing the construction work accordance to this procedure requirements

依照本程序文件的要求施工

4.0 – PROCEDURE 程序

4.1 – General 概述

4.1.1 -- The welding consumables shall be selected in correlation between the various steel grades and the welding consumable grades as per Class Rules and / or recognized international standard requirements, and to produce the welds of compatible chemical composition and mechanical properties equal to but not less than the minimum values specified for the base material. In addition, wire-flux combination for SAW shall be selected and based on each technique to be used e.g. 2-run or multi-run technique or both.

须根据分级规则、公认的国际标准及不同级别钢与焊材的相关性选择焊材，以产生化学成分相容、机械性能大于等于母材规范性能最小值的焊缝。

4.1.2 -- Electrodes for welding of high strength steels shall satisfy a hydrogen test requirement of at least H10.

高强度钢焊接用的焊条应满足至少H10的测氢试验要求。

4.1.3 -- Each batch of flux and wire shall be labeled with AWS Classification. Unidentified, damaged, wet, rusty or contaminated consumables and fluxes shall be discarded.

每批焊剂和焊丝均应有AWS分级标签。未经标识的、损坏的、潮湿的、锈蚀的或污染的焊材和焊剂均应废弃。

4.1.4 -- Any unidentified, wet, rusty and damaged consumable shall be immediately removed from the welding area when found.

任何未经标记的、潮湿的、锈蚀的、损坏的焊材一经发现，须立即从焊接区除去。

4.2 -- Receiving Inspection 验收

4.2.1 -- All incoming welding consumables shall be received, inspected and accepted with Class certificates. Delivery without valid Class certificates shall be rejected.

所有焊材进厂须有分级证书，并据此检查、验收。没有有效分级证书的来货须拒收。

4.2.2 -- Upon satisfactory receipt of incoming welding consumables, the Warehouse Keeper shall generate a “Welding Consumable Verification Report” and place the consumables in warehouse storage until they are issued to the Welding Material Issue Room.

收到的焊接材料一经检验合格，仓库管理员应制定一份“焊材检验报告”并将焊材存储在仓库内，直至发送到焊接材料发送室。

4.3 – Storage 存储

4.3.1 -- The designated Welding Material Issue Room shall be dedicated for the storage of welding consumables for this project and shall be so identified. It shall be manned by a dedicated Keeper. Unauthorized personnel shall be prohibited from entering the Welding Material Issue Room.

用于本项目的焊接材料须在指定的库房存储，且标识项目专用。库房须标识指定的管理员名字。未经授权人员不得进入焊接材料库。

4.3.2 -- Welding consumables shall be stored in a clean and dry environment with ambient temperature of not less than 17o C and relative humidity of less than 60% to preserve its properties. Equipments required for maintaining and monitoring the environmental temperature and relative humidity shall be regularly calibrated. The ambient temperature and humidity shall be documented on a daily basis by the Keeper on the “Temperature and Humidity Record of Welding Material Issue Room”.

为保持性能，焊材须存储在清洁、干燥的环境下，温度不得低于17℃，相对湿度小于60%。须定期校准用于保持、监测温度和相对湿度的设备。管理员应每天在“焊接材料发送室温度和湿度记录”上做记录。

4.3.3 -- Welding consumables shall be stored and issued on a “first-in, first-out” ba sis and segregated according to the Brand name, size and Classification. Labels of welding consumables shall face outwards for easy identification.

焊材的存储与发送应基于“先入先出”的原则。不同商标名称、尺寸大小和级别的焊材须分隔开。焊材的标签应朝外以便于识别。

4.3.4 -- During storage, the welding consumables shall remain intact in their original package and any consumable where identification has been lost shall be discarded. Particular care shall be taken when handling covered electrodes to prevent any possible damages on their covering. Electrodes and wires shall be stored off ground level.

存储期间，焊材须保持原包装完整，任何丢失标识的焊材均须废弃。搬运药皮焊条时须格外小心，以免损坏药皮。焊条和焊丝不得直接放在地面上。

4.3.5 -- Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other types, such as the rutile or organic type electrode. Electrodes of the same class and marking may be stored together.

低氢焊条不得存放在装有其它类型焊条的热的柜内，如钛钙或有机类型的焊条。相同等级和标志的焊条可存储在一起。

4.3.6 -- All electrodes shall be 300mm away from ground and wall.

所有焊条距地面和墙壁300mm。

4.4 -- Baking and Holding 烘烤和保温

4.4.1 -- Low hydrogen electrodes shall be purchased in hermetically sealed containers or shall be baked by The Keeper prior into use. Immediately, after opening the hermetically sealed container, electrodes shall be stored in ovens held at a temperature of at least 120o C.

须采购应密封包装的低氢焊条，或使用前由管理员烘烤。密封包装一经打开，焊条须立即存入温度最低为120℃的烤炉内。

4.4.2 -- Baking and Holding conditions for welding consumables shall be in accordance with the Table below and conditions documented on the “Baking and Holding Record

for Electrodes”.

焊材的烘烤、保温条件须符合下表，并且记录在“焊条烘烤和保温记录”。

Notes: 注：

1): All electrodes shall be placed in a suitable oven at a temperature not exceeding one half the final temperatures for a minimum of one and half hour prior to increasing the oven temperature to the final baking temperature. Final baking time shall start after the oven reaches final baking temperature. (This table is only used for guidance, and the manufacturer’s recommendations shall be adhered to).

所有焊条须置于适当的，温度不超过最终温度一半的烤炉内。达到最终烘烤温度最少要一个半小时。炉内温度达到最终烘烤温度后开始计算烘烤时间。（此表仅作为指导，还须遵从制造商的建议）。

2): For the maximum allowable exposure time of other electrode Classification, Table 5.1 in AWS D1.1 shall be used for guidance.

其它级别焊条的最大容许暴露时间，以AWS D1.1中表5.1为指导。

3): Electrodes exposed to the atmosphere for periods less than those specified in the above Table may be returned to a holding oven maintained at 120o C minimum.

焊条暴露于室外的时间少于上表规定的，可返回最低温度维持在120℃的保温炉内。

4.4.3 -- For very low hydrogen electrode, come with “Ready Pack”. Upon open the pack, welder shall fill up the boxes printed on the pack with relevant information ie. Welder ID, Date, Time. Electrodes can be kept in the pack and consumed within 4 hours or electrodes can be placed in heated quiver and consumed within 8 hours. Electrodes not consumed within specified time to be re-dry 2-4 hours 350±25℃.

对于每根低氢焊条，应以“现成包装”接收。一经拆装，焊工须在包装上印的方框内填写相关信息，即焊工ID，日期和时间。焊条可以在包内保存，并在4小时内消耗掉或是置于加热的保温筒内并在8小时内消耗掉。未在规定时间内消耗掉的焊条应在350±25℃温度下重新干燥2至4小时。

4.4.4 -- Equipments required to maintain or monitor the oven baking or holding the temperature shall be regularly calibrated.

用于维持或监测烤炉内烘烤或保温温度的设备应定期校准。

4.4.5 -- An identification tag shall be attached to each oven indicating the consumable Specification, Classification, Brand Name, Lot Number and size.

每个烤炉应贴有标签以显示焊材的规范、级别、商标名称、批号及尺寸大小。

4.4.6 -- Each SMAW process welder shall be issued with a portable container (quiver) and allowing him to keep his electrodes dry at more than 70o C.

每个SMAW过程中，焊工都须配有便携式容器（箭筒），使焊条能在高于70℃时保持干燥。

4.4.7 -- FCAW wire spool shall be covered at all times while it is on the wire feeder. The spool shall be kept in a dry place during welding at all times considering the possibility of rain, wind and snow.

FCAW焊丝盘在送丝机上须予以覆盖。考虑到焊接过程中可能下雨、刮风、下雪，焊丝盘须一直放在干燥位置上。

4.5 -- Re-Baking / Drying 再烘烤/干燥

4.5.1 -- Covered electrodes and fluxes which have been exposed to the atmosphere

longer than the time specified shall be re-baked.

暴露于大气中的时间大于规定的药皮焊条和焊剂须再次烘烤。

4.5.2 -- Covered electrodes shall be re-baked no more than once. All re-baked electrodes shall be suitably identified (e.g. color coding) prior to re-issuance.

药皮焊条只允许再烘烤一次。所有再次烘烤的药皮焊条，重新下发前须予以标识（如颜色编码）。

4.5.3 -- SAW flux that has not been melted during the welding operation may be reused after recovery by vacuuming, catch pans, sweeping or other means. During each re-cycle, new virgin flux shall be added suc h that the flux combination and particle size distribution at the weld puddle are relatively constant.

焊接操作中未熔化的SAW焊剂，可用真空泵、畚箕、扫帚或其它方式回收再用。每次循环利用时，需增添新的原始焊剂。这样，熔池内焊剂粒度大小、分布，焊剂化合物的量就会相对恒定。

4.5.4 -- Flux used for SAW shall be dry and free of contamination, dirt, mill scale or other foreign material.

用于SAW的焊剂应保持干燥，不被尘土、锈皮或其它外来杂质污染。

4.6 – Consumable Issuance 焊材发送

4.6.1 -- Only 1 type of covered electrode shall be issued to a welder at any one time and maximum amount shall not exceed 5 kg. However, when the welder is welding with combination electrodes for root and fill, then he is permitted to be issued with 2 type s of electrodes. Previously issued electrodes must be consumed or returned to the Welding Consumable Issue Room before any issuance of additional electrodes.

一次只能发给焊工一种药皮焊条，且数量不得超过5kg。当焊工用焊条组合进行根部或填充焊接时，可发给两种焊条。发送新焊条时，之前发送的焊条必须已用完，或返送至焊材发送室。

4.6.2 -- During use, the portable containers (quivers) shall be continuously heated and

the cover shall be closed at all times, except when taking out electrodes.

使用时，便携式容器（箭筒）须持续加热并盖好盖子，取焊条时除外。

4.6.3 -- All welding consumables shall be identified for traceability at all times during use and for this purpose, the following requirements shall be mandatory applied for.

所有焊材使用期间须标识，以备追踪。鉴于此目的，以下要求须强制实施。

4.6.3.1 -- Covered Electrodes (SMAW) 药皮焊条（SMAW）

? Each electrode shall be marked on coverings as per AWS Classification number.

每根焊条都应按AWS 分级编号在药皮上标记。

? Lot number marking on each pack of electrodes shall be traceable to the consumable test certificate.

焊条包装上的批号须能追溯到焊材检测证书。

4.6.3.2 -- Wire Spools (FCAW) 焊丝盘（FCAW）

? Each spool shall have a visible secured label indicating as a minimum the AWS Classification number and wire diameter. Any spool without a label shall be discarded.

每个焊丝盘均须有一个清晰可见的固定标签，至少标明AWS分级编号和焊丝直径。任何没有标签的焊丝盘废弃。

? Lot number marking on each label shall be traceable to the consumable test certificate.

每个标签上的批号须能追溯到焊材检测证书。

? For stainless steel (316L or 316), TIG wires shall be marked with Black color. For Carbon or C-Mn steel, TIG wires shall be marked with Red color.

对于不锈钢（316L或316），TIG焊丝须用黑色标记。对于碳钢或碳-锰钢，TIG焊丝须用红色标记。

4.6.3.3 -- Wire Coil & Bare Electrodes (SAW) 焊丝盘和裸焊条（SAW）

A label indicating at least the AWS Classification and the Lot number shall be attached

to the consumable reel and shall be maintained during welding.

焊丝盘须贴标签，至少标明AWS的分级编号和批号，焊接过程中须保留标签。

4.6.3.4 – Flux 焊剂

All fluxes shall be identified with the AWS Classification and Lot number on the flux container.

所有焊剂须在焊剂容器上标明AWS分级编号和批号。

4.6.4 -- All welding consumable shall be issued only to the individual welder responsible for using the welding consumable.

所有焊材仅限发送给负责使用该焊材的焊工。

4.6.5 -- Ceramic Backing Material 陶瓷垫衬材料

? Ceramic backing material shall be protected from rain, snow, dew or other form of moisture.

陶瓷垫衬材料须受保护，防雨、雪、露水及其它形式的潮湿。

? Unused ceramic material shall be kept in the original package in an area free from moisture and returned to the Welding Material Issue Room.

未被使用的陶瓷衬垫，须以原包装置于不受潮气影响的区域内，并返送至焊接材料发送室。

? Ceramic backing shall be installed just prior to welding. Unused ceramic backing that has been installed and is contaminated shall be discarded.

陶瓷垫衬须在焊接前安装。已安装但未使用的和污染了的陶瓷垫衬须废弃。

4.7 -- Return of Unused Welding Consumable未被使用的焊材返送

4.7.1 -- At the end of each working shift or when welding is not scheduled to begin at the next immediate shift, unused covered electrodes and ceramic backing material shall be returned to the Welding Material Issue Room.

每个工作班次末尾或下一班次开始时没有焊接计划时，没使用的药皮焊条和陶瓷衬

垫须返送至焊材发送室。

4.7.2 -- Damaged covered electrodes shall be returned to the Welding Material Issue Room to be discarded.

药皮损坏的焊条，须返送至焊材发送室予以废弃。

4.7.3 -- After return of unused welding consumable, the Welding Material Issue Room Keeper shall place them in the oven with identification of returned welding consumables.

未使用焊材返送后，焊接材发送室管理员须将其置于，标识为返送焊材的烤炉内。

4.7.4 -- Returned flux shall be re-baked prior to re-issue in accordance with this procedure. 依据本程序，返送的埋弧焊剂重新发送前须再次烘烤。

4.7.5 -- Unused and recovered flux shall be identified and controlled separately.

未经使用的和回收的焊剂须分别标识、控制。

5.0 -- REFERENCED DOCUMENTS 参考文件

? DNV-OS-C401 Fabrication & Testing of Offshore Structures

DNV-OS-C401 近海结构制造与测试

? AWS D1.1-2004 - Structural Welding Code – Steel

AWS D1.1-2004- 钢结构焊接规范

? ASME IX Boiler & Pressure Vessel Code

ASME IX 锅炉和压力容器规范

? Manufacture Recommendations

制造介绍