江陰東方閥門WCB+DMo堆焊工藝

1、江陰東方閥門有限公司W(wǎng)CB堆焊工藝評(píng)定報(bào)告匯編編號(hào) ：PQR-20焊接方法SMAW母材牌號(hào)：WCB-GB12229/A216焊材牌號(hào) :D507MO- GB984-1985/E410完成日期 :江陰東方閥門有限公司W(wǎng)CB堆焊工藝評(píng)定報(bào)告目錄序號(hào)名稱頁數(shù)備注1WCB 鋼堆焊評(píng)定試驗(yàn)大綱12WCB 鋼堆焊工藝規(guī)程（WPS）23D507Mo 焊條質(zhì)量證明書14WCB 母材質(zhì)量證明書15滲透檢測(cè) (PT) 報(bào)告16硬度檢測(cè)報(bào)告17侵蝕檢測(cè)報(bào)告18加工后堆焊面化學(xué)成分19彎曲試驗(yàn)110WCB 焊接工藝評(píng)定記錄 （ PQR）焊接3(含操作記錄表 )11閥門密封面堆焊工藝卡112閥門零部件密封面堆焊記錄1備

2、注：江陰東方閥門有限公司W(wǎng)CB鋼堆焊工藝評(píng)定大綱一、目的：為保證 WCB 堆焊工藝評(píng)定順利進(jìn)行，特制訂本大綱。二、范圍：適用于 WCB 堆焊工藝。三、內(nèi)容：1、焊接設(shè)備：電弧焊機(jī) ZX 5-4002、母材： WCBGB12229/ASTM A2163、母材試樣尺寸：16016010壹?jí)K4、焊條： D507Mo GB984-1985-EDCr-A2-155、D507Mo/GB984-1985-EDCr-A2-15 化學(xué)成分 (%)：CNiCrWMo硬度（ HRC） 0.2 1.010.0-16.0 2.0 2.50 386、焊條直徑：3.24.07、焊前焊條烘焙：烘焙溫度 300350oC，保溫

3、時(shí)間 1 小時(shí)8、施焊操作記錄（含工藝參數(shù)外觀檢驗(yàn)、探傷、硬度）9、侵蝕檢測(cè)報(bào)告10、PT 探傷報(bào)告11、硬度測(cè)試報(bào)告12.工藝評(píng)定編號(hào)： PQR-20QW-482Jiangyin Eastern Valve Co.,Ltd江陰東方閥門有限公司焊接工藝規(guī)程 Welding Procedure Specification（ WPS）（參見ASME鍋爐壓力容器規(guī)范第卷ASME Boiler and Pressure Vessel Code, Section IX）公司名稱 company焊接規(guī)程編號(hào)WPS No.:WPS-20修改號(hào)Revision No:焊接方法WeldingProcess(es

4、)Jiangyin Eastern Valve Co., Ltd簽字人 By:Shen Genping日期Date:依據(jù)的工藝評(píng)定記錄編號(hào):Supporting PQR No(s).:E-01日期 Date:SMAW自動(dòng)化等級(jí)Type(Automatic,Manual, MachineorPQR-20 Semi-Auto)Manual接頭Joints (QS-402)簡(jiǎn)圖2mmAftermachining接頭型式 Joint DesignHardface OverlayJane figure襯墊 Backing ( 有 yes)YES(無 No )/襯墊材料 (型式 ) Backing Mat

5、erial(Type)Base Metal or Weld metal金屬 不熔金屬非金屬 其它材料應(yīng)當(dāng)用簡(jiǎn)圖、施工圖、焊接代號(hào)或文字說明來說明被焊零件布置，需要時(shí)，可給出根部間隙和坡口詳圖 (根據(jù)制造者的選擇，可附簡(jiǎn)圖說明接頭型式、焊層數(shù)和焊道的順序。例如，對(duì)于有缺口韌性要求的焊接工藝、對(duì)于多道焊工藝等需要簡(jiǎn)圖 )Sketches Production Drawings, weld symbols or written Description should show the general arrangement of the parts to be welded. Where applic

6、able, theroot spacing and the details of weld groove many be specified.母材 (Base Metals)(QW-403)P-NO.1組號(hào) (Group No.2與 to P-NO./組號(hào) (Group No./相焊或鋼號(hào)和等級(jí)為Specification type and gradeGB12229 (A216) Gr.WCB與鋼號(hào)和等級(jí)為to Specification type and grade/相焊或 化學(xué)成分和力學(xué)性能為chem. Analysis and Mech. Prop./與化學(xué)成分和力學(xué)性能為to/chem

7、. Analysis andMech.Prop./相焊厚度范圍 Thickness Range：母材 Base Metal：25mm管子直徑范圍 (Pipe Dia, Range)：N/A其它 other角焊Fillet角焊FilletN/AAllAll填充金屬 Filler Metals * (QW-404)SFA NO.5.4GB984-1985AWS NO.( 分類號(hào) )E410-15D507MoF-NO4A-NO.6填充金屬尺寸 Electrode Size5.0mm5.0mm熔敷焊縫金屬厚度范圍 Thickness Range2t2t焊絲焊劑 (分類號(hào) ) Flux(class)/焊

8、劑商標(biāo)名稱Flux brand name/可熔化嵌條Consumable inserts/其它 Other/對(duì)于每一母材一填充金屬的組合均需分別填表For each parent metal filler metal combinationall needs to fill out a form,respectivelyQW-482(續(xù))焊接工藝規(guī)程 (WPS)WPSNO.WPS-20焊接位置 Position(QW-405)坡口的位置Groove Position1G焊接方向 Weld progression：向上 up/向下 down/角焊縫位置Fillet welding positio

9、n1F、 2F預(yù)熱 Preheat (QW-406)最小預(yù)熱溫度Preheat Temperature0最大層間溫度Interpass Temperature200預(yù)熱的保持方式Preheat Maintenance/(應(yīng)記載采用連續(xù)加熱或特殊加熱法Continuous or specialheating where applicable should be record )電特性Electrical Character (QW-409)電流 AC 或 DCDC極性Polarity修改號(hào) Rev.：E-01焊后熱處理Postweld Heat Treatment(QW-407)溫度范圍Temp

10、. Range/時(shí)間范圍Time .Range/氣體 Gas (QW-408)(百分比組成Composition)氣體混合比流量GasCompositionFlow Rate保護(hù)氣 Shielding gas(es)/尾部保護(hù)氣Gas Trailing/Shielding/背面保護(hù)氣Gas Backing/EP安培 (范圍 )Amps(Range)See notes伏特 Volts (Range)See notes(To fill in current and voltage separately as per welding position and thickness)鎢級(jí)尺寸和類型 W

11、pole specification and typeN/A金屬過渡方式 (FCAW)N/A送絲速度范圍 Travel Speed (cm/min)N/A焊接技術(shù) Technique(QW-410)直進(jìn)焊或橫擺焊 String or weavingstring Or weaving bead嘴孔或噴嘴尺寸 Size of welding spoutN/A打底焊道和中間焊道的清理方法(刷理或打磨等 ) Before welding or level clearanceGrinding、Burnish背面清根方法 Revise Side boot clearance typeN/A橫擺方法 Swi

12、ng TypeN/A導(dǎo)電嘴至工作距離 Distance between electric conduction spout and workpieceN/A多道焊或單道焊（每側(cè)） Multiple or Single passes(per side)Multiplepasses多絲焊或單絲焊 Multiple or single ElectrodesSingle electrode焊接速度 (范圍 ) Travel Speed(Range) (mm/min)See notes錘擊有無 Hammer ImpactNo其它 Other/Notes填充金屬電流焊接速焊層焊接方法Filler Meta

13、lCurrent電壓范圍度范圍Volt.熱輸入WeldWelding安培Travel種類直徑極性RangeHeat InputLayer(s)TypeAmp RangespeedClassDia（ mm）Polarity（v ）J/mm（A ）Rangemm/min1-nSMAWE410-155DCRP145-20721-28104-1511164-3344Jiangyin Eastern Valve Co.,Ltd江陰東方閥門有限公司W(wǎng)ELDING PROCEDURE QUALIFICATION RECORDS(PQR)焊接工藝評(píng)定記錄（ PQR）（參見 ASME 鍋爐壓力容器規(guī)范第卷ASM

14、E Boiler and Pressure Vessel Code, Section IX ）Procedure Qualification Record No. /Rev 工藝評(píng)定報(bào)告編號(hào)PQR-20 /Rev:E-01Date 日期 :Page頁次1 /3Welding Process(es ) 焊接方法SMAWType 類型ManualWPS No./Rev.工藝規(guī)程編號(hào)WPS-20 /Rev:E-01接頭JOINTS(QW-402)2mmAfter machining（組合評(píng)定時(shí)，熔敷的焊縫金屬厚度應(yīng)按每種填充金屬或焊接方法分別記錄）(For combination qualifica

15、tions, the deposited weld metal thickness shall be recorded for each filler metal or process used.)BASE METALS(QW-403) （母材）POSTWELD HEA T TREATMENT(QW-407)焊后熱處理材料規(guī)范Material Spec.A216To_型號(hào)或等級(jí)Type or GradeWCBToP-No1試件厚度Thickness of Test Coupon26mm試件直徑Diameter of Test Coupon_ N/A _其它Others_ N/A _FILLER

16、 METALS(QW-404) 焊接材料 SFA 規(guī)范SFAGB984-1985( 5.4 )AWS 焊材型號(hào)AWS ClassificationD507Mo(E410-15)填充金屬 F-NO.Filler Metal F-No.4焊縫金屬成份A-No.Weld Metal Analysis A-No.6填充金屬規(guī)格Size of Filler Metal5.0mm;焊材廠 Filler Supplier:Shanghai Bele welding Cosumable Co.,Ltd焊材 Filler Lot No.:410510焊縫金屬厚度Weld Metal Thicknessmin.

17、3 mm,POSITION(QW-405) 位置坡口位置Positon of Groove1G焊接方向 (向上、向下 )Weld Progression (Uphill, Downhill)N/A其它Other/_PREHEAT(QW-406) 預(yù)熱預(yù)熱溫度Preheat Temp.RoomTemp層間溫度Interpass Temp.150其它Other/溫度Temperature/時(shí)間Time/其它Other/GAS(QW-408) 保護(hù)氣體Percent composition（氣體成份）Gas(es)氣體(Mixture) 混合比FlowRate 流量正面保護(hù)ShieldingN/AN

18、/AN/A層面保護(hù)TrailingN/AN/AN/A背面保護(hù)BackingN/AN/AN/AELECTRICAL CHARACTERISTICS(QW-409)電特性電流CurrentDC極性PolarityEP安培Amps.See notes鎢極尺寸Tungsten Electrode SizeN/A其它Other/Technique(QW-410) 施焊技術(shù)焊接速度Travel SpeedSee notes不擺動(dòng)或擺動(dòng)String or Weave BeadString or Weave Bead擺動(dòng) OscillationN/A多道焊或單道焊（每側(cè)）Multipass or Single

19、 Pass(per side)Multipass單絲或多絲焊Single or Multiple ElectrodesSingleElectrode其它Other/_WELDING PROCEDURE QUALIFICATION RECORDS(PQR)(Continued)PQR No. /Rev: 工藝評(píng)定編號(hào)PQR-20 /Rev:E-01Page頁次2/3Notes:填充金屬電流焊接速度焊層Filler MetalCurrent伏特焊接方法范圍Weld安培范圍 Volt備注Travel SpeedLayer(Process種類直徑極性范圍RangeRemarksRanges)VClas

20、sDiaPolarityAmp. RangeMm/minA1SMAWE410-15 5.0DCEP170241252SMAWE410-15 5.0DCEP170241313SMAWE410-15 5.0DCEP180251224SMAWE410-15 5.0DCEP18025128Tensile Test(QW-150)拉力試驗(yàn)Specimen No.WidthThicknessAreaUltimate Total LoadUltimate Unit StressType of Failure &KNMPaLocation試樣號(hào)寬度厚度面積極限總載荷極限單位應(yīng)力破壞性質(zhì)和位置Guided-Be

21、nd Tests(QW-160)導(dǎo)引彎曲試驗(yàn)Report No : QR/JEV GY201402006Type and Figure NoResult類型和圖形結(jié)果20-06-1(180side bend)Accepted20-06-2(180 side bendAccepted20-06-3(180side bend)Accepted20-06-4(180side bend)AcceptedToughness Tests(QW-170)韌性試驗(yàn)Specimen No.Notch LocationSpecimen SizeTest Temp.Impact Value 沖擊功試樣號(hào)缺口位置試樣

22、尺寸試驗(yàn)溫度J 能量%Shear 剪切斷面百分比Comments:_WELDING PROCEDURE QUALIFICATION RECORDS(PQR)(Continued)PQR No. /Rev: 工藝評(píng)定編號(hào)PQR-20 /Rev:E-01Page 頁次3/3硬度試驗(yàn)Hardness TestReport No : QR/JEVGY201402006pointHV10pointHV10PointHV10134561631115323107159121503332816013149433691651415253291016115157Hardness of Base Metal and

23、 HAZ meet NACE MR0175 HRC22 max. ; Weld hardness meet API 600化學(xué)成分檢驗(yàn) Chemical composition testReport No : QR/JEVGY201402004CSiMnPSCrNiMoCuAlTiVNbW0.080.410.70.0280.00.0170.0050.0040.0270.0170.010Fillet-Weld Test(QW-180)角焊縫試驗(yàn)結(jié)果好壞熔縫透材好壞Result-Satisfactory: YesN/ANoN/APenetration into Parent

24、Metal: YesN/ANoN/AMacro-Results 宏觀試驗(yàn)N/AOther Tests其它試驗(yàn)Visual Inspection 外觀檢驗(yàn)AcceptedType of Test 試驗(yàn)類型Penetration testing (GY201402003)AcceptedErosion test (GY201402001)AcceptedDeposit Analysis 金相及成分分析/Welder s Name焊工姓名Miao JianfaID No. 證件tamp No.鋼印號(hào)6Test conducted by 試驗(yàn)執(zhí)行人 : Jian

25、gyin Eastern Valve Co.,LtLaboratory Test No. 試驗(yàn)編號(hào)PQR-20We certify that the statements in this record are correct and that the test welds were prepared, welded and tested in accordance with the requirements of Section IX of the ASME Code.茲證明本報(bào)告所述均屬正確，并且試驗(yàn)是根據(jù)ASME 規(guī)范第 IX 卷的要求進(jìn)行試件的準(zhǔn)備、焊接和試驗(yàn)的。Sign(簽字 )She

26、n GenpingDate(日期 )Approval ( 批準(zhǔn) )Liu JianqingDate(日期 )江陰東方閥門有限公司Jiangyin Eastern Valve Co., Ltd滲透探傷報(bào)告QR/JEV7.4(19)-2010Liquid Penetrant Test ReportReport No: QR/JEVGY201402003生產(chǎn)令號(hào)155 80 25訂單號(hào)商標(biāo)規(guī)格名稱焊接工藝試板ProductionPO.No.BrandType of Partwelding procedure testNo.plate數(shù)量產(chǎn)品編號(hào)WPS-20Quantity1Product No.爐

27、號(hào)Heat No.標(biāo)準(zhǔn)試塊材料探傷部位堆焊面Std TestYM-DWCB+E410InspectionMaterialOverlaying surfaceSpecimenSection滲透劑型號(hào)清洗劑型顯象劑型號(hào)號(hào)Type ofDPT-5DPT-5Type ofDPT-5Type ofPenetrantDeveloperWashing滲透時(shí)間顯象時(shí)間執(zhí)行標(biāo)準(zhǔn)15MinDevelopin15MinAcceptableQW195Penetrant Timeg Timestandard探傷示意圖：Sketch:探傷結(jié)論：Result:Measure up to standard卞良華卞曉慶2014

28、-10-20檢測(cè)人員 /日期審核人員 /日期2014-10-20Reviewed by/DateBian XiaoqingInspector/DateBian Lianghua江陰東方閥門有限公司力學(xué)性能試驗(yàn)報(bào)告單Jiangyin Eastern Valve Co., Ltd.Mechanical property test reportReport No: QR/JEVGY201402002委托單位 Entrusting party焊接試驗(yàn)室Welding laboratory產(chǎn)品名稱 Product namePQR-20-02工藝評(píng)定Procedure qualification鋼 號(hào) M

29、aterialWCB+E410技術(shù)要 求 Technical requirementAPI 6D試驗(yàn)溫度 Temperature22 項(xiàng)目 Item檢測(cè)結(jié)果RelAZAKVJ結(jié)論RmResultMPa%HVHRCResultMPa%爐號(hào)Heat No .PQR-20-02-1PQR-20-02-2PQR-20-02-3PQR-20-02-4PQR-20-02-5PQR-20-02-6PQR-20-02-7PQR-20-02-8PQR-20-02-9PQR-20-02-10PQR-20-02-11PQR-20-02-12PQR-20-02-13PQR-20-02-14PQR-20-02-1534

30、5合格 Accepted310合格 Accepted332合格 Accepted336合格 Accepted329合格 Accepted163合格 Accepted159合格 Accepted160合格 Accepted165合格 Accepted161合格 Accepted153合格 Accepted150合格 Accepted149合格 Accepted152合格 Accepted157合格 Accepted報(bào)告日期檢驗(yàn)員卞良華審核劉建清Report Date2014-10-25Bian LianghuaApproved byLiu JianqingInspector注：本檢測(cè)結(jié)果僅來樣試

31、件負(fù)責(zé)Remark: The result is only for the test coupon江陰東方閥門有限公司腐蝕性測(cè)試報(bào)告Jiangyin Eastern Valve Co., Ltd.Etching test reportReport No : QR/JEV GY201402001產(chǎn)品名稱工藝評(píng)定試板 Test couponProduct name材料牌號(hào)WCB+E410試樣編號(hào)PQR-20-01MaterialTest coupon no測(cè)試內(nèi)容浸蝕試驗(yàn)報(bào)告日期Etching test2014-10-20Test nameReport date測(cè)試步驟：Test descript

32、ion：1 將試樣二端堆焊層垂直暴露斷面進(jìn)行打磨平整，并進(jìn)行拋光處理；2 試樣在硝酸與水比例1： 3 的浸蝕劑溶液中浸蝕3 分鐘；3 用 5 倍放大鏡對(duì)暴露斷面進(jìn)行100%目測(cè)檢查。1. Cut the test coupon into two pcs perpendicular to alloy overlay layers, grind and polish the exposed section smooth.2. Put the two test pieces into a nitric acid and water solution ratio of 1:3 for 3 minute

33、s.3. 100 percent visual inspection to exposed section with 5 times magnifying glass.測(cè)試結(jié)果：Test result試樣二個(gè)垂直暴露斷面基層金屬和熱影響區(qū)處無裂紋，堆焊接合處完會(huì)熔合。Base metal and HAZ on the two vertical section no cracks and complete fusion on welding joints.測(cè)試結(jié)論：Test conclusion:按 ASME 規(guī)范卷焊接與補(bǔ)焊評(píng)定QW-183 規(guī)定，判定合格。It is acceptable a

34、ccording to ASME section ,QW-183.說明1 以上結(jié)果僅對(duì)來樣負(fù)責(zé). 1. The result is only for the test coupon.Remark2 試樣保存三個(gè)月 .2. Samples remain for 3 months.測(cè)試人員卞良華審核人員劉建清日期Inspector日期2014 -10-24ApprovedLiuBian2014-10-24DatebyJianqingDateLianghuaAnalyses protocol:SampleId1:FOR WPS-20-04SampleId2:1Cr13SampleId3:Sample

35、Id4:SampleId5 :SampleId6:Date/Time of analyses:Report No: QR/JEVGY201402004CSiMnPSCrNiMoCuAlTiVNbW0.080.410.70.0280.00.0170.0050.0040.0270.017 0.010江陰東方閥門有限公司力學(xué)性能試驗(yàn)報(bào)告單Jiangyin Eastern Valve Co., Ltd.Mechanical property test reportReport No: QR/JEVGY201402006委托單位 Entrusting party焊接試驗(yàn)室產(chǎn)品名稱

36、Product namePQR-20-06鋼 號(hào) MaterialWCB+E410技術(shù)要試驗(yàn)溫度 Temperature22 項(xiàng)目 Item檢測(cè)結(jié)果RmRelAResultMPaMPa%爐號(hào)Heat No .PQR-20-06-1側(cè)彎 Side bendPQR-20-06-2側(cè)彎 Side bendPQR-20-06-3側(cè)彎 Side bendPQR-20-06-4側(cè)彎 Side bendWelding laboratory工藝評(píng)定 Procedure qualification求 Technical requirementQW-163ZAKV結(jié)論HVHRCJ%ResultD=3S=180 無缺陷合格no defectUp to standard無缺陷合格no d