海工建造規(guī)范培訓(DNV建造標準)C401中文版

1、 DNV-OS-C401 ”Fabrication and Testing of Offshore Structures”Version Slide 2January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures This is whats all aboutVersion Slide 3January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures Course Purpose. 培訓目的培訓目的nTo give a b

2、rief overview of DNV offshore standards.n介紹DNV海工標準nTo give basic knowledge of fabrication standard OS C-401n介紹海工建造標準OS C-401的基礎知識Version Slide 4January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures DNVs ROLE IN OFFSHORE CLASSIFICATIONnDET NORSKE VERITAS (DNV) is an autonomous an

3、d independent foundation with the objectives of safeguarding life, property and the environment, at sea and onshore. nDET NORSKE VERITAS(簡稱DNV)是一家獨立的公司。致力于在海上或海岸上保護工作人員的生命，公共財產(chǎn)及設備的安全和對環(huán)境進行保護。nDNV undertakes classification, certification, and other verification and consultancy services relating to qu

4、ality of ships, offshore units and installations, and onshore industries worldwide, and carries out research in relation to these functions.nDNV提供在下列領域內為客戶提供分級、驗證、認證和咨詢服務：造船、海工部件和安裝、海岸工程以及在這些相關領域的專業(yè)研究。Version Slide 5January 22, 2022Offshore Standards海工標準包括：DNV-OS-C401”Fabrication and Testing of Offs

5、hore Structures”uA: Quality and Safety Methodologyu 質量和安全控制方法uB: Materials Technologyu材料技術uC: Structuresu結構uD: Systemsu系統(tǒng)uE: Special Facilitiesu特殊設備uF: Pipelines and Risersu安裝管道和豎管Version Slide 6January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures Offshore Standards. 海工標準海工標準 n

6、Provide technical provisions and acceptance criteria for general use by the offshore industry as well as the technical basis for DNV offshore services.n海工標準為海工建造提供技術條款和可接受的標準Version Slide 7January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures Recommended Practices. nProvide prov

7、en technology and sound engineering practice as well as guidance for the higher level Offshore Service Specifications and Offshore Standards.n提供技術和錄音實例以及提供高水平的海工服務規(guī)格和海工標準指南。Version Slide 8January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures DNV Offshore Codes are offered within

8、 the following areas:- A) Qualification, Quality and Safety Methodology- 資格、品質和安全控制方法- B) Materials Technology- 材料技術- C) Structures- 結構- D) Systems- 系統(tǒng)- E) Special Facilities- 特殊設備- F) Pipelines and Risers- 安裝管道和豎管- G) Asset Operation- 資產(chǎn)管理- H) Marine Operations- 海工運營Version Slide 9January 22, 2022D

9、NV-OS-C401”Fabrication and Testing of Offshore Structures” Difference Ship Rules versus Offshore rules 船舶規(guī)范與海工規(guī)范不同的原因Rules for Offshore projects are in some areas quite different from the traditional Ship Rules, due to long time on location with no or limited possibilities leave the location. ( 20 2

10、5 years service time)海工產(chǎn)品必須在海上持續(xù)工作2025年船舶可以進塢進行檢驗（中間檢驗、特檢）Version Slide 10January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures” Some important aspects:幾個重要方面- Structural integrity and strength (Loads based on environmental conditions on actual location)- 結構形式和強度（載荷根據(jù)工作地點的實際環(huán)境）-

11、 Accidental loads to be included in Design Loads (DAL)- 設計載荷還考慮到可能受到的意外載荷- Fatigue (attention to details)疲勞問題- Maintenance保養(yǎng)維修- Corrosion protection防腐- In service inspection ( Access etc. should be planned and provided during newbuilding phase)使用過程中的檢驗- Increased reliability of Marine systems, utili

12、ty systems and equipment.- 提高各種系統(tǒng)和設備、設施的可靠性- Safety systems (Fire, explosion, abandon installation etc.)- 防火、防爆、逃生等安全系統(tǒng)- Shelf state requirements to accommodation and working environment- 當?shù)氐木幼『凸ぷ鳝h(huán)境要求Version Slide 11January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”nDNV-OS-C

13、401”Fabrication and Testing of Offshore Structures”nDNV-OS-C401海工結構建造和試驗- CH. 1 INTRODUCTION 介紹- CH. 2 TECHNICAL PROVISIONS技術條款- CH. 3 CERTIFICATION AND CLASSIFICATION驗證與入級Version Slide 12January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures” CH. 1 INTRODUCTIONA 200 Objective201

14、 The objectives of this standard are to:Provide an internationally acceptable standard to ensure the quality of all welding operations used in offshore fabrication, through identifying appropriate welding procedures, welder qualifications and test methods.提供國際認可的標準，通過對焊接程序、焊工資格和測試方法的認證來保障海工焊接質量Serve

15、 as a technical reference document in contractual matters between purchaser and contractor.為買方和承包人就合同問題提供技術參考文件Serve as guideline for designer, purchaser and contractor為設計者、買方和承包商提供指導Specify minimum requirements for welding operations subject to DNV certification and classification.將焊接工作的要求最細化，使其符合D

16、NV的認證和分級要求Version Slide 13January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures” Chapter 2 Technical provisionsn 第二章：技術條款- Sec. 1 Welding Procedures and Qualification of Welders- 焊接工藝和焊工取證- Sec. 2 Fabrication and Tolerances建造與公差- Sec. 3 Non-Destructive Testing無損探傷- Sec. 4 Other

17、Tests其它試驗- Sec. 5 Corrosion Protection Systems防腐系統(tǒng)- Sec. 6 Miscellaneous其它 Version Slide 14January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures” Sec. 1 Welding Procedures and Qualification of Welders 焊接工藝與焊工取證Welding procedures焊接工藝Pre-Welding Procedure Specification to be prepa

18、red and accepted by purchaser.焊接預試驗工藝必須得到船東認可WPQT to be based on accepted Pre-WPS 按照焊接預試驗工藝進行焊接工藝認可試驗WPS may be based on purchaser accepted WPQT and in conformance with an agreed qualification scheme.焊接工藝建立在焊接工藝認可實驗及其質量控制方案WPS shall reflect conditions and equipment used for the actual production wel

19、ding.焊接工藝須反映實際工作所使用的設備和相關條件WPS shall reflect the working environment for the work shop or site where the production welding will be performed.焊接工藝須反映實際工作場所的工作環(huán)境Specific requirements to WPQT for C-Mn steels are found in OS-C401 Ch.2, Sec.1, C.關于C-Mn系鋼的焊接工藝與焊工資格的具體要求，詳見OS-C401 Ch.2, Sec.1, C.Version S

20、lide 15January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”A WPS can be established by one of the following methods:編制焊接工藝說明書的方法：nPerforming of welding procedure test (WPQT) and subsequent review of the welding procedure qualification records (WPQR) n進行焊接工藝評定試驗，并對相關記錄進行評定nRevi

21、ew of previously qualified welding procedures tests (WPQT) which has been witnessed by a party recognized by the purchasern對其它船級社或其它組織認可的焊接工藝評定記錄進行評定nReview of WPS評定焊接工藝說明書nReview and verification of documentation showing successful application of welding procedures over a prolonged period of time.對

22、經(jīng)過長期使用后被認為是成功的焊接工藝進行評定、驗證Version Slide 16January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures” Welders qualification焊工的評定Welders who are welding in manual or partly mechanized welding processes shall be qualified in accordance with a recognized standard (E.g. EN 287, ISO 9609,

23、ASME IX or ANSI/AWS D1.1)手工焊和半自動焊焊工須得到相關組織的認可Welders using fully mechanized welding or automatic welding processes, need generally not pass a qualification test, but shall receive adequate training for setting and operation of equipment.自動焊的操作人員無需進行專門的考試，但需要通過專門的培訓來學會設置和操作設備Version Slide 17January 2

24、2, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures” Sec.2. Fabrication and tolerances.第二章 建造與許可公差 Fabrication Planning建造方案As a prerequisite for fabrication, procedures, inspection and test plans and work instructions for execution and control of fabrication activities shall be establi

25、shed.工藝方案、檢驗和試驗方案是執(zhí)行和控制建造的先決條件Contractors involved in fabrication of structural members shall have a documented and implemented quality system according to ISO 9001 or equivalent. 承包商應該具有完善的質量體系Workmanship shall be in accordance with written procedures accepted by the purchaser. 必須按照船東認可的工藝進行施工All w

26、ork shall be executed with adequate control by the contractor. Repair work shall be carried out in accordance with written procedures accepted by the purchaser . 所有施工過程必須有嚴格的控制，修補工作也必須按照認可的工藝進行Version Slide 18January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”Faults and defic

27、iencies shall be corrected before painting or other means of permanent covers have been applied. 所有錯誤和缺陷必須在油漆和其它東西覆蓋前得到修復Prior to commencement of the work the contractor shall submit a plan for NDT, NDT procedures and documents for NDT inspectors certification for acceptance by the purchaser. The pr

28、ogramme shall contain information and documents for planning, controlling, reporting etc. Acceptance criteria for NDT shall be accepted by the purchaser if they are not specified in relevant documents.開工前承包商需要提供無損探傷方案，方案應包括整個過程控制和驗收標準。整個方案應包括計劃、控制和匯報等方面的信息和文件。如果沒有特別的要求，承包商需接受NDT的驗收標準。Version Slide 1

29、9January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”Inspection.檢驗檢驗nTo be carried out in accordance with accepted inspection and test plans covering:檢驗要按照檢驗和試驗方案進行，應包括： correct identification and documentation and use of materials 材料跟蹤 qualification and acceptance of fabricat

30、ion procedures and personnel評定施工人員資質和建造方案 inspection of preparatory work (assembly, fit-up form work, reinforcement etc.)檢驗成型、裝配、加強等準備工作 welding inspection焊接的檢驗 inspection of fabrication work for compliance with specifications and procedures確認施工人員資質以及是否按工藝施工 witnessing NDT, control and testing跟蹤無損探傷

31、和其它試驗 inspection of repairs修補工作的檢驗Version Slide 20January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”ninspection of corrosion protection systems防腐系統(tǒng)的檢驗nensure functionality of examination or testing equipment and of recording and/or measuring devices vital for correct functio

32、ning of equipment and machinery used in fabrication.確保檢驗設備的可靠性nDue consideration shall be given to the access and the time required for adequate inspection during fabrication.確保留有足夠的檢驗時間和通道nHigh non-conformance rates in execution of the work or in the product itself shall call for special considerat

33、ions. Such special considerations may include, but not be limited to, increased inspection, re-qualification of personnel or other agreed remedial actions.n在建造過程中不按規(guī)定施工人次較多，或產(chǎn)品質量問題較多的情況下，需要采取增加檢驗、對施工人員重新評定以及其它彌補措施NOTE!注意！注意！nInspectors shall be qualified according to a recognized scheme and shall be

34、 able to provide documentation of proficiency.n檢驗人員需要經(jīng)過專門培訓并得到認可Version Slide 21January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”Material Identification, Cutting and Forming 材料識別，切割和成型材料識別，切割和成型 Material identification材料識別材料識別- A traceability system that ensures correct ins

35、tallation and documentation of the material grades or strength classes shall be established by the contractor throughout the prefabrication and installation process.- 建立材料跟蹤系統(tǒng)確保正確使用材料，記錄材料：材質、等級- Proper care shall be exercised during handling and storage to preserve identification of such material.

36、- 材料識別和跟蹤應貫穿下料、運輸、儲存等全過程Version Slide 22January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”Cutting and forming.- The effect of work hardening shall be considered if shearing is used for cutting of material. Special attention shall be paid to the risk of cracked edges.材料剪切后邊緣會

37、產(chǎn)生硬化和裂紋，要特別注意- Attention shall be paid to excessive local hardening and carbon contaminations by thermal cutting. This may be reduced by suitable heat treatment or removed by mechanical means.- 通過熱工切割可能產(chǎn)生的局部硬化和滲碳，可以通過熱處理和機械方法消除- Forming and straightening of materials shall be performed according to

38、agreed procedures. Such work shall be controlled by the contractor.- 成型和校平工藝需要得到認可，并得到有效控制- The degree of cold deformation of special and primary structural elements shall be less than 5%. If the deformation exceeds 5%, either heat treatment or strain ageing tests shall be carried out according to a

39、n agreed procedure.- 主體結構和特殊結構的冷變形大于5時，要通過認可的熱處理方法校正Version Slide 23January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”Tolerances公差nAllowable fabrication tolerances shall be submitted to the purchaser for acceptance.規(guī)定公差需得到船東認可nSpecial considerations shall be given in providi

40、ng proper alignment of structural members. Allowable fabrication tolerances shall be established on basis of due consideration to the criticality of the design.特別要注意結構對中問題nThe maximum fabrication tolerances may generally be taken in compliance with IACS Shipbuilding and Repair Quality Standard Part

41、A Sec.6 and Sec.7.n建造工程可參照國際船級社的標準Part A Sec.6 and Sec.7NOTE! 注意注意nStraightness of members which are based on buckling calculations according to DNV-RP-C201 and/or DNV-RPC202 shall be within the tolerances given in Table E3.結構的直線度參照DNV-RP-C201 and/or DNV-RPC202 的E3表格n106 Alignments of the non-contin

42、uous plates in cruciform joints and butt welds shall be within the tolerances given inFig.1, Table E1 and Table E2.n非連續(xù)構件的對中參照以下E1（非連續(xù)）,E2（連續(xù)對接）表格的標準Version Slide 24January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”表E1表示十字接頭，依次分別為：特殊結構、重要結構和次要結構的錯位表E2表示對接接頭，依次分別為：特殊結構、重要結構和次

43、要結構的錯位Version Slide 25January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”Version Slide 26January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”Assembly, Welding, Heat treatment and RepairsAssembly and Welding.裝配和電焊裝配和電焊nAssembly and welding operations sha

44、ll be carried out by qualified personnel and supervision.裝配工和電焊工都必須持證裝配工和電焊工都必須持證nA fabrication sequence shall be established to ensure that the structure can be assembled in a manner which allows for effective control at all stages of work.為了對整個工程進行有效控制，必須編制建造次序nFit-up, preparation for welding and

45、welding operations shall take place in accordance with procedures accepted by the purchaser.n裝配、焊前準備工作、焊接都必須按認可的工藝進行nThe welding sequence shall be such that the amount of shrinkage, distortions and residual stresses are minimized. 焊接順序要有利于焊接變形和殘余應力的最小化焊接順序要有利于焊接變形和殘余應力的最小化Version Slide 27January 22,

46、 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”nThe fit-up shall be checked for dimensional accuracy before welding. Surfaces to be welded shall be free from mill scale, slag, rust, grease, paint etc. Edges are to have a smooth and uniform surface. No welding shall be performed when

47、 the surfaces are damp. Suitable protection shall be arranged when welding is performed during inclement weather conditions. The groove shall be dry at the time of welding.n焊接前必須檢驗裝配的準確性。焊接區(qū)域必須清除氧化皮、熔渣、鐵銹、油漬、油漆等。板縫必須保證平直。嚴禁在潮濕的板縫上焊接，焊縫必須保持干燥。天氣惡劣的情況下，焊接前要采取適當?shù)姆雷o措施。nPreheating shall preferably be per

48、formed with electric heating elements. Gas burners may be used under controlled conditions. Cutting torches should not be used.當板縫需要加熱時，最好使用電加熱。烘槍的使用必須在嚴格控制下進行。嚴禁使用割刀加熱。nFor welds of structural category special, primary and butt-welds in secondary structural elements a WPS shall be established for a

49、cceptance by the purchaser.主體結構、重要結構焊接的焊接工藝以及次要構件的對接縫的焊接工藝必須得到船東的認可。Version Slide 28January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”nGuidance note:nThe weld connection between two components shall be assigned the structural category area equal to the higher category of the

50、 joined components. For stiffened plates not classified as structural category special, the weld connection between stiffener and stringer and girder web to plate may normally be assigned structural category secondary.兩個構件焊接時，按照較高等級的材料的焊接要求進行。非重要構件的扶強材的焊接、平臺扶強材的焊接、桁材扶強材的焊接、扶強材之間的焊接都可以按照次要構件的焊接要求進行。n

51、Tack welding shall, when integrated in production welding, be qualified. For welds specified in 112 a WPS shall be submitted to the purchaser for acceptance.n定位焊作為結構焊的一部分時，點焊工或焊工必須持證。對于112項規(guī)定的焊接，焊接工藝需要得到船東的認可。nAll fabrication welding shall be performed within the limits of essential variables of the

52、 qualified welding procedure. This also includes tack welding, seal welding, welding of lifting lugs and attachment welds as well as repair welding.n所有的焊接都不能超過認可的焊接工藝范圍。這包括：定位焊、蓋面、吊耳和其它附件的焊接以及電焊修補工作。Version Slide 29January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”nWhen resu

53、ming welding on partially filled joints in special areas, preheating shall be performed and the temperature within the specified tolerances, shall if not otherwise agreed, be equal to the interpass temperature for the welding pass in question.n在多道焊焊縫未一次性焊完的情況下，繼續(xù)施焊前需要按要求對焊縫進行加熱。加熱溫度要符合規(guī)定要求或等同于同類焊縫的層

54、間溫度。nGrooves produced by gouging shall be followed by grinding removing carbonized material and the groove shall be dressed to a shape consistent with tolerances in agreement with the purchaser.n碳刨坡口要用打磨的方法去除滲碳層，坡口成型的公差范圍也要得到船東的認可。nWelding consumables shall be classified with respect to strength , a

55、pplication area and hydrogen level according to recognized scheme.n焊材的使用要按照規(guī)范，符合強度、焊接位置的要求，氫含量也要符合相應的要求。Version Slide 30January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”nRecycling of fluxes for submerged-arc welding shall be performed in a manner that ensures a mixture of n

56、ew and used flux with continually homogenous properties.n焊劑的回收利用以及新老焊接的混合使用要保證焊劑的純度。nWelds shall be terminated in a manner that will ensure sound welds without end-craters. Extension bars and run-off plates shall be removed upon completion and cooling of the weld. The end of the weld shall be made s

57、mooth and flush with the edges of abutting parts.n起弧和息弧分別要使用，確保兩端沒有弧坑，引弧板和息弧板在焊縫冷卻后去除。端頭電焊要光順，與板邊保持平直。n121 Grinding of welds with the intention of increasing the fatigue life and/or reducing the probability of brittle fracture shall be carried out according to agreed specifications.n用打磨的方法來提高焊縫的疲勞壽命

58、或者消除裂紋要符合規(guī)范。Version Slide 31January 22, 2022DNV-OS-C401”Fabrication and Testing of Offshore Structures”nStorage and handling of welding consumables shall be in accordance with the manufacturers recommendations, and in accordance with procedures giving details regarding conditions in storage rooms, t

59、emperature in storage ovens and quivers, length of exposure and conditions, as applicable.n焊材的使用和保存都要得到船東認可，包括：儲存室的條件、烘箱、焊條筒的溫度等。nWelding production tests shall be made during fabrication of welds in special areas and in primary structural elements to verify that the produced welds are of acceptable

60、 quality. Minimum one test coupon is required from each applied welding process.n主體結構和重要結構的焊接要通過同等環(huán)境下的試驗來驗證其可靠性，每種結構至少做一個試驗。nImportant welding operations shall be carried out under daily supervision of an inspector, who has the experience and qualifications, which enable him to judge this type of wo