(設備管理)船舶艙室設備底座焊接工藝規(guī)范

1、船舶艙室設備底座焊接工藝規(guī)范WELDINGPROCEDURESPECIFICATIONFOREQUIPMENTBASEOFHULLCABIN范圍Scope本規(guī)范規(guī)定了船舶艙室重要設備底座焊接與普通設備底座焊接施工前的準備、人員、工藝要求、工藝過程、檢驗。Thespecificationrulestherequirementsofforeweldingtopreparation,personnel,technrequirements,technologyprocess,examination;whichareforbaseofimportantequipmentsandcommonequipme

2、ntsofhullcabin.本規(guī)范適用于各類船舶艙室設備底座的焊接。Thespecificationapplytotheweldingforequipmentbaseofdiversifiedhullcabin.規(guī)范引用文件船舶建造質量檢驗ReferringtodocumentWQUALITYINSPECTIONOFSHIPBUILDING三焊接前準備PreparationofforeweldingCJ422鈦鈣型藥皮碳鋼焊條參數(shù)(CJ422parametersforCsteelelectrodeofTiandCacovering)表3.1-1(form)試驗項目（丁$土project）5s

3、(Mpa)5b(Mpa)55(%)AKV(-20)J三330三420三22三47X射線探傷(Radiographicinspection):II級(Gradetwo)焊條直徑（MM）Diameter2.53.245焊接電流(A)Current601101201501602102202703.2CJ507低氫鈉藥皮碳鋼焊條參數(shù)(CJ422parametersforCsteelelectrodeoflowhydrogenNacovering)表3.2-1(form)試驗項目（丁$土project）5s(Mpa)5b(Mpa)55(%)AKV(-20)J(-30)三400三490三22三47三27X

4、射線探傷(Radiographicinspection)II級(Gradetwo)焊條直徑(MM)Diameter2.53.2455.8焊接電流(A)Current60110120150160210220270210260焊前施工人員應先了解被焊工件的施工要求及作業(yè)環(huán)境、鋼材牌號等級、據(jù)此按材料的選配原則確定焊條焊絲牌號、規(guī)格及極性。Weldershouldknowabouttheweldingrequirements,environment,brandandgrandofsteelbeforewelding.Accordingtothat,todecidethebrand,sizeofele

5、ctrodeandwireandpolarityontheprincipleofchoosingmaterial.定位焊Tackwelding定位焊用的焊條牌號應與正式焊縫的焊條牌號相同。Electrodebrandfortackweldingshallbeuniformwithnormalwelds.定位焊高度不得超過正式焊縫的高度，焊后的熔渣應立即去除。Theheightoftackweldingdontexceednormalwelds,eliminatingpostweldslagatonce.由于CO2定位焊容易產(chǎn)生焊接缺陷，定位焊縫不宜過短，一般強度鋼為（3040）mm,高強度鋼為

6、50mm，焊縫厚為（34）mm。ThelengthoftackweldsshallbelongerbecauseofmakingdefectseasilywithCO2gas-shieldedarcwelding.Commonstrengthsteel（3040）mm,highstrengthsteel50mm,thicknessofwelds（34）mm.所要焊接的設備底座已經(jīng)按照裝配要求定位好，并且打磨焊前認可才能進入焊接階段。Equipmentbasetobeweldedmustbefittedonrequirementslikeandgrinded,beforeitwelded.對于船

7、舶重大設備如主機、發(fā)電機、中間軸承、錨絞車、舵機及主甲板設備吊艇、舷梯等基座應選用CJ507低氫鈉型藥皮碳鋼焊條或CO2氣體保護焊。Forthegrandshipequipmentweldingofbaseofmainengine,generator,intermediatebearing,windlass,steeringgear,anddavit,accommodationladderwhichisonthemaindeck;shouldchooseCJ507lowhydrogenNacoatingCsteelelectrodeorCO2gas-shieldedarcwelding.其他普

8、通設備基座可選用普通的CJ422鈦鈣型藥皮碳鋼焊條。MaychoosecommonCJ422CsteelelectrodeofTiandCacoveringforothercommonequipmentbase.焊接材料Weldingconsumable焊絲：WeldingwireCO2焊絲可選用直徑為（01.2）mm的實芯焊絲或藥芯焊絲，并須經(jīng)船級社認可。并有規(guī)則地盤繞在焊絲盤或焊絲筒內(nèi)。Diameter1.2mmflux-coredwirewillbeusedforCO2gas-shieldedarcweldingandneedbeapprovedbySociety.CO2氣體：CO2ga

9、s使用的液體二氧化碳其質量應符合國家標準GB6052-85工業(yè)液體二氧化碳中規(guī)定的I類或H類一級標準ThequalityofliquidCO2usedshallaccordwithgradeoneoftypeIorIIruledbynationalstandardGB6052-85WIndustryliquidCO2三CO2氣瓶壓力低于1MPa時不能使用。Dontuseitagainwhencylinderpressureisbelow1Mpa.焊接設備WeldingequipmentCO2氣體保護焊焊接設備應采用設備制造廠生產(chǎn)的專用設備，并應定期進行嚴格的檢測與維修。ForCO2gas-sh

10、ieldedarcweldingusethespecialequipmentthatneedbeexaminedandmaintainedcarefullyeverytime.CO2焊接電源必須具備必要的電流容量及適合于焊接的電氣特性，并應有可靠的外殼安全接地。WeldingpowersourceforCO2gas-shieldedarcweldingmusthavenecessarycurrentvolumeandelectriccharacteristicsuitableforwelding.Itmusthavereliablesafegroundingforcrust.送絲機構的控制裝置

11、，必須具備與焊接電源輸出特性相應的控制機能，必須能均勻地調(diào)節(jié)焊接電流或電弧電壓。Controllingdeviceofwirefeedermusthavecorrespondingcontrollingfunctionaswiththeinputcharacteristicofweldingpowersource,rugulatecurrentandvoltageuniformly.焊槍必須具備必要的電流容量及耐用性能，而且還要有良好的操作性能，必須能穩(wěn)定地送絲，焊槍的外殼必須有良好的絕緣性能。Weldinggunmusthavecurrentvolumeandcanbeusedforalon

12、gtime,convenientoperationtowelder,feedingwiresteadily.Crustofweldinggunmusthavebetterinsulatedproperty.人員PersonnelCO2保護焊的焊工必須經(jīng)過專門培訓和考試，并按船級社合格證所規(guī)定之類別從事產(chǎn)品焊接。手工電弧焊焊接的焊工持證方能上崗。WelderforCO2gas-shieldedarcweldingwhomustbespeciallytrainedandexaminedcanbepermittedtoworkonitemsruledincertificateissuedbySoci

13、ety.Welderforcoveredelectrodemanualarcweldingcantworkunlesswithcertificate.工藝要求Technologyrequirement根據(jù)圖紙的要求或者焊工根據(jù)焊接規(guī)范中焊件的厚度等確定設備底座的焊腳尺寸、焊接順序、方式等。Accordingtodrawingrequirementsorthicknessofweldmentwhichisinweldingspecification,sizeofweldingtoe,weldingsequence,weldingmeansetcwhichareforequipmentbasewi

14、llbedecided.焊接規(guī)范中對焊接電流與電弧電壓的匹配要求較高，因此在施焊過程中，若焊接電流發(fā)現(xiàn)變化，應及時調(diào)整電弧電壓，使之處于最佳狀態(tài)。Inthecourseofweldingprocess,adjustvoltageintimetomakethembest,ifweldingcurrentchanged.wedoso,becausethereishigherrequirementstocurrentandvoltage.設備底座上船安裝前應作好防繡漆，底座吊運上船后應妥善放置，并盡快安裝，不宜隨意亂丟，以防遺失、損壞。Antirustcoatingshouldbewell-done

15、onthegroundforequipmentbasetobeinstalled,itshallbeputingoodorderonthehull,installitasquicklyaspossible,avoidlosing,destruction.查看底座所裝區(qū)域的甲板或圍壁是否平整(一般待火工校正后安裝)。Checktheplaceofdeckorhousewallswherethebaseshallbeinstalledwhetheritisflat(installitafterbeingproofreadedbyfire)凡有甲板敷料的艙室其底座要在敷料施工前定位裝焊結束。Base

16、ofthecabinwithdeckcoveringshouldbefittedandweldedcompletelybeforecovering.底座切割后應清除氧化鐵及毛刺等，其焊縫空隙不超過3mm,空隙長度不得超過全長勺10%。Toeliminate-andinclusionafterthebasewascut,theweldsgapshouldntexceed3mm,thelengthofgapshouldntexceed10percentofall.底座高度應符合圖紙要求，甲板上的底座高度允許公差5mm，圍壁上的底座高度允許公差2mm。Heightofbaseshouldaccord

17、withrequirementofthedrawing,thepermittedtoleranceforheightofbaseonthedeckis5mm,thepermittedtoleranceforheightofhousewallsis2mm.坐標位置正確，常規(guī)底座允許公差W5mm。Correctcoordinateposition,thepermittedtoleranceforcommonbasei云5mm.底座面水平，四角不平度1米長度內(nèi)W2mm。Basesideshouldbeplane,planenessamongfourangles:W2mmintherangeofone

18、meter.底座結構方向符合圖紙要求，其底腳最低處必要時須開流水孔。Directionofbasestructureshouldaccordwithdrawingrequirements.Makingaholewhichwillbetodischargewaterifthereisaneedatthelowestplaceofbottomtoe.Technologyprocess安裝程序Installingprocedure劃線一底座就位水平面校正一對角線校正一劃出底腳切割線一切割底座多余部位T去除毛刺一第二次就位一校對水平面、對角線一底座焊裝Drawingline-Baseprimaryfi

19、xing-Proofreadlevel-Proofreaddiagonal-Drawcuttinglineofbottomtoe-Cuttingsuperfluouspartsofbase-Removinginclusions-Formalfixing-ProofreadlevelanddiagonalWeldingofbase手工電弧焊Coveredelectrodemanualarcwelding應按焊接材料保管要求，焊條經(jīng)過焙烘、保溫后保存。每次領出堿性焊條使用不能超過4小時，高強度鋼用焊條須用保溫筒加熱保溫。Electrodeneedbeheatedandkeptwarm,before

20、preserved.Allthethingsshouldbedoneaccordingtostoragerequirementsofweldingconsumable.Alkalineelectrodetakenoutshouldbeusedupwithin4hours,electrodeforhighstrengthsteelneedtobekeptwarmwithkeepingwarmbox.施焊規(guī)范和要求，應嚴格遵照有關工藝文件的規(guī)定，不得隨意更改。Weldingspecificationandrequirementruledbytechnologicaldocumentcouldntr

21、ejiggeroptionally,itshouldbecarriedoutstrictly.薄板焊接，焊前應采取一定的預防變形的工藝措施。Beforewelding,technologymeasuresofpreventingdeformationshouldbetakenforslightplate.應根據(jù)板厚和施焊工藝位置來決定其直徑，第1、2道打底焊縫最好采用“3.2、4焊條，打底焊縫不宜過薄。Accordingtoplatethicknessandweldingpositiontochooseelectrodediameter,03.2,04arethebestchoiceforth

22、efirstandthesecondrunofbottomweld,bottomweldsshouldbefilledmore.采用多層焊時，每層焊道的始末端應交錯(3050)mm。Formultilayerwelding,thereisa30-50mmdistanceofstartandendbetweenrunweldedandtheruntobewelded.多層焊時，必須清除前一道焊縫的焊渣和金屬飛濺，修補結束后才可施焊下一層。Mustremovetheslagandspatterofthelastlayerandrepairit,andthentoweldnextlayer.對高強度

23、、高拘束管節(jié)點采用手工電弧多層焊時，應考慮在焊縫的最表面一層，施以小直徑低線能量的退火焊道以提高抗低周疲勞強度。Annealingrunthatimproveresistingfatiguestrengthwillbeoperatedonthetoplayerofweldswithlowdiameterlowenergyinput,whenweldbuttjointofpipesforhighstrengthandlimitwithCoveredelectrodemanualarcwelding.焊縫末端收口處應填滿弧坑，以防止產(chǎn)生弧坑裂紋。Endcratershouldbefilledful

24、lyinordertopreventproducingcratercracking.在去除臨時焊縫、定位焊縫、缺陷、焊疤和清根時，均不得損傷母材。Dontdestroybasemetal,whenremovetemporarywelds,tackwelds,defects,overlapsandgouging.CO2氣體保護焊CO2gas-shieldedarcwelding在焊接部位清除水份，鐵銹，氧化皮，油污等雜物。Removingwater,rust,oxidation,oilandotherinclusions.檢驗確認焊機及其附屬設備以及供氣系統(tǒng)都能正常工作。Checkingweld

25、ingmachineanditssubsidiaryequipment,thesystemofsupplygas,whethertheycandowell.在更換焊機的主要部件后必須檢驗并確認焊機能在使用的焊接條件下正常工作。Mustcheckandconfirmthatweldingmachinecanworknormallyontheconditionofwelding,aftermajorcomponentwillbechanged.噴嘴必須經(jīng)常清理，導電嘴亦須經(jīng)常更換。在焊接過程中要避免焊槍軟管過渡彎曲。Nozzlemustbecleaned,contactnozzlemustofte

26、nchangedtoo.Wireconduitshouldavoidbeingbent.由于風對氣體的保護效果危害較大，室外焊接施工時在風速超過2m/sec環(huán)境下使用時，應采取相應的防風措施。Takecorrespondingprotectivemeasure,ifwindspeedexceeds2m/secoutsidewhenwelding.6.3.6焊縫的起端和終端容易出現(xiàn)缺陷，因此施工時必須特別注意。Paymuchattentiontothestartandendofwelds,wheredefectscomeintobeingeasily.焊前按工藝規(guī)范要求調(diào)節(jié)焊接規(guī)范，達到要求后，

27、開始焊接。Atfirst,regulateweldingspecificationbytherequirementsofweldingprocedure,andthentoweld.CO2氣體保護焊操作要領OperationitemsforCO2gas-shieldedarcwelding.焊接中，焊槍角度后仰1520，焊絲伸出長度為（1015）mm。Theangleofgunis1520backwards,dryextensionofwireis1015mm.當采用橫向擺動運條方法時，擺動幅度稍大于根部間隙或前一層焊縫兩趾端，并略作停頓，以保證根部及兩趾間熔透。Whentaketransve

28、rseswingmovingwire,thewidthofswingrangeislittlebiggerthangapofrootorthewidthoflayer,stoppingalittletimethere,inordertomakesurethepenetrationofrootandedges.中途熄弧時，必須用砂輪將弧坑打磨成圓滑過渡，再引弧繼續(xù)焊接。當焊縫與定位焊相接時，必須將定位焊去除，然后再引弧焊接。Ifyouwanttocontinuetoweldfromthepositionwhereyoustopwelding,mustgrindthecratermakingitp

29、liable.Whenweldsmeettackwelds,removetackweldsandthentoignite.安全衛(wèi)生Safetyandprotecting焊接操作者必須使用面罩、安全帽、皮手套等遮光保護用具，防止灼傷和燙傷。Topreventburning,weldermustuseprotectivethings,suchas:veil,cap,leathernglovesetc.工作中，應注意周圍環(huán)境是否有易燃易爆物品，以防止飛濺引起的火災事故。Spattercouldcausefire,sohavetocheckwhethertherearesomethingthatwillbeburningandexplodingeas