xxx石化项目xxx罐区碳钢储罐工程焊接工艺评定报告及指导书PQRWPS

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1、 xxx石化项目xxx罐区碳钢储罐工程焊接工艺评定报告及指导书PQR&WPS目 录1概述 General22储罐一览表Basic Date Sheet of The Steel Plate23焊接工艺评定报告PQR44焊接工艺指导书WPS55附表Attach7 1 概述 General本程序制定了所有xxx石化项目xxx罐区碳钢储罐的焊接工艺评定报告及焊接工艺指导书。 This procedure covers Welding Procedure Specification(WPS) and Procedure Qualification Reports(PQR) applyed in Xxx

2、 Petrochemical XxxProduct Carbon Steel Tank Project.本程序适用于xxxxxx石化项目xxx罐区碳钢储罐焊接。The procedure is applicably adopted to conduct the welding of Xxx Peterochemical XxxProduct Tank.2 储罐一览表Basic Date Sheet of The Steel Plate 序号Serial No.储罐编号Storage tank item No.储罐名称Storage tank name储罐直径与高度（m）Storage tank

3、 Diameter and Height(m)材质Material 底板 Bottom Plate顶板Roof Plate(mm)壁板 Shell Plate边缘板Annular Plate(mm)中幅板 Medium Plate(mm)Q235-B(mm)16MnR(mm)1451废液罐SLOP6x9Q235-Bt=10Q235-Bt=10Q235-AT=8Q235-Bt=682452废液罐SLOP6x9Q235-Bt=10Q235-Bt=10Q235-AT=8Q235-Bt=683453废液罐SLOP 6x9Q235-Bt=10Q235-Bt=10Q235-AT=8Q235-Bt=6844

4、54废液罐SLOP6x9Q235-Bt=10Q235-Bt=10Q235-AT=8Q235-Bt=685901A纯碱储罐Sodium carbonate tank16x15Q235-Bt=12Q235-Bt=10Q235-AT=5.5Q235-Bt=8166901B纯碱储罐Sodium carbonate tank16x15Q235-Bt=12Q235-Bt=10Q235-AT=5.5Q235-Bt=8167551废烧碱储罐Waste caustic soda tank14x14.3Q235-Bt=12Q235-Bt=10Q235-AT=5.5Q235-Bt=812895093%硫酸储罐93%

5、 sulfuric acid tank8x10Q235-Bt=14Q235-Bt=14Q235-AT=5.5Q235-Bt=10149411苯乙烯残余物储罐EB/SM/Residus8x9Q235-Bt=9Q235-Bt=9Q235-AT=5.5Q235-Bt=6810415热油储罐Hot oil 12.5x12Q235-Bt=10Q235-Bt=8Q235-AT=5.5Q235-Bt=61011417环氧丙烷废液储罐SM/PO Slops6x8Q235-Bt=10Q235-Bt=10Q235-AT=5.5Q235-Bt=6812418燃料油储罐Fuel oil 8x12Q235-Bt=9Q2

6、35-Bt=9Q235-AT=5.5Q235-Bt=6813412A污水储罐Aqueous Effluent20x16Q235-Bt=12Q235-Bt=10Q235-AT=8Q235-Bt=81614412B污水储罐Aqueous Effluent20x16Q235-Bt=12Q235-Bt=10Q235-AT=8Q235-Bt=81615412C污水储罐Aqueous Effluent20x16Q235-Bt=12Q235-Bt=10Q235-AT=8Q235-Bt=81616413碳酸盐溶液储罐Carbonate Slurry6x9Q235-Bt=10Q235-Bt=10Q235-AT=

7、8Q235-Bt=6817423碱液储罐Caustic6x5Q235-Bt=10Q235-Bt=10Q235-AT=8Q235-Bt=681820一乙醇储罐MEG-Storge25x22Q235-Bt=10Q235-Bt=8Q235-AT=5.5Q235-Bt=681921一乙醇储罐MEG-Storge25x22Q235-Bt=10Q235-Bt=8Q235-AT=5.5Q235-Bt=682022二乙二醇储罐DEG Stroage12.5x10Q235-Bt=10Q235-Bt=8Q235-AT=5.5Q235-Bt=682123二乙二醇储罐DEG Stroage12.5x10Q235-Bt

8、=10Q235-Bt=8Q235-AT=5.5Q235-Bt=682224三乙二醇储罐TEG Stroage6x7Q235-Bt=8Q235-Bt=8Q235-AT=5.5Q235-Bt=6823801MPG产品储罐MPG product 15x13Q235-Bt=12Q235-Bt=10Q235-AT=5.5Q235-Bt=61024802MPG产品储罐MPG product 15x13Q235-Bt=12Q235-Bt=10Q235-AT=5.5Q235-Bt=61025803MPG产品储罐MPG product 15x13Q235-Bt=12Q235-Bt=10Q235-AT=5.5Q2

9、35-Bt=61026805DPG产品储罐DPG product 8x6Q235-Bt=8Q235-Bt=8Q235-AT=5.5Q235-Bt=6827806DPG产品储罐DPG product8x6Q235-Bt=8Q235-Bt=8Q235-AT=5.5Q235-Bt=6828410苯乙酮储罐MPK Feed20x12Q235-BT=10Q235-BT=8Q235-AT=5.5Q235-BT=81229422A苯乙醇储罐Crude MPC/MPK22x2116MnRT=10Q235-BT=8Q235-AT=5.5Q235-Bt=816MnRT=81430422B苯乙醇储罐Crude MP

10、C/MPK22x2116MnRT=10Q235-BT=8Q235-AT=5.5Q235-Bt=816MnRT=81431403粗环氧丙烷储罐 Crude PO15x15Q235-BT=10Q235-BT=8Q235-AT=5.5Q235-BT=61032407苯乙烯成品储罐Crude SM15x15Q235-BT=12Q235-BT=10Q235-AT=5.5Q235-BT=61233408苯乙烯成品储罐Finished Styrol 15x15Q235-BT=12Q235-BT=10Q235-AT=5.5Q235-BT=61034409苯乙烯成品储罐Finished Styrol15x15Q

11、235-BT=12Q235-BT=10Q235-AT=5.5Q235-BT=61035401A乙苯进料储罐EB Feed Rundown22.5x2416MnRt=10Q235-BT=8Q235-AT=5.5Q235-Bt=816MnRt=81836401B乙苯进料储罐EB Feed Rundown22.5x2416MnRt=10Q235-BT=8Q235-AT=5.5Q235-Bt=816MnRt=81837402循环乙苯储罐Recycle EB20x18Q235-BT=12Q235-BT=10Q235-AT=5.5Q235-Bt=81438406苯乙醇储罐EB/PMC/PMK20x2216

12、MnRT=12Q235-BT=10Q235-AT=5.5Q235-BT=816MnRT=81439419多乙苯残余物储罐PEB Reside8x6Q235-BT=8Q235-BT=8Q235-AT=5.5Q235-Bt=6840421乙醇停留储罐EB Hold-Up12.5x9Q235-BT=8Q235-BT=8Q235-AT=5.5Q235-Bt=6841961轻凝析油储罐Lightcondensate day20x2016MnRT=10Q235-BT=8无Q235-BT=816MnRT=81242962轻凝析油储罐Lightcondensate day20x2016MnRT=10Q235-

13、BT=8无Q235-BT=816MnRT=81243963重凝析油储罐Heavcondensate day20x2016MnRT=10Q235-BT=8无Q235-BT=816MnRT=81244964重凝析油储罐Heavcondensate day20x2016MnRT=10Q235-BT=8无Q235-BT=816MnRT=81245965LCCCO储罐LCCCO storage 10x14Q235-BT=8Q235-BT=8Q235-AT=5.5Q235-BT=6846966粗5储罐Untreated C5 storage 12.5x14Q235-BT=8Q235-BT=8Q235-AT

14、=5.5Q235-BT=6847967粗C6储罐Untreated C6 storage20x2016MnRT=10Q235-BT=8Q235-AT=5.516MnRT=81248968粗汽油储罐Naphtha tank25x2216MnRT=10Q235-BT=8Q235-AT=5.5Q235-BT=816MnRT=81649970回收乙腈储罐CAN Recycle8x1116MnRT=10Q235-BT=8Q235-AT=5.5Q235-BT=816MnRT=81650971新鲜乙腈储罐Fresh ACN6x5Q235-BT=8Q235-BT=8Q235-AT=5.5Q235-BT=685

15、1974乙腈溶剂储罐ACN solventDrips8x5Q235-BT=8Q235-BT=8Q235-AT=5.5Q235-BT=685210车用汽油储罐Mogas25x2216MnRT=10Q235-BT=8Q235-AT=5.516MnRT=8145311车用汽油储罐Mogas25x2216MnRT=10Q235-BT=8Q235-AT=5.516MnRT=8145430苯罐Benzene Storage27.5x2216MnRT=10Q235-BT=8Q235-AT=5.516MnRT=8165531苯罐Benzene Storage27.5x2216MnRT=10Q235-BT=8Q

16、235-AT=5.516MnRT=8165640乙烯-1储罐Hexene-1 20x1816MnRT=10Q235-BT=8Q235-AT=5.516MnRT=8125716苯乙烯储罐Styrene storage tank36x2216MnRT=12Q235-BT=8Q235-AT=5.516MnRT=8225817苯乙烯储罐Styrene storage tank36x2216MnRT=12Q235-BT=8Q235-AT=5.516MnRT=8222 焊接工艺评定报告 Procedure Qualification Report (PQR)2.1 焊接工艺评定报告编号 Welding p

17、rocedure qualification report numbering2.1.1 CC-PQR-003材质16MnR =12mmMaterial焊接材料：J507Welding material焊接方法：SMAW Welding method 2.1.2 CC-PQR-004材质16MnR =12mmMaterial焊接材料：H08Mn2SiAWelding material焊接方法：GMAW Welding method 2.1.3 CC-PQR-005材质Q235-B =10mm Material焊接材料：J427 Welding material焊接方法：SMAW welding

18、 method2.1.4 CC-PQR-006材质Q235-B =10mmMaterial焊接材料：H08Mn2SiAWelding material焊接方法：GMAW Welding method3 焊接工艺指导书WPS Welding Procedure Specification3.1 焊接工艺评定指导书编号Welding procedure specification numbering3.1.1 CC-P1-A-Lh-01lue注：以下的WPS编号与上述内容相同。Note: unbering method of following WPS is same as description

19、 above.材质16MnR Material适用厚度范围t24mmApplicable range焊接材料：J507Welding material焊接方法：SMAWWelding method支持此焊接工艺指导书的焊接工艺评定报告为CC-PQR-003 This WPS is supported by PQR CC-PQR-003.3.1.2 CC-P1-A-Lh-02材质16MnR Material适用厚度范围t24mmApplicable range焊接材料：H08Mn2SiAWelding Material焊接方法：GMAWWelding method支持此焊接工艺指导书的焊接工艺评

20、定报告为CC-PQR-004 This WPS is supported by PQR CC-PQR-0043.1.3 CC-P1-A-Lh-03材质Q235-BMaterial适用厚度范围t20mmApllicable range焊接材料：J427Welding material焊接方法：SMAWWelding method支持此焊接工艺指导书的焊接工艺评定报告为CC-PQR-005 This WPS is supported by PQR CC-PQR-0053.1.4 CC-P1-A-Lh-04材质Q235-BMaterial适用厚度范围t20mmApplicable range焊接材料

21、: H08Mn2SiAWeldign material焊接方法：GMAWWelding method 支持此焊接工艺指导书的焊接工艺评定报告为CC-PQR-006 This WPS is supported by PQR CC-PQR-0064 附表 Attachment4.1 焊接工艺评定报告及焊接工艺指导书PQR&WPSWelding Procedure Specification and Welding Procedure Quailfication Report4.2 试板材质质量证明书Qualification certificate of test pieces4.3 焊材质量证明

22、书Qualification cerficates of welding materialcc公司Cc Petrochemical Engineering Corporation焊 接 工 艺 评 定welding procedure qualification编 号: CC-PQR-003Serial number: CC-PQR-003 编 制: xxx Compiled by: Xxx 审 核: xxx Verified by： Xxx 批 准： xxx Approved by: Xxxg 目 录Table of contents一、焊接工艺评定报告(PQR) （共4页）welding

23、procedure qualification report (PQR)(4 pages in total)二、检验报告 （共5页）Inspection report (5pages in total)焊 接 工 艺 评 定 报 告（PQR）Welding Procedure Qualification Report (PQR)单位名称: cc公司 （CC） Name of the unit: Cc Petrochemical Engineering Corporation (CC) 焊接工艺评定报告编号: CC-PQR-003 焊接工艺指导书编号: CC-P1-A-Lh-01 Serial

24、No. of the welding procedures qualification report: CC-PQR-003 Serial No. of the welding procedure specification: CC-P1-A-Lh-01 焊接方法: SMAW 机械化程度: (手工、半自动、自动) 手工 Welding method: SMAW Degree of mechanization: (manual, semiautomatic or automatic) manual 接头简图: (坡口形式、尺寸、衬垫、每种焊接方法或焊接工艺、焊缝金属厚度)0.81.56551.5

25、2.512Schematic of a weld joint: (form of welding groove, dimensions, liner, every welding method and welding procedure, and thickness of weld metal)母材Base metal：材料标准: GB6654-86 Material standard: GB6654-86 钢号: 16MnR Steel grade: 16MnR 类、组别号: -1 (GB) / P1-2(ASME) 与Class/group number: II-1(GB) / P1-2

26、(ASME) and类、组别号: -1 (GB) / P1-12(ASME) 相焊Class/group number: II-1(GB) / P1-2 (ASME) are welded together厚度Thickness: 12mm 直径Diameter: 其他Miscellaneous: 焊后热处理Post-weld heat treatment:热处理温度 (): / Heat treatment temperature () / 保温时间 (h): / Holding time (h) / 保护气体Protective gas:气体 混合比 流量(L/min)gas Mixing

27、 ratio Flow (L/min)保护气体: _ Protective gas尾部保护气: _ _ _Tail protective gas背面保护气: _ Rear protective gas填充金属Filler metal:焊材标准: GB/T5117-95 Standard of the weld material: GB/T5117-95 焊材牌号: E5015（J507 ） Brand of the weld material: E5015（J507 ） 焊材规格: 3.2mm ; 4.0mm Specification of the weld material: 3.2mm

28、; 4.0mm 焊缝金属厚度: 12mm Thickness of the weld metal: 12mm 焊材烘干温度: 350400 烘干时间: 12小时 Baking temperature of the weld material: 350400Time of constant temperature: 12 hours 其他Miscellaneous: / 电特性Electrical properties:电流种类: 直流 Type of electric current: direct current 极性: 反接 Polarity: reverse connection 钨极尺

29、寸: / Dimensions of the tungsten electrode: / 焊接电流(A) :3.2 ：80120；4.0：120150 Welding current (A) : 3.2 ：80120；4.0：120150 电弧电压(V): 2230 Arc voltage (V): 2230 其他Miscellaneous: _/_ _ 焊接位置Position of weld:对接焊缝位置: 水平 方向: (向上、向下)Position of butt welds: horizontal Direction: (upward, downward)角焊缝位置: _方向: (向

30、上、向下)Position of fillet welds: _Direction: (upward, downward)预热Preheating:预热温度() : / Preheating temperature () : / 层间温度() : / Interlayer temperature () : / 其他Miscellaneous: _/ _ 技术措施Technical measures:焊接速度 (cm/min): 612 Welding speed (cm/min): 612 摆动或不摆动: 摆动 Oscillatory or non-oscillatory: oscillato

31、ry 摆动参数: 微摆 Oscillatory parameters: slightly oscillatory 多道焊或单道焊(每面): 单道焊 Multi-pass or single-pass welding (each side): single-pass welding多丝焊或单丝焊: / Multi-wire or single-wire welding: / 其他Miscellaneous: _/_ 拉 伸 试 验Tensile test 试验报告编号Serial No. of the test report: LH-03-003-1 试样编号Sample No试样宽度Sampl

32、e width (mm)试样厚度Sample thickness (mm)横截面积Cross sectional area (mm2)断裂载荷Breaking load (KN)抗拉强度Tensile strength (MPa)断裂部位和特征Position of fracture and fracture characteristics1-125.112.2306.22160.1523断于母材Fractured at the weld1-224.911.8293.8160.0541断于母材Fractured at the weld 弯曲试验Bending test 试验报告编号Serial

33、 No. of the test report: LH-03-003 -1 试样编号Sample No.试样类型Sample type试样厚度Sample thickness(mm)弯心直径Bend diameter(mm)弯曲角度Bend angle( )试验结果Test result2-1面弯Front-bent1040180合格Qualified2-2背弯Back-bent1040180合格Qualified2-3面弯Front-bent1040180合格Qualified2-4背弯Back-bent1040180合格Qualified 冲击试验Impact test 试验报告编号Ser

34、ial No. of the test report: LH-03-003-2 试样编号Sample No.试样尺寸Sample dimensions缺口类型Notch type缺口位置Notch position试验温度Test temperature ( )冲击吸收功Impact absorption work ( J )备 注Remark焊缝中心center of weld98848889.3平均值average value热影响区Heat affected zone46406550.3平均值average value金相检验（角焊缝）：Metallographic examinatio

35、n (fillet weld):根部：（焊透、未焊透）_ 焊缝：（熔合、未熔合）_Root: (penetratively or non-penetratively welded)_ Weld: (fused or not fused)_ _焊缝、热影响区：（有裂纹、无裂纹）_。 Weld and heat-affected zone: (with or without cracks)_ _检 验 截 面Inspection cross section焊脚差Wed leg difference（mm）无损检验Nondestructive examinationRT： 合格 Qualified

36、UT：_MT：_ PT：_其他 Miscellaneous _耐蚀堆焊金属化学成分（重量%）Chemical composition of the corrosion-proof built-up welding metal (percent by weight)CSiMnPSCrNiMoVTiNb分析表面或取样开始表面至熔合线的距离（mm）：_Distance between the analyzed surface or the face from which sampling starts, and the weld junction (mm):_ _附加说明Additive expla

37、nation：结论：本评定按 JB4708-2000、ASME（） 规定焊接试件、检验试样，测定性能，确认试验记录正确 Conclusion: the welding, inspection and performance testing of the sample were carried out according to the stipulations of the JB4708-2000 and ASME () standards. It has been verified that the record of the test is correct.评定结果： 合 格 Qualifi

38、cation result: Qualified 焊工姓名Welder namexxxXxx焊工代号Welder code390施焊日期Date of weld2004-3-09编制Compiled byxxx日期Date2004-3-18审核Verified byxxx日期Date2004-3-18批准Approved byxxx日期Date2004-3-18cc公司射线探伤报告Cc Petrochemical Engineering Corporation Ray Detection Report SH3505 J729C-2工 程 名 称Project name焊接工艺评定Welding

39、 procedure qualification检件名称Name of the test piece板材对接焊缝试件Metallic plate butt weld test piece工件Work piece委托单位Entrustment unit焊接技术培训中心Welding technology training center检件编号Serial No. of the test pieceCC-PQR-003材质Material composition16MnR规格Specification=12mm检测条件及工艺参数源 种 类Type of the radioactive source

40、X射线X-ray设备型号Equipment modelXXQ2005X光机XXQ2005X X-ray machine焦点尺寸Dimensions of the focal point1.5x1.5胶片牌号Brand of the film天津GYX TianjinGYX胶片规格Specification of the film300x80增感方式Mode of sensibility increasePb0.03 Pb back and forth 0.03冲片条件Condition for film rinsing涤箱手工Wash tank, manual显影液配方Formula of t

41、he eveloper厂家推荐配方Formula recommended by the manufacturer显影温度Developing temperature202显影时间Developing time5 min照相质量等级Quality grade of the photosAB级底片黑度Photographic blackness1.2-3.5透照方式Mode of transillumination垂直透照Vertical transillumination管电流Tube current5mA象质计型号Model of the image quality meterFe16/10

42、焊缝长度Weld length (mm)L1(mm)Leff（mm）象质指数Image quality index (Z)管电压Tube voltage（KV）曝光时间Exposure time (min)280585260131403焊缝编号Serial No. of the weldCC-PQR-003焊口总数Total number of craters1应照总数Total number of photos required1要求检测比例Required detection proportion100 %返修总数Total number of reworks共照总数Total numbe

43、r of photos actually taken1实际检测比例Actual detection proportion100%检测执行标准Standard adopted in the detectionJB4730-94合格级别Grade regarded as qualified 级Grade 工 艺 编 号Serial No. of the technological process合格片数Number of qualified photosA类焊缝(张) Grade-A welds(piece)B类焊缝(张) Grade-B welds(piece)相交焊缝(张) Cross wel

44、ds(piece)共计(张) Total (piece)最终评定结果Final assessment resultI级(张) Final assessment resultII级(张) Grade II(piece)III级(张) Grade III(piece)级(张) Grade (piece)111缺陷及返修情况说明Explanation regarding defects and reworks检 测 结 果Detection result1、返修共计 处，最高返修次数 次。There were reworks in total. The biggest number of rewor

45、ks is .2、超标缺陷部位返修后经复验合格。Defective positions, which had been found to be not in conformity with the standard, were qualified through reexamination after being reworked.3、返修部位原缺陷情况,见焊缝射线检测底片评定表.Refer to the weld ray detection negative film assessment table for the original situation of the defective p

46、ositions before being reworked.1、 本管线焊缝质量符合 II 级的要求，结果合格。The quality of the welds of this pipeline complies with the requirements as stipulated by the grade II. The test results are qualified.2、 检测位置及底片情况详见焊缝射线底片评定表及射线检测位置示意图。For detailed information about the detecting positions and negative films,

47、 please refer to the weld ray detection negative film assessment table and the ray detecting position schematic.报告人Reporter:： xxx Huang ShengKai 资格：RT-II级Qualification: Grade RT-II2004年 3 月 11日2004year 3 month 11 day审核人Verifier： xxx Zeng XiongXin资格： RT-II级Qualification: Grade RT-II2004年 3 月 11日2004y

48、ear 3 month 11 day检验专用章Private inspection seal共 2 页 第 1 页Page 1 of 2cc公司射线探伤评定表4.3.1 Cc Petrochemical Engineering Corporation Ray Detection Assessment Table SH3503 J729C续表Table succeeding J729C工程名称Project name焊接工艺评定Welding procedure qualification检件名称Name of the test piece板材对接焊缝试件Metallic plate butt

49、weld test piece检验编号Metallic plate butt weld test piece片位号Serial No. of a film segment透照日期Picture taken缺 陷 种 类判 定裂纹Crack mm未熔合Lack of fusion mm未焊透Incomplete fusion mm条渣Bar-shaped welding slag mm条孔Bar-shaped hole mm圆形缺陷点Circular defective point凹陷Dent评定级别Assessed grade结论Conclusion备注RemarkCC-PQR-0032004.3.111I合格Qualified