焊接技術(shù)培訓(xùn)aws d1.1與eemua 158 2000不同要求

1、AWS D1.1 &EEMUA 158 不同要求焊接技術(shù)培訓(xùn)之1AWS D1.1 &EEMUA 158 不同要求內(nèi) 容A 課程培訓(xùn)概述（Preface） B 內(nèi) 容 (Content) 1. 標(biāo)準(zhǔn)的范圍（Scope ） 2. 材料（Material ） 3. 焊接工藝和焊工的評(píng)定（Qualification of WPS and welder） 4. 建造（Construction and Fabrication） 焊接技術(shù)培訓(xùn)2A.課程培訓(xùn)概述 通過本次培訓(xùn)，讓各位了解AWS D1.1 2010和 EEMUA 158: 1994 標(biāo)準(zhǔn)的基本內(nèi)容，了解兩標(biāo)準(zhǔn)中一些重點(diǎn)要求及其不同。了解建造過程

2、中的相關(guān)要求，以免違反標(biāo)準(zhǔn)和工藝文件要求。減少船東、船檢的Comments、投訴等，提高產(chǎn)品質(zhì)量，加快報(bào)驗(yàn)過程，在建造和檢驗(yàn)過程中，減少因不了解EEMUA 158標(biāo)準(zhǔn)中的要求而出現(xiàn)不必要的問題和麻煩。焊接技術(shù)培訓(xùn)31. 標(biāo)準(zhǔn)的范圍（Scope ）AWS D1.1 &EEMUA 158 不同要求AWS D1.1 This code contains the requirements for fabricating and erecting welded steel structures. When this code is stipulated in contract documents, co

3、nformance with all provisions of the code shall be required, except for those provisions that the Engineer (see 1.4.1) or contract documentsspecifically modifies or exempts.EEMUA158:1994This Specification defines the basic requirements for the fabrication work on primary structures of offshore insta

4、llations. These will normally include, but not be limited to, the following:jacket structure including nodes, cones, braces, legs and conductor framing piles and followers J-tubes and caissons riser clamps flotation tanks and buoyancy tubes module support frame including nodes, cones, braces, padear

5、s, module framing including nodes, columns, fabricated beams and padears. Flareboom helideck - when constructed of steelany other areas designated primary on the Drawings.42. Material 材料AWS D1.1 &EEMUA 158 不同要求AWS D1.1 -2010/2008 Clause 3 Prequalification of WPSs 按材料等級(jí)和強(qiáng)度進(jìn)行了分類。而 EEMUA 158 1994 secti

6、on 3 簡(jiǎn)單的講述了，焊材、鋼板等材料的替代、儲(chǔ)存、標(biāo)識(shí)、發(fā)放等 。EEMUA 158:1994 中規(guī)定，生產(chǎn)中所用的母材的供貨狀態(tài)必須與材料評(píng)定試驗(yàn)中所用的母材有相同的供貨狀態(tài)。 53. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求AWS D1.1 -2010/2008 Section 4 Qulification Part B 對(duì)焊評(píng)做了詳細(xì)的規(guī)定和要求。Part C 對(duì)焊工資質(zhì)考試做了相關(guān)的規(guī)定和要求。而 EEMUA 158： 1994 section 4 Qualification of weldin

7、g procedures and personnel 在焊接工藝評(píng)定中對(duì)一些重要變素進(jìn)行了比AWS D1.1 更為嚴(yán)格的要求。在 NDT and mechanical testing 要求上也有不同。其中，對(duì)CTOD實(shí)驗(yàn)，進(jìn)行了詳細(xì)的說明。 63. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 現(xiàn)場(chǎng)生產(chǎn)中，若與4.5.1到4.5.5 中規(guī)定的不同，要重新做評(píng)定試驗(yàn)。以下是選的一些規(guī)定，建造過程中需要注意，并嚴(yán)格按批

8、準(zhǔn)的適用的WPS執(zhí)行。4.5.1 Materials Related Variables (f ) If flame-cut weld bevels are not ground to bright metal. 火焰切割喉的焊縫坡口面沒有打磨至光亮的金屬。(g) If a protective finish applied to the weld bevel is changed. 如果坡口采用的保護(hù)漆被更換。73. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section

9、4 4.3 Restrictions on Welding Practices (b) SMAW bead widths exceeding the lesser of 16 mm or four times the core wire diameter.焊條電弧焊根部打底焊道寬度我們要求8mm 以內(nèi)。(h) SSFCAW and GSFCAW for heat inputs exceeding 1.5 kJ/mm except for vertical-up root passes. 藥芯氣體保護(hù)焊（氣體保護(hù)和自保護(hù)）熱輸入除根部立焊焊道，不得超1.5 kJ/mm。所以立焊時(shí)，要控制焊道寬度

10、不得超寬(WPS要求小于17mm)。還要控制好焊接參數(shù)哦。83. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.3 Restrictions on Welding Practices (o) Included angles of bevelled welds below 45 degrees (except as covered by 4.5.2 (g). 斜面焊縫接頭的坡口角度不得小于45（除已經(jīng)評(píng)定小角度的外）(p) Included angles be

11、low 60 degrees for closing welds in tubulars above 40 mm thick. 40mm以上板厚的管道上密封焊接接頭的坡口角度不得小于 60。93. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.3 Restrictions on Welding Practices (S) Maximum interpass temperature exceeding 250C. (T) Single-pass fillet

12、welds (other than by SAW) with a design leg length greater than 6 mm. 單道角焊縫大于6mm，重評(píng)。(V) Use of backing strips. (U) Use of ceramic inserts. 103. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geometry Related Variables (f)

13、If the shape of the weld preparation changes, except that: a single bevel qualifies a single V; K qualifies X; and 2:1 and 1:1 preparations qualify each other and all intermediate geometries. 坡口覆蓋。按WPS選用。1/2 V只能支持1/2V或V型坡口；K型只能支持K和X型坡口。(g) If the included angle of the groove is less than the value t

14、ested and qualified by the WPS. Acute angles in stub to barrel welds, where the included angle is less than 45, are qualified by the test in 4.4.2.3(b). 角度不小于WPS中的規(guī)定。113. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geom

15、etry Related Variables (h) For single-sided welds: if the root face is more than 0.5 mm above or 1.5 mm below that qualified, or if the root gap is more than 3.0 mm above or 0.5 mm below that qualified. 單邊坡口： 根部鈍邊公差 f (+0.5, -1.5); 根部間隙公差 R (+3 , -1.5);(i) For double-sided welds: if the root face is

16、 more than 2 mm above or below that qualified or if the root gap exceeds 6 mm. 雙邊坡口： 根部鈍邊公差 f (+2, 2); 根部間隙公差 R ( 6); AWS D1.1 中 f (+2, -2); R (+3 , -2); （+10，-5）123. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geometry

17、 Related Variables (j) For fillet welds, any increase in root gap. 角焊縫，不得增加根部間隙。However, for multipass fillet welds any root gap shall be compensated for by a corresponding increase in fillet leg length up to a maximum of 6 mm.除非多道角焊縫要深熔，間隙增加，焊腳應(yīng)加大相應(yīng)增加。增量最大不超過6mm.For single-pass fillet welds the roo

18、t gap shall be limited to 3 mm maximum, and the weld leg length shall be increased by the same amount. 單道角焊縫根部間隙最大不超過3mm.133. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geometry Related Variables (k) If the joint misal

19、ignment on tubulars and skid beams exceeds the following: 在管子和梁的焊接接頭中：- for double-sided joints: the smaller of 6 mm or 10% of the joint thickness, except that a 2 mm misalignment is permitted regardless of thickness 雙面坡口焊縫：最大6mm或0.1T ，取較小者。允許錯(cuò)邊2mm以內(nèi)時(shí)，可以不考慮板厚。- for single-sided joints: the smaller o

20、f 3 mm or 10% of the joint thickness, except that a 2 mm misalignment is permitted regardless of thickness. 單面坡口焊縫：最大3mm或0.1T ，取較小者。允許錯(cuò)邊2mm以內(nèi)時(shí)，可以不考慮板厚。143. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.2 Weld Geometry Related Va

21、riables (k) If the joint misalignment on sections other than those in (k) exceeds the smaller of 5 mm or 12% of the joint thickness, except that a 2 mm misalignment is permitted regardless of thickness.除了（k）中的接頭形式，在型材對(duì)接的接頭中，最大5mm或12%T ，取較小者。允許錯(cuò)邊2mm以內(nèi)時(shí)，可以不考慮板厚。153. Qualification of WPS and welder 接工藝

22、和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.3 Consurnables and Equipment Variables (e) If the core diameter of a SMAW electrode used for the capping passes is reduced. 用于蓋面的焊條直徑大小不能減少，WPS要求多少就是多少。163. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158

23、不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.4 Procedural Variables (a) If the welding process used for any part of the weld (i.e. root, second pass, fill or cap) is changed. 焊縫分根部焊道，第二道，填充焊道，蓋面焊道，每層每到要按WPS來。(g) If the first side to be welded in an unequal double-sided preparation (or o

24、ne using different consumables on either side) is changed. 焊接順序：雙面不等邊坡口，先焊大坡口側(cè)，還是小坡口側(cè)，要按WPS來。（兩側(cè)用什么焊材，是不是相同等等，不能用錯(cuò)）173. Qualification of WPS and welder 接工藝和焊工評(píng)定AWS D1.1 &EEMUA 158 不同要求EEMUA 158： 1994 Section 4 4.5 Essential Variables 4.5.4 Procedural Variables 對(duì)打磨和碳刨的要求也比AWS D1.1 嚴(yán)格。(c) If grinding

25、between passes is omitted or if back-gouging is omitted.(d) If the depth of back-gouging / grinding is reduced. (e) If the depth of back-gouging/grinding is increased to more than 10 mm. (f ) If the back welding used in qualification is omitted. 184. construction and Fabrication 建造AWS D1.1 &EEMUA 15

26、8 不同要求AWS D1.1 -2010/2008 Clause 5 中 對(duì)以下方面給予了規(guī)定：Base matal /Welding cosumables and electrodes requirement/WPS Variables /Preheat and interpass Temperatures/Heat input control for Quenched and temperatures/Stress-relief heat Treatment / Backing, backing Gas or inserts/Backing / Welding and Cutting Eq

27、uipment /Welding Environment/Minimum fillet weld size /Preparation of base matel/ Reentrant corners/Weld Access holes, Beam copes, and Connection material /Tack weld and construction aids/194. construction and Fabtication 建造AWS D1.1 &EEMUA 158 不同要求AWS D1.1 -2010/2008 Clause 5 Camber in bulit-up Memb

28、ers/Splice in Cylically loaded Structures /Control of distortion and shinkage /Tolerance of joint dimensions / Dimensional tolerance of welded struction members/Weld profiles/ Repairs/ Peening/ Arc strikes/ Weld cleaning/ EEMUA 158: 1994 Clause 5 整個(gè)章節(jié)都要了解。因?yàn)檫@里對(duì)TKY結(jié)構(gòu)的規(guī)定比AWS更為詳細(xì)。204. construction and

29、Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.4 Design of Welded Connections Where point-to-point construction is employed, consideration shall be given to the possible effects of this method of construction on root quality. 焊接時(shí)，要注意根部焊道的質(zhì)量。Consideration shall also

30、be given to the practicality of performing NDT in the root region of such joints, together with appropriate acceptance criteria. 對(duì)這種接頭，要考慮根部區(qū)域做 NDT的實(shí)際性。Where the use of an asymmetric single bevel or K preparation is proposed, consideration shall be given to access for effective ultrasonic testing. 采

31、用不對(duì)稱的單邊坡口或 K形破口設(shè)計(jì)時(shí)，要考慮使用UT的有效性。214. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.5 Forming The forming of T-sections into flanged ring stiffeners of any diameter will require mechanical tests (to demonstrate that the properties required by the pur

32、chase specification are maintained after trial forming) to justify acceptance, regardless of the proposed diameter. T型材加工成環(huán)狀加強(qiáng)筋，不論直徑大小，都要做力學(xué)性能試驗(yàn)。224. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.5 Forming If hot straightening is proposed, the temp

33、erature shall not exceed 500C unless otherwise approved by the Purchaser. These limits also apply to re-rolling of cans after welding to restore shape to within tolerance limits. Acceptance of wedges or other techniques to assist rolling will be subject to the visual acceptability of the product and

34、 to acceptable mechanical test results from regions of maximum strain. 234. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.6 Edge Preparation Plates or tubulars shall be prepared by machining, or by flame cutting followed by grinding to bright metal

35、. If the Contractor successfully qualifies all welding procedures using materials which have not been ground after flame cutting, the Purchaser may consider relaxing this requirement for edges to be welded. 一般坡口都要打磨至金屬原色。如果承包商成功地使用沒有打磨切割面的板材做出了焊評(píng)，業(yè)主可以考慮放寬這條規(guī)定。244. construction and Fabtication 建造 EEM

36、UA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.6 Edge Preparation Surfaces to be welded shall be visually examined to ensure freedom from laminations, cracks, slag inclusions and cutting notches. Any such defects observed shall be dressed out by grinding. If the depth of excavation e

37、xceeds 5 mm, a weld repair shall be made using an Approved WPS. 254. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.6 Edge Preparation The surface of the steel within 75 mm of the proposed weld shall be dry, clean and free from loose scale or paint

38、(except that the use of a protective primer may be qualified by use in all welding procedure qualification tests). 而AWS要求的打磨坡口邊緣至少20mm。Flame cut edges which are not subsequently welded shall be ground smooth to remove nicks and burrs, The use of flame gouging or washing is not permitted. 不準(zhǔn)用割刀熔削，不準(zhǔn)烊

39、坡口面。264. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints For any through member whose thickness exceeds 25 mm, the portion which will lie under, or within 50 mm of, a T-butt weld (or a fillet weld with leg leng

40、th exceeding 20 mm) shall be examined by ultrasonic testing in accordance with BS 5996. 穿插件厚度超過25mm，位于T型接頭下面50mm以內(nèi)（或角焊縫焊腳超過20mm），要做UT，檢驗(yàn)材料內(nèi)部缺陷。Where low sulphur steels with guaranteed Zdirection properties are used, this examination is not required. Weld preparation tolerances shall comply with, and

41、 misalignment at butt welds shall not exceed, the values given in 4.5.2.274. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints Single-sided closure butt weld root gaps of 12 mm maximum up to 150 mm in length are

42、permitted even if this exceeds the tolerance on the basic welding procedure. 單面對(duì)接焊允許150mm長度內(nèi)最大12mm根部間隙，即使不符合基本的焊接程序?qū)畹囊蟆?84. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints Where root gaps are out of toleranc

43、e, except as permitted above, the joint shall be dismantled to permit local grinding, or buttering followed by grinding, back to the required profile. The depth of buttering on any member shall not exceed 15 mm. Alternatively the requirements of 4.4.2.3 (c) and 4.6.3 (c) may be applied. 294. constru

44、ction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints定位點(diǎn)焊接注意事項(xiàng)：Fit-up using clamps or other fabrication aids may be used where appropriate. When tack welds are necessary they shall be at least 50 mm long and shall consist o

45、f at least two passes of sufficient cross sectional area to resist restraint cracking. 304. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.7 Alignment and Fit-up of Welded Joints 定位點(diǎn)焊接注意事項(xiàng)：The preheat shall not be less than for welding the joint. Ta

46、ck welds which are to form part of the completed joint are permitted for double-sided welds provided they are feathered at both ends. For single-sided welds, mild steel bars temporarily welded to the fusion face of the bevel are preferred so that the root pass can be deposited with minimum interfere

47、nce. When agreed with the Purchaser, root tacks which are to remain in the joint may be permitted in single-sided welds if the ends are feathered. 314. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.8 Rat-holes, Penetrations and Cut-outs Rat-holes p

48、enetrations, and other cut-outs shall be avoided wherever possible. Where considered essential, and their use approved by the Purchaser (or when directed by the Drawings), the following shall apply: (a) Permanent rat-holes shall be cut by automatic processes and ground smooth unless otherwise agreed

49、 by the Purchaser. Permanent rat-holes shall have a radius of 50 mm or twice the plate thickness whichever is the greater. Where rat-holes of these dimensions would jeopardise structural integrity, the Purchaser may require them to be less than 50 mm radius. Fillet welds shall be continued through t

50、he rat-hole. 永久性的過焊孔半徑為 50mm或2T中較大者。角焊縫應(yīng)連續(xù)穿過。324. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.8 Rat-holes, Penetrations and Cut-outs (b) Temporary rat-holes (those approved subject to their being reinstated or sealed) shall have a radius not less

51、 than twice the plate thickness and shall be reinstated to an approved procedure. Filling with weld metal is not permitted. 臨時(shí)性的過焊孔 半徑大于厚度的2倍。（R2T）。不允許填充。334. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.2 Preparation and Assembly5.2.8 Rat-holes, Penetrations and Cut-outs (c)

52、The radius of any approved cut-outs other than rat-holes shall not be less than 100 mm. Where necessary, the area shall be checked by UT before cutting to ensure that no cut is made within 300 mm of internal stiffeners. The original plate shall be clearly marked and shall be welded back into the cut

53、-out, unless other proposals are approved by the purchaser.挖孔（不含過焊孔）半徑不小于100mm. 必要時(shí)，切割前還要做UT，保證內(nèi)部加強(qiáng)構(gòu)件300mm以內(nèi)不準(zhǔn)切割。割下來的板，應(yīng)標(biāo)記好，以便重新裝焊。344. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.3 Control of Production Welding 5.3.1 Welding Environment All welding shall be carried out in co

54、nditions which permit satisfactory welding and adequate inspection. Whenever possible, welds should be made in fabrication shops with outdoor welding being restricted to final erection or to sub-assemblies which are too large or heavy to be welded elsewhere. Node fabrication shall always be undertak

55、en in fabrication shops. Outdoor welding shall be protected from the effects of adverse weather by the use of temporary shelters. Closure joints shall not be welded if there is water trapped in the members to be joined. 354. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.3 Contr

56、ol of Production Welding 5.3.1 Welding Consumables and Equipment 沒AWS D1.1 詳細(xì)。按標(biāo)準(zhǔn)、廠家推薦和以及公司技術(shù)程序相關(guān)文件執(zhí)行。一下是對(duì)設(shè)備的要求。1）Welding equipment shall be maintained in good working order, and earth connections to the work piece shall make good electrical contact. 2）Regular calibration checks shall be carried out

57、 on all equipment to an agreed procedure. 3） For iron powder metering systems, a calibration check shall be made each half shift until the Purchaser advises otherwise. 364. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.3 Control of Production Welding 5.3.2 Preheat and Interpass

58、 Temperature Requirements In establishing the minimum permissible preheat, the Contractor shall use BS 5135. The particular diagram to be used for reference (in Fig. 4 of that Standard) shall be established by using the maximum permitted CE value for the steel to be welded, together with the maximum

59、 weld metal hydrogen level guaranteed by the manufacturer. 預(yù)熱和層間溫度依照 BS 5135。BS 5135 根據(jù)母材組合厚度，碳當(dāng)量，焊材擴(kuò)散氫含量，熱輸入來規(guī)定最低預(yù)熱溫度。而AWS D1.1 在Table 3.2 列出最低預(yù)熱溫度和層間溫度。附件 Annex I 中，有2種預(yù)熱溫度計(jì)算方法，從控制硬度和氫含量分別考慮預(yù)熱溫度。根據(jù)碳當(dāng)量，冷裂紋敏感指數(shù)，擴(kuò)散氫含量，拘束度等來考慮預(yù)熱溫度。374. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求

60、5.3 Control of Production Welding 5.3.2 Preheat and Interpass Temperature Requirements AWS D1.1 Table 3.2A類材料的最低預(yù)熱和層間溫度 384. construction and Fabtication 建造 EEMUA 158 AWS D1.1 &EEMUA 158 不同要求5.3 Control of Production Welding 5.3.2 Preheat and Interpass Temperature Requirements Having identified the