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堆焊工藝評定報告匯編編號 ：PQR-20焊接方法SMAW母材牌號：WCB-GB12229/A216焊材牌號 :D507MO- GB984-1985/E410完成日期 :江陰東方閥門有限公司W(wǎng)CB堆焊工藝評定報告目錄序號名稱頁數(shù)備注1WCB 鋼堆焊評定試驗大綱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 (PT) 報告16硬度檢測報告17侵蝕檢測報告18加工后堆焊面化學成分19彎曲試驗110WCB 焊接工藝評定記錄 （ 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鋼堆焊工藝評定大綱一、目的：為保證 WCB 堆焊工藝評定順利進行，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 ZX 5-4002、母材： WCBGB12229/ASTM A2163、母材試樣尺寸：16016010壹塊4、焊條： D507Mo GB984-1985-EDCr-A2-155、D507Mo/GB984-1985-EDCr-A2-15 化學成分 (%)：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、時間 1 小時8、施焊操作記錄（含工藝參數(shù)外觀檢驗、探傷、硬度）9、侵蝕檢測報告10、PT 探傷報告11、硬度測試報告12.工藝評定編號： 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WPS No.:WPS-20修改號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)的工藝評定記錄編號:Supporting PQR No(s).:E-01日期 Date:SMAW自動化等級Type(Automatic,Manual, MachineorPQR-20 Semi-Auto)Manual接頭Joints (QS-402)簡圖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)當用簡圖、施工圖、焊接代號或文字說明來說明被焊零件布置，需要時，可給出根部間隙和坡口詳圖 (根據(jù)制造者的選擇，可附簡圖說明接頭型式、焊層數(shù)和焊道的順序。例如，對于有缺口韌性要求的焊接工藝、對于多道焊工藝等需要簡圖 )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 (Group No.2與 to P-NO./組號 (Group No./相焊或鋼號和等級為Specification type and gradeGB12229 (A216) Gr.WCB與鋼號和等級為to Specification type and grade/相焊或 化學成分和力學性能為chem. Analysis and Mech. Prop./與化學成分和力學性能為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 )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 ) Flux(class)/焊

8、劑商標名稱Flux brand name/可熔化嵌條Consumable inserts/其它 Other/對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 Rev.：E-01焊后熱處理Postweld Heat Treatment(QW-407)溫度范圍Temp

10、. Range/時間范圍Time .Range/氣體 Gas (QW-408)(百分比組成Composition)氣體混合比流量GasCompositionFlow Rate保護氣 Shielding gas(es)/尾部保護氣Gas Trailing/Shielding/背面保護氣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 工藝評定報告編號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WPS-20 /Rev:E-01接頭JOINTS(QW-402)2mmAfter machining（組合評定時，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_型號或等級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/時間Time/其它Other/GAS(QW-408) 保護氣體Percent composition（氣體成份）Gas(es)氣體(Mixture) 混合比FlowRate 流量正面保護ShieldingN/AN

18、/AN/A層面保護TrailingN/AN/AN/A背面保護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不擺動或擺動String or Weave BeadString or Weave Bead擺動 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: 工藝評定編號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Specimen No.WidthThicknessAreaUltimate Total LoadUltimate Unit StressType of Failure &KNMPaLocation試樣號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Specimen No.Notch LocationSpecimen SizeTest Temp.Impact Value 沖擊功試樣號缺口位置試樣

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

23、 HAZ meet NACE MR0175 HRC22 max. ; Weld hardness meet API 600化學成分檢驗 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N/AOther Tests其它試驗Visual Inspection 外觀檢驗AcceptedType of Test 試驗類型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6Test conducted by 試驗執(zhí)行人 : Jian

25、gyin Eastern Valve Co.,LtLaboratory Test No. 試驗編號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.茲證明本報告所述均屬正確，并且試驗是根據(jù)ASME 規(guī)范第 IX 卷的要求進行試件的準備、焊接和試驗的。Sign(簽字 )She

26、n GenpingDate(日期 )Approval ( 批準 )Liu JianqingDate(日期 )江陰東方閥門有限公司Jiangyin Eastern Valve Co., Ltd滲透探傷報告QR/JEV7.4(19)-2010Liquid Penetrant Test ReportReport No: QR/JEVGY201402003生產(chǎn)令號155 80 25訂單號商標規(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WPS-20Quantity1Product No.爐

27、號Heat No.標準試塊材料探傷部位堆焊面Std TestYM-DWCB+E410InspectionMaterialOverlaying surfaceSpecimenSection滲透劑型號清洗劑型顯象劑型號號Type ofDPT-5DPT-5Type ofDPT-5Type ofPenetrantDeveloperWashing滲透時間顯象時間執(zhí)行標準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性能試驗報告單Jiangyin Eastern Valve Co., Ltd.Mechanical property test reportReport No: QR/JEVGY201402002委托單位 Entrusting party焊接試驗室Welding laboratory產(chǎn)品名稱 Product namePQR-20-02工藝評定Procedure qualification鋼 號 M

29、aterialWCB+E410技術(shù)要 求 Technical requirementAPI 6D試驗溫度 Temperature22 項目 Item檢測結(jié)果RelAZAKVJ結(jié)論RmResultMPa%HVHRCResultMPa%爐號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報告日期檢驗員卞良華審核劉建清Report Date2014-10-25Bian LianghuaApproved byLiu JianqingInspector注：本檢測結(jié)果僅來樣試

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

32、ion：1 將試樣二端堆焊層垂直暴露斷面進行打磨平整，并進行拋光處理；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 倍放大鏡對暴露斷面進行100%目測檢查。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.測試結(jié)果：Test result試樣二個垂直暴露斷面基層金屬和熱影響區(qū)處無裂紋，堆焊接合處完會熔合。Base metal and HAZ on the two vertical section no cracks and complete fusion on welding joints.測試結(jié)論：Test conclusion:按 ASME 規(guī)范卷焊接與補焊評定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)果僅對來樣負責. 1. The result is only for the test coupon.Remark2 試樣保存三個月 .2. Samples remain for 3 months.測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性能試驗報告單Jiangyin Eastern Valve Co., Ltd.Mechanical property test reportReport No: QR/JEVGY201402006委托單位 Entrusting party焊接試驗室產(chǎn)品名稱

36、Product namePQR-20-06鋼 號 MaterialWCB+E410技術(shù)要試驗溫度 Temperature22 項目 Item檢測結(jié)果RmRelAResultMPaMPa%爐號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