船舶艙室設(shè)備底座焊接工藝規(guī)范

1、船舶艙室設(shè)備底座焊接工藝規(guī)范 WELDING PROCEDURE SPECIFICATION FOR EQUIPMENT BASE OF HULL CABIN 1       范圍 Scope 本規(guī)范規(guī)定了船舶艙室重要設(shè)備底座焊接與普通設(shè)備底座焊接施工前的準(zhǔn)備、人員、工藝要求、工藝過程、檢驗。The specification rules the requirements of forewelding to preparation , personnel ,technological requirements ,technology

2、process ,examination ;which are for base of important equipments and common equipments of hull cabin . 本規(guī)范適用于各類船舶艙室設(shè)備底座的焊接。The specification apply to the welding for equipment base of diversified hull cabin .2 規(guī)范引用文件 «船舶建造質(zhì)量檢驗» Referring to document QUALITY INSPECTION OF SHIPBUILDING 3 焊接前

3、準(zhǔn)備Preparation of forewelding 3.1 CJ422鈦鈣型藥皮碳鋼焊條參數(shù)( CJ422 parameters for C steel electrode of Ti and Ca covering) 表3.1-1(form)試驗項目(Test project)s(Mpa)b(Mpa)5(%)AKV（-20°）J3304202247X射線探傷(Radiographic inspection)：級（Grade two） 焊條直徑(MM) Diameter2.53.245焊接電流(A) Current601101201501602102202703.2 CJ507

4、低氫鈉藥皮碳鋼焊條參數(shù) (CJ422 parameters for C steel electrode of low hydrogen Na covering ) 表3.2-1(form)試驗項目(Test project)s(Mpa)b(Mpa)5(%)AKV（-20）J(-30)400490224727X射線探傷(Radiographic inspection) 級（Grade two） 焊條直徑(MM) Diameter2.53.2455.8焊接電流(A) Current601101201501602102202702102603.3 焊前施工人員應(yīng)先了解被焊工件的施工要求及作業(yè)環(huán)境、鋼

5、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。 Welder should know about the welding requirements ,environment ,brand and grand of steel before welding .According to that ,to decide the brand ,size of electrode and wire and polarity on the principle of choosing material . 3.4 定位焊 Tack welding定位焊用的焊條牌號應(yīng)與正式焊縫的焊條牌號相同。

6、 Electrode brand for tack welding shall be uniform with normal welds . 定位焊高度不得超過正式焊縫的高度，焊后的熔渣應(yīng)立即去除。 The height of tack welding dont exceed normal welds , eliminating postweld slag at once .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(qiáng)度鋼為（3040）mm，高強(qiáng)度鋼為50mm，焊縫厚為（34）mm。 The length of tack welds shall be longer because

7、 of making defects easily with CO2 gas-shielded arc welding .Common strength steel (3040)mm, high strength steel 50mm ,thickness of welds (34)mm . 3.5 所要焊接的設(shè)備底座已經(jīng)按照裝配要求定位好，并且打磨焊前認(rèn)可才能進(jìn)入焊接階段。 Equipment base to be welded must be fitted on requirements like and grinded ,before it welded .3.6對于船舶重大設(shè)備如主機(jī)、

8、發(fā)電機(jī)、中間軸承、錨絞車、舵機(jī)及主甲板設(shè)備吊艇、舷梯等基座應(yīng)選用CJ507低氫鈉型藥皮碳鋼焊條或CO2氣體保護(hù)焊。 For the grand ship equipment welding of base of main engine , generator , intermediate bearing , windlass , steering gear , and davit , accommodation ladder which is on the main deck ; should choose CJ507 low hydrogen Na coating C steel elect

9、rode or CO2 gas-shielded arc welding . 3.7其他普通設(shè)備基座可選用普通的CJ422鈦鈣型藥皮碳鋼焊條。 May choose common CJ422 C steel electrode of Ti and Ca covering for other commonequipment base .3.8 焊接材料 Welding consumable3.8.1 焊絲： Welding wireCO2焊絲可選用直徑為（1.2）mm的實芯焊絲或藥芯焊絲，并須經(jīng)船級社認(rèn)可。并有規(guī)則地盤繞在焊絲盤或焊絲筒內(nèi)。Diameter 1.2mm flux-cored wi

10、re will be used for CO2 gas-shielded arc welding and need be approved by Society .3.8.2 CO2氣體： CO2 gas使用的液體二氧化碳其質(zhì)量應(yīng)符合國家標(biāo)準(zhǔn)GB6052-85工業(yè)液體二氧化碳中規(guī)定的類或類一級標(biāo)準(zhǔn)The quality of liquid CO2 used shall accord with grade one of type I or II ruled by national standard GB6052-85Industry liquid CO2 CO2氣瓶壓力低于1MPa時不能使用。D

11、ont use it again when cylinder pressure is below 1 Mpa .3.9 焊接設(shè)備 Welding equipment3.9.1 CO2氣體保護(hù)焊焊接設(shè)備應(yīng)采用設(shè)備制造廠生產(chǎn)的專用設(shè)備，并應(yīng)定期進(jìn)行嚴(yán)格的檢測與維修。 For CO2 gas-shielded arc welding use the special equipment that need be examined and maintained carefully every time . 3.9.2 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(yīng)有可靠的外殼安全接地。

12、 Welding power source for CO2 gas-shielded arc welding must have necessary current volume and electric characteristic suitable for welding . It must have reliable safe grounding for crust .3.9.3 送絲機(jī)構(gòu)的控制裝置，必須具備與焊接電源輸出特性相應(yīng)的控制機(jī)能，必須能均勻地調(diào)節(jié)焊接電流或電弧電壓。 Controlling device of wire feeder must have correspondi

13、ng controlling function as with the input characteristic of welding power source , rugulate current and voltage uniformly .3.9.4 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。 Welding gun must have current volume and can be used for a long time , convenient operation to welder , feeding w

14、ire steadily . Crust of welding gun must have better insulated property .4 人員 Personnel CO2保護(hù)焊的焊工必須經(jīng)過專門培訓(xùn)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。Welder for CO2 gas-shielded arc welding who must be specially trained and examined can be permitted to work on items ruled in certificate issued by Socie

15、ty .Welder for covered electrode manual arc welding cant work unless with certificate .5 工藝要求 Technology requirement 5.1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(shè)備底座的焊腳尺寸、焊接順序、方式等。 According to drawing requirements or thickness of weldment which is in welding specification , size of welding toe ,welding sequence ,

16、welding means etc which are for equipment base will be decided .5.2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(yīng)及時調(diào)整電弧電壓，使之處于最佳狀態(tài)。 In the course of welding process , adjust voltage in time to make them best ,if welding current changed . we do so , because there is higher requirements to current and vo

17、ltage .5.3 設(shè)備底座上船安裝前應(yīng)作好防繡漆，底座吊運上船后應(yīng)妥善放置，并盡快安裝，不宜隨意亂丟，以防遺失、損壞。 Antirust coating should be well-done on the ground for equipment base to be installed ,it shall be put in good order on the hull , install it as quickly as possible , avoid losing , destruction . 5.4 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）。Check t

18、he place of deck or house walls where the base shall be installed whether it is flat(install it after being proofreaded by fire) 5.5 凡有甲板敷料的艙室其底座要在敷料施工前定位裝焊結(jié)束。 Base of the cabin with deck covering should be fitted and welded completely before covering .5.6 底座切割后應(yīng)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的10%。

19、 To eliminate - and inclusion after the base was cut , the welds gap shouldnt exceed 3mm , the length of gap shouldnt exceed 10 percent of all .5.7 底座高度應(yīng)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。 Height of base should accord with requirement of the drawing , the permitted tolerance for heig

20、ht of base on the deck is ±5mm , the permitted tolerance for height of house walls is ±2mm .5.8 坐標(biāo)位置正確，常規(guī)底座允許公差5mm。 Correct coordinate position , the permitted tolerance for common base is 5mm .5.9 底座面水平，四角不平度1米長度內(nèi)2mm。 Base side should be plane , planeness among four angles : 2mm in the ra

21、nge of one meter .5.10 底座結(jié)構(gòu)方向符合圖紙要求，其底腳最低處必要時須開流水孔。 Direction of base structure should accord with drawing requirements . Making a hole which will be to discharge water if there is a need at the lowest place of bottom toe . 6 工藝過程 Technology process6.1 安裝程序 Installing procedure 劃線 底座就位 水平面校正 對角線校正 劃

22、出底腳切割線 切割底座多余部位去除毛刺 第二次就位 校對水平面、對角線 底座焊裝 Drawing line Base primary fixing Proofread level Proofread diagonal Draw cutting line of bottom toe Cutting superfluous parts of base Removing inclusions Formal fixing Proofread level and diagonal Welding of base 6.2手工電弧焊 Covered electrode manual arc welding

23、應(yīng)按焊接材料保管要求，焊條經(jīng)過焙烘、保溫后保存。每次領(lǐng)出堿性焊條使用不能超過4小時，高強(qiáng)度鋼用焊條須用保溫筒加熱保溫。 Electrode need be heated and kept warm , before preserved . All the things should be done according to storage requirements of welding consumable . Alkaline electrode taken out should be used up within 4 hours , electrode for high strength

24、steel need to be kept warm with keepingwarm box . 施焊規(guī)范和要求，應(yīng)嚴(yán)格遵照有關(guān)工藝文件的規(guī)定，不得隨意更改。 Welding specification and requirement ruled by technological document couldnt rejigger optionally , it should be carried out strictly .6.2.3 薄板焊接，焊前應(yīng)采取一定的預(yù)防變形的工藝措施。 Before welding , technology measures of preventing def

25、ormation should be taken for slight plate .6.2.4 應(yīng)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。 According to plate thickness and welding position to choose electrode diameter , 3.2 , 4 are the best choice for the first and the second run of bottom weld , bottom welds should be filled more .6.2.5

26、采用多層焊時，每層焊道的始末端應(yīng)交錯(3050)mm。 For multilayer welding , there is a 30-50mm distance of start and end between run welded and the run to be welded . 6.2.6 多層焊時，必須清除前一道焊縫的焊渣和金屬飛濺，修補(bǔ)結(jié)束后才可施焊下一層。 Must remove the slag and spatter of the last layer and repair it , and then to weld next layer .6.2.7 對高強(qiáng)度、高拘束管節(jié)點

27、采用手工電弧多層焊時，應(yīng)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(qiáng)度。 Annealing run that improve resisting fatigue strength will be operated on the top layer of welds with low diameter low energy input , when weld butt joint of pipes for high strength and limit with Covered electrode manual arc welding . 焊縫末端收口處應(yīng)填滿弧坑，以

28、防止產(chǎn)生弧坑裂紋。 End crater should be filled fully in order to prevent producing crater cracking . 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。 Dont destroy base metal , when remove temporary welds , tack welds , defects ,overlaps and gouging .6.3 CO2氣體保護(hù)焊 CO2 gas-shielded arc welding6.3.1 在焊接部位清除水份，鐵銹，氧化皮，油污等雜物。 Remov

29、ing water ,rust , oxidation , oil and other inclusions . 檢驗確認(rèn)焊機(jī)及其附屬設(shè)備以及供氣系統(tǒng)都能正常工作。 Checking welding machine and its subsidiary equipment , the system of supply gas ,whether they can do well . 在更換焊機(jī)的主要部件后必須檢驗并確認(rèn)焊機(jī)能在使用的焊接條件下正常工作。 Must check and confirm that welding machine can work normally on the con

30、dition of welding , after major component will be changed . 噴嘴必須經(jīng)常清理，導(dǎo)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。 Nozzle must be cleaned , contact nozzle must often changed too . Wire conduit should avoid being bent .6.3.5 由于風(fēng)對氣體的保護(hù)效果危害較大，室外焊接施工時在風(fēng)速超過2m/sec環(huán)境下使用時，應(yīng)采取相應(yīng)的防風(fēng)措施。 Take corresponding protective measure ,

31、if wind speed exceeds 2m/sec outside when welding .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。 Pay much attention to the start and end of welds , where defects come into being easily.6.3.7 焊前按工藝規(guī)范要求調(diào)節(jié)焊接規(guī)范，達(dá)到要求后，開始焊接。 At first , regulate welding specification by the requirements of welding procedure ,and then t

32、o weld .6.4 CO2氣體保護(hù)焊操作要領(lǐng) Operation items for CO2 gas-shielded arc welding . 焊接中，焊槍角度后仰15°20°，焊絲伸出長度為（1015）mm。 The angle of gun is 15°20°backwards , dry extension of wire is 1015 mm . 當(dāng)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。 When take transverse swing moving wire , the

33、 width of swing range is little bigger than gap of root or the width of layer , stopping a little time there , in order to make sure the penetration of root and edges . 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(dāng)焊縫與定位焊相接時，必須將定位焊去除，然后再引弧焊接。 If you want to continue to weld from the position where you stop welding

34、 , must grind the crater making it pliable . When welds meet tack welds , remove tack welds and then to ignite .7 安全衛(wèi)生 Safety and protecting 7.1 焊接操作者必須使用面罩、安全帽、皮手套等遮光保護(hù)用具，防止灼傷和燙傷。 To prevent burning , welder must use protective things , such as : veil , cap , leathern gloves etc .7.2 工作中，應(yīng)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(zāi)事故。 Spatter could cause fire , so have to check whether there are something that will be burning and exploding easily aro