锅炉厂焊接专业施工组织设计.doc
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目录
第一章工程概况及编制依据·························································1
1.1工程概况·····································································1
1.2编制依据····································································2
1.3主要焊接工程量及焊接方法···················································2
第二章项目组织机构设置··························································7
2.1焊接人员的配备及职责························································7
2.2焊接人员应具备的资格条件···················································9
2.3焊接组织机构································································10
第三章焊接材料管理······························································10
3.1焊接材料管理制度····························································10
3.2焊接材料检验制度····························································11
3.3焊接材料复查检验····························································11
3.4焊接材料保管制度····························································12
3.5焊接材料烘干制度····························································12
3.6焊接材料发放及回收制度······················································13
3.7过期焊接材料处理制度························································13
第四章焊接机械设备管理··························································13
4.1焊接用气体的供应及布置·····················································13
4.2焊机电源及焊机集装箱布置····················································13
4.3热处理机电源及热处理机布置··················································14
4.4焊接材料烘干机电源及布置····················································14
4.5焊接机械设备管理·····························································14
第五章主要施工方案和技术措施·····················································14
5.1焊接工艺评定及焊工的岗前培训···············································14
5.2焊接方法·····································································15
5.3焊接坡口形式及组装要求······················································17
5.4焊接工艺及热处理规范························································19
5.5焊接接头质量检验····························································26
5.6不合格焊口处理······························································26
5.7焊接过程管理································································27
5.8质量检验及验收······························································28
第六章重要部件或特殊钢材的焊接施工方案·········································29
6.1SA335-P91焊接施工方案······················································29
6.2SA213-T91焊接施工方案······················································31
6.315NiCuMoNb5（WB36）焊接施工方案·············································32
第七章创优工程焊接工艺质量要求··················································33
7.1T/P91高合金耐热钢焊接工艺质量要求··········································33
7.2奥氏体不锈钢及镍基合金管焊接工技术要求······································35
7.3中低压管道焊接工艺质量要求····················································36
第八章焊接质量管理及质量保证措施················································36
8.1施工质量目标································································36
8.2质量管理····································································37
8.3质量保证措施································································37
8.4施工各个环节的控制与检查···················································38
8.5特殊条件下焊接质量保证措施·················································38
8.6焊接接头的标识······························································38
8.7质量标准····································································38
第九章焊接施工中的环境保护、劳动防护及安全文明施工····························38
9.1执行标准·····································································38
9.2安全方针····································································39
9.3安全目标····································································39
9.4安全文明施工管理体系························································39
9.5环境因素识别与评价··························································39
9.6危害因素识别与评价··························································39
9.7应急准备及响应······························································39
9.8安全文明施工措施····························································42
9.9安全生产保证措施····························································42
9.10安全危害因素辨识控制·······················································42
9.11环境因素评价及控制·························································45
9.12安全操作规程·······························································46
9.13特殊情况下焊接施工安全措施················································47
9.14竣工后的资料移交···························································50
9.15焊接作业指导书编制计划····················································51
第十章强制性条文的执行计划和措施················································51
附录I：
焊接工艺评定目录及应用范围统计表··········································55
附录Ⅱ：
本工程常用钢材性能一览表··················································57
附录Ⅲ:
本工程常用焊接材料性能一览表···············································59
附录Ⅴ:
本工程焊接一览表····························································62
附录Ⅵ:
环境因素分析及评价表······················································68
附录Ⅶ:
危害辨识、风险评价及控制对策表············································70
焊接专业施工组织设计
第一章工程概况及编制依据
1.1工程概况
1.1.1AAAAAAAAAAAAAAAAAAAAAA工程AAAAAAAAAAAAA锅炉为哈尔滨锅炉厂有限责任公司生产的HG-2192/25.4-YM16型锅炉，为超临界参数、控制循环、四角切向燃烧方式、一次中间再热、单炉膛平衡通风、固态排渣、紧身【封闭、全钢构架的∏型直流炉。
主要部件位置分布：
炉膛上部布置有分隔屏过热器、末级过热器；水平烟道中布置有末级再热器；后烟道布置低温再热器、低温过热器、省煤器和吊挂管。
汽水流程：
给水由炉前右侧进入省煤器，流经省煤器后由省煤器出口导管进入螺旋水冷壁下集箱、经螺旋水冷壁进入中间集箱至上集箱出口连接管道到混合集箱、再进入降水管，从下降管汇集到折焰角水冷壁和水平烟道水冷壁之后进入汽水分离器进行汽水分离，从分离器分离出来的水进入贮水罐排往冷凝器，蒸汽则依次经顶棚过热器、包墙过热器、中隔墙、吊挂管过热器、低温过热器、分隔屏过热器和末级过热器。
调节过热蒸汽温度的一级减温器装于低温过热器出口到分隔屏过热器进口连接管；二级减温器装于分隔屏过热器出口到末级过热器进口连接管上。
锅炉主要技术参数如下（BMCR工况）：
锅炉型号HG-2192/25.4-YM16
过热蒸汽流量t/h2192
过热器出口蒸汽压力MPa（g）25.4
过热器出口蒸汽温度℃571
再热蒸汽流量t/h1840
再热器进口蒸汽压力MPa（g）4.528
再热器出口蒸汽压力MPa（g）4.328
再热器进口蒸汽温度℃317
再热器出口蒸汽温度℃569
省煤器进口给水压力MPa（g）28.87
省煤器进口给水温度℃283
空预器进/出口一次风温度℃30/308
1.1.2汽机系统
1.1.2.1本期工程汽轮机为哈尔滨汽轮机厂有限责任公司生产、制造的汽轮机型式：
为超临界参数、一次中间再热、单轴、三缸四排汽、直接空冷凝汽式汽轮机；发电机为哈尔滨电机厂有限责任公司生产的水、氢、氢冷却、静态励磁660MW汽轮发电机。
主蒸汽，主蒸汽管道采用2-1-2连接方式，从过热器出口集箱双管接出，在炉内合成一路后单管引出在进汽机前分成两路分别接至汽轮机左右侧主汽门。
第58页共71页
1.1.2.2再热蒸汽，再热冷段管道采用2-1-2连接方式，锅炉和汽机接口均为2个，从再热器出口集箱双管接出合成一路后在进汽机前分成两路接入。
1.2编制依据
《火力发电厂焊接技术规程》DL/T869-2012
《火力发电厂焊接热处理技术规程》DL/T819-2010
《焊工技术考核规程》DL/T679—2012
《焊接工艺评定规程》DL/T868-2014
《火力发电厂异种钢焊接技术规程》DL/T752-2010
《电力建设施工质量验收及评价规程》（焊接篇）DL/T5210.7-2010版
《铝母线焊接技术规程》DL/T754-2001
《火力发电厂金属监督规程》DL/T438-2009
《电力工业锅炉压力容器监察规程》DL/T612-1996
《电站锅炉压力容器检验规程》DL/T647-2004
《压力容器焊接规程》NB/T47015-2011
《管道焊接接头超声波检验技术规程》DL/T820-2002
《钢结构工程施工质量验收规范》GB/T50205-2001
《钢制承压管道对接焊接接头射线检验技术规程》DL/T821-2002
《焊接材料质量管理规程》JB/T3223-1996
《基建安全管理规定》
《工程建设标准强制性条文》电力工程部分2013年版
《特种设备焊接操作人员考核细则》TSGZ6002-2010
《大同煤矿集团塔山2×660MW坑口电厂（二期扩建）工程施工组织总设计》
山西电建二公司焊接工艺评定报告
其它：
相关法律、法规，电力行业、建设部及有关标准、规范。
1.3主要焊接工程量及焊接方法
1.3.1锅炉部分
1.3.1.1省煤器系统、水冷壁系统、过热器系统、再热器系统、中大径连接管的焊接；
1）省煤器系统
a.省煤器焊口共计2720个，规格为φ44.5×7，材质为SA-210C。
b.炉膛布置紧凑，造成蛇形管排片与片的间距、每片管子与管子的间距较小，焊接时候有些局部地方是肉眼无法观察到的，要求焊工在焊接这些位置的时候利用镜面焊的方法以保证焊接质量。
（低温再热器、低温过热器蛇形管排的分布情况和省煤器类似，焊接方法同上）
2）水冷壁系统
a.水冷壁部件主要有，前、后、左、右侧水冷壁，后水冷壁排管、折焰角水冷壁、左、右侧水平烟道水冷壁；焊口共计19074个，规格有φ38×7.3、φ31.8×6.2、φ42×7、φ44.5×7、φ63.5×14、φ89×16，材质为15CrMoG。
b.水冷壁焊接的难点主要在灰斗区的螺旋水冷壁（拐角和前、后水中部均以散管连接且数量较多）,安装过程中由于设备的原因不可避免的会出现焊口难以组对（错口、折口）的情况，为避免出现焊接质量问题，在施工过程中严格执行焊接强条,有无法达到焊接要求的可跳过焊下一根。
无法焊接的问题散管，由焊接专工联系项目部工程技术科以书面形式联系专业监理工程师及甲方专业专工予以解决。
（其它部件遇到类似情况，处理方法同上）
3）过热器系统
a.过热器系统主要部件有：
顶棚过热器、包墙过热器、吊挂管过热器、低温过热器、分隔屏过热器、末级过热器和流体冷却定位管；焊口共计16377个。
材质主要有15CrMoG、12Cr1MoVG、SA-213T91、SA-213TP347H；规格有φ44.5×7、φ63.5×10、φ42×11、φ63.5×11.5、φ51×13.5、φ51×11、φ70×11、φ51×9、φ63.5×14等（详细规格参数见焊接一览表）
b.需要焊前预热焊后热处理的焊口。
因为管排、管子间距较小,管排焊口焊前预热采用火焰加热的方法，使用远红外测温枪测温，焊后热处理采用电加热的方法。
4）再热器系统
a.再热器系统主要部件有：
低温再热器和高温再热器；焊口共计9974个，材质主要有15CrMoG、12Cr1MoVG、SA-213T91、SA-210C；规格有φ57×4.5、φ60×5、φ54×5、φ70×5等。
5）中、大径连接管
中大径管道主要包括省煤器集箱、水冷壁集箱、包墙环形集箱、前顶棚集箱、下降管及其连接管、折焰角及水平烟道连接管、水冷壁平衡管、顶棚旁路管、包墙连接管焊口及手孔；焊口共计636个，材质主要有15CrMoG、SA-182F91、SA-210C、WB36（规格较多，详见焊接工程一览表）。
1.3.1.2锅炉本体密封主要包括水冷壁一次密封、包墙过热器一次密封、水冷壁二次密封、包墙过热器二次密封、再热器、过热器二次密封，为非承压焊接工作量的主要部分。
1.3.1.3锅炉燃油系统。
1.3.1.4回转式空气预热器系统焊接为直通长焊缝、角接焊缝、T型焊缝。
1.3.1.5锅炉杂项管道的焊接，如工业水系统，仪用压缩空气系统，热工仪表管，工业压缩空气系统，暖风器供汽、取样、减温水、放空气、加药、吹扫蒸汽、充氮及疏水系统。
1.3.1.6吹灰系统焊接。
1.3.2汽机部分
1.3.2.1四大管道及高、低旁路部分：
主蒸汽管道焊接，高压给水管道焊接，热再热蒸汽管道焊接，再热冷段焊接；
1.3.2.2中低压管道的焊接；
1.3.2.3凝汽器焊接；
1.3.2.4除氧器焊接；
1.3.2.5油系统管道的焊接；
1.3.2.6封闭铝母线的焊接；
1.3.2.7其他杂项管路焊接；
1.3.2.8热控仪表压力管路焊接。
1.3.3焊接方法
1.3.3.1承压管道部分
一般情况下对于壁厚不大于6mm的小径管焊口，应采用手工氩弧焊；壁厚大于6mm的管子，应采用氩弧焊打底、电弧焊盖面（GTAW/SMAW）；但是对于焊接位置困难,难以采用氩加电组合焊时，应全部采用全氩弧的焊接方法，以保证焊接质量。
1.3.3.2钢结构部分
钢结构的焊接应符合DL/T678-1999《电站钢结构焊接通用技术条件》的规定，钢结构部件焊接时采用手工电弧焊（SMAW），使用的焊条按标准进行烘焙，焊机采用逆变式弧焊机或交流弧焊机。
焊工要准备砂轮机、扁铲、榔头和钢丝刷等清理工具。
凡是对接的方形或工字形钢结构须配备两名焊工对称分段焊，对于间隙过大的构件，对接前采用电焊补焊而缩小其间隙，严禁填加金属物。
焊接较大的钢柱时，焊接途中不能停焊或隔夜焊，否则会产生裂纹。
施焊人员在焊接时要随时对焊缝进行宏观检查、清理，特别是焊缝饱满度，咬边，表面裂纹等是检查的重点，对于重要的承重钢结构，焊完后应以相关标准去做检验，焊工焊完应认真填写自检记录。
1.3.3.3锅炉本体密封
所有密封焊缝都采用双面焊接的焊接工艺进行焊接，对因设计原因造成局部焊接位置困难无法施焊时，采用单面全焊透。
施焊时保证焊缝高度及成形，所有焊缝均应打磨光滑、平整，对于厚度较大的密封扁钢，应严格按施工设计图要求开坡口，以保证焊接质量。
密封焊缝对接时避免添加密封材料。
对组合件的密封焊缝，尽量在地面组合时完成。
穿墙套管与墙体密封焊缝在穿墙管对口焊接时同时进行。
密封对接全部开坡口，开坡口采用砂轮机打磨，采用小直径电焊条、小电流密度、较小的焊接速度、薄焊道。
四角合拢的角焊缝适当加厚，密封焊接时采用从中间向两边分段跳焊法，间距为200—400mm，管子与密封鳍片焊接时特别注意烧穿管子，如发生后必须割掉重新换管。
1.3.3.4承压部件上的管座采用氩弧焊打底、电弧焊填充盖面（GTAW/SMAW）组合焊接方法进行焊接，而插入式插座采用手工电弧焊（SMAW）。
1.3.3.5汽轮机、发电机的冷却、汽机润滑油及工作油管道、锅炉燃油管道焊口采用全氩方法焊接（GTAW）或采用氩弧焊打底、电焊盖面焊接方法。
1.3.3.6主蒸汽管道、再热蒸汽管道、高压给水管道、高中压导汽管道均采用氩弧焊打底、电焊填充、盖面的焊接方法（GTAW/SMAW）。
1.3.3.7大直径（Φ≥1000mm）管道或容器接头的焊接，采取焊缝背面清根双面电弧焊。
1.3.3.8管道或容器上焊接非开孔型管座、吊架、加强筋等采取手工电弧焊方法（SMAW）。
1.3.3.9中、低压管道
中压管道焊接时采用氩弧焊打底，电焊盖面焊接工艺；低压管道的焊接采用手工电弧焊焊接工艺。
对于直径大于194mm的管子采用两个焊工对称焊。
1.3.3.10油系统管道
采用全氩弧焊工艺，当管壁δ＞6mm时采用氩弧打底、电弧焊盖面的工艺。
不锈钢管道需进行管内充氩，每道口焊完后才允许停止管内充氩。
1.3.3.11热控仪表管的焊接
采用全氩弧焊工艺，由于管子外径小，管壁最薄，适当留有焊缝间隙，通常只焊一层，既要根部焊透，无焊瘤，外观又要成型美观。
焊接时为保证其质量，焊丝选用最小直径，采用较小的电流密度，较慢的焊接速度，点一个焊一个，注意漏焊。
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