wps - 楚卡斯蜗壳工地焊接工艺守则

THE PEOPLE'S REPUBLIC OF CHINA
HARBIN ELECTRIC MACHINERY COMPANY LIMITED

HARBIN
Form No.00

Welding Procedure of Spiral Case
for Site Erection of CHUCAS
0637-351

Rev.A

This document contains proprietary information of Harbin Electric
Machinery Co., Ltd.HECand it can not be used in any way or
disclosed to others without the written permission of HEC.

Form No.G
MOD.ADVICENOTE No. REV. MODIFICATION CONTENT ABSTRACT DATE
PAGE OF

HARBIN ELECTRIC MACHINERY
COMPANY LIMITED
PAGE&ITEM
REVIEWED BY
PREPARED BY &

Welding Procedure of Spiral Case for
Site Erection of CHUCAS
0637-351
Rev.A
1
1 1
1

A

Issue for the 1
st
time

2012.4.24

Welding Procedure of Spiral Case for Site
Erection of CHUCAS
0637-351
Rev.A
1 21
1 21

Date Prepared by
PAGE OF
HARBIN ELECTRIC MACHINERY
COMPANY LIMITED

Form No.01

Approved by

Counter sign

Authorized by
zation
Standardi-
Reviewed by

Checked by

Date

Date

Date

Date

Date

Date

Date

Counter sign

Contents

1 Scope 2
2 Qualification 24
3 57
Requirements of Material, Tools and Instruments 57
4 Requirements of Technology 8
5 The Procedure for Assembly and Welding 917
6 Safety Notes Items 18
1 Accessional table 1 19
2 Accessional table 2 20
Accessional fig 21

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Form No.02
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Welding Procedure of Spiral Case for Site Erection of CHUCAS
0637-351
1 Scope

ASTM A516 Gr70GB
16MnR2 2
1
The technical instruction is adapted for assembly and welding spiral case of CHUCAS
Hydropower Project at site. The material of spiral case is ASTM A516 Gr70GB 16MnR.It has
two locating segments and compensation segments.The welding method is SMAW.
Specific structure refers to figure 1.

1
Fig1 STRUCTURE DRAFT OF CHUCAS SPIRAL CASE

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0637-351
2 Qualification

2.1 Qualification of welders

Welder shall pass one qualified examination out of a multitude according to following standards,
or holding the qualified certificate which is signed and published by relevant office.
ASME
DL/T 679
According to ASME Code Section WELDER EXAMINATION SPECIFICATION of
BOILER and PRESSURE CONTAINERprepared by national labor bureau and the qualified
welders who pass DL/T 679WELDER TECHNOLOGY EXAMINATION SPECIFICATION.

Holding the qualified certificateWELDER EXAMINATION of BOILER and PRESSURE
CONTAINERwhich is signed by China quality supervision bureau in the period of validity.

Welder examination qualified certificate of water project steel structure which is signed by
electrical industry ministryhydraulic ministry.
2.2 Qualification of NDT inspectors.

NDT inspectors should hold at least one of following qualified certificates.
ASNT Level
Be qualified in accordance with ASNT-TC-IA. level or above.

The NDT certificate (level or above) of Boiler and pressure container which is signed and
published by national labor and personnel bureau.

Hold the qualified certificate (in accordance with the work)which is signed by China machinery
and project NDT institute. The person who hold the post of judging the quality of welding seam
shall be the inspectors (level or above).
10

NoteThe establish company should provide the name list, the serial numbers, the certificate

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0637-351
of competency etc. of the welders and inspectors who will take part in the establish process of the
spiral case to HEC welding engineer or the supervisor at site. These documents provided from
them shall be examined and approved. The welders have to be retested at site if necessary. All the
equipment, the material and the instruments etc. has to be provided by the established company.

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3
Requirements of Material, Tools and Instruments
3.1 The Material
The Material List

item

model

specification

quantity

remark

electrodes
AWS E7015
/GB E5015
3.2mm4.0mm

available

used for welding

electrodes
AWS E309-15
/GB E309-15
3.2mm

available

used for welding

oxygen and acetylene

available

used for cutting

ceramic preheater
4KW 220V

available

including
Temp.controlling
system

temporary stiffening plate
Q235
(S235)
16mm250mm150mm
20mm40mm60mm

available

angular grinding wheel
100mm180mm

available

used for grinding

alloy grinding head

F1225D1014
D1009C1020

available

carbon rod
8.0mm10.0mm

available
used for gouging

paint

available

compressed air

available

wood and gang board

available

adjusting shim
Q235
(S235)
0.5mm,1mm,2mm

available

Notes: All the material mentioned above should be prepared by established company.

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0637-351
3.2 Tools and Measuring Devices
Tools and Measuring Devices List

item

model

specification

quantity

remark

levelling rule
22.5m 1

jack

10t, 20t, 30t,
50t

available

Tape
2m10m
2
2 for each

gas cutting torch
4

callipers

0500
mm
1

carbon arc air gouging
torch
2

sledge hammer

20
20 pound
2

hand hammer
2

pneumatic digger
C6B

available

Used for chiping welding stress

angular electric grinder

100mm
180mm
2
2 for each

rotary file
S40
S60L

available

used for grinding carburizing
surface after backgouging

pneumatic digger
CZ2

available

used for interpass cleaning

Tensioning device

available

Notes: All the tools mentioned above should be prepared by established company.

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3.3 Instruments
Instruments List

item

model

specification

quantit
y

remark

level

accurate type
ordinary type
1
1 for
each

Specification for reference

SMAW machine
500A 8

oxygen meter and acetylene
meter

2
2 for
each

digital surface thermodetector
0500 2

ultrasonic flaw detector
CTS-22
26
1


magnflux crack detector
CYE-1000 1


radiation flaw detector
1

carbon arc gouging machine
DZBQ-15
00
2


compressed air machine
1

temperature-controlled cabinet
KWC-1


electrode heating oven
ZYH-50 0500 1


electrode dryer
TRB-50 8


Notes: All the instruments mentioned above should be prepared by established company.

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4 Requirements of Technology

4.1
Any way shall be used to prevent the influence which may be caused by wind, rain etc.
4.2
There should be foundation or platform for assembly.
4.3
Ensure that the supplies of compressed air, power and all kinds of gas are necessary at site.
4.4 36V
The whole process needs enough light whose voltage should be not more than 36V.
4.5 585%
The temperature at site is not less than 5and the relative humidity of air is not more than
85%.
4.6 60%
The electrode and flux material storeroom have to be kept dry, and the relative humidity of air is
not more than 60%.
4.7

All of the instruments, meters, equipments, measuring tools and so on, which are not allowed to
use if they are out of effective period or disqualified, have to be inspected by the relevant
organizations.
4.8 30 (WPS)
(PQR)
Erection company should submit the WPS and PQR to HEC for checking and approving about
30 days before the project start, or perform welding produce according to the parameters which
recommend by HEC.
4.9

All the procedure of assembly and welding, operation requirements, fireproofing measures and
notice proceedings that are explained to workers by professional should be listed and performed
with monitor.
4.10 PT
Before site welding, Liquid Penetrate Testing PT of the chamfers to be performed.
4.11
Procedure of baking electrode should be referred to manufacturer product specification.

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5 The Procedure For Assembly And Welding

5.1 general processing requirement
5.1.1 50100
Preheating Temp.50Preheating Temp. for compensation segment: 100
5.1.2 260
Interpass temperature: 260.
5.1.3
Welding material:
/GB E5015
Electrode mode standard GB E5015
AWS E7015
Correspond to AWS E7015
/GB E309-15
Electrode mode standard GB E309-15
AWS E309-15
Correspond to AWS E309-15
5.1.4 1
Welding parameter is shown in Table 1:
AWS E7015Electrode AWS E7015

Electrode diameter
V
Voltage(V)
Flat &
Horizontal(A)

Vertical(A)

Overhead
(A)

Travel
speed(mm/min)
3.2mm 2228 100150 80120 90130 60200
4.0mm 2228 150190 130170 140180 60200
AWS E309-15Electrode AWS E309-15

Electrode diameter
V
Voltage(V)
Flat &
Horizontal(A)

Vertical(A)

Overhead
(A)

Travel
speed(mm/min)
3.2mm 2226 80130 80120 160280
5.2 Z1a003434
Assembly of spiral case (drawing No. Z1a003434)
5.2.1 X-XY-Y
Re-check the flatness, center, X-X and Y-Y axis lines and level center line of stay ring before

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0637-351
assemble spiral case.
5.2.2 Weld each segment of spiral case.
5.2.2.1
2
Lay out the projective line of each segment on platform, lift and assembly each segment
according to the lines, take tack welding firmly after fire-righting, and assemble and weld inner
stiffener according to fig 2. Do not assemble compensation segment temporarily.

2
Fig 2
5.2.2.2 30mm
5.1.15.1.25.1.3
5.1.4
Rust, oil failure, oxide skin etc. on the surfaces of grooves and the adjacent areas at least
30mm out of the grooves shall be cleared. The requirements of preheating before welding is the
same as clause 5.1.1, the requirements of interpass Temp.is the same as 5.1.2,the welding material
is the same as clause 5.1.3 and welding parameter is the same as clause 5.1.4.
5.2.2.3 100mm500mm600mm,
20mm
Firstly take tack welding. The length of each tack welding seam is not less than 100mm , the
distance between tack welding seam and nearby one is 500mm600mm, and thickness is not less
than 20mm.
Center altitude
stiffener
stiffener

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5.2.2.4 2/3MT PT
300mm400mm
50mm
Weld bigger groove to 2/3 height, take back gouging to smaller groove, and grind the smaller
surface. After MT or PT is qualified , take welding to the inner and outer groove alternately whose
process is segmentation, thin-layer, multiple tracks and back-step, which is separated to 300mm
400mm length and whose interpass joints are staggered at least 50mm.
5.2.2.5
Take NDT to the welding seams of spiral case whose standard is according to the drawing
requirements.
5.2.3 1
The assembly sequence of spiral case is shown in fig 1.
5.2.3.1

Before assembly, line out locating points of each segment and then fit baffle plates on the
upper and lower transition plates of stay ring based on the azimuth angle presented by the drawing.
According to the lifting and assembling position of spiral case, adjust the pedestal buttress wedge
plates corresponding to each segment before lifting and assembling.
5.2.3.2 2 12
There are two compensation segments for assembly of the spiral case and the lifting and
assembling process is started from the three positions, two locating segments and casing tail.
5.2.3.3 :

Lift and assemble item 14 locating segment of spiral case. Adjust the level points and section
lines deviation according to the mark of assemblage by manufacturer. Firstly connect locating
segment and upper transition plate, tack spot welding firmly to the inner locating segment with two
blocks, and then take tack welding between locating segment and lower transition plate firmly to
the outer locating segment with two bridging blocks.
5.2.3.4 Locating segment checking
a R0.004Rmm
The distance between the level point of locating segment and the center of stay ring R0.004Rmm.
b 10mm15mm

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The tolerance of level point of locating segment is permitted to 10mm15mm upwards.
c 5mm
The deviation between inlet and projective line is permitted 5mm Max.
d 2mm5mm 2mm

The welding gap between locating segment and transition segment shall be controlled within
2mm5mm , and the unfitness of butt weld shall be not more than 2mm. if the detentions are not
satisfied , the seams shall be taken overlay welding.
e 3mm
The inlet and outlet verticality deviation of locating segment shall be not more than 3mm.
f
Locate the locating segment with jacks and screw bolts supporting after the checking results are
qualified.
5.2.3.5

Check the level point deviations of every segments, the distance between level points to
center of stay ring, and the welding gap and unfitness butt weld between every segments and
transition plates which shall be in accordance with the drawings and installation regulations.
Locate the locating segment with jacks and screw bolts supporting after the checking results are
qualifiedTake tack welding firmly with bridging blocks.
5.2.3.6 1

The assembly sequence of other segments is shown in fig1. Control the level point deviation
the unfitness butt of each segment and assembly clearance between each segment and transition
plates.
5.2.3.7
Compensation segment is not assembled temporarily.
5.2.3.8 1000mm
Fix butt welding grooves of circular seams of spiral case firmly with blocks on every
1000mm distance.
5.2.3.9

It is permitted that spiral case is preheated with oxyacetylene fire temporarily in the process

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0637-351
of assembly and welding of spiral case, but it is not permitted to strike arc on the surfaces of the
plates of spiral case.
5.2.3.10
Temporary welding blocks and fastenings should be cleared with gas cutting, it is not
permitted to remove the blocks with hammer.
5.3 Welding of spiral case
5.3.1 30mm

Rustoil failureoxide skin etc. on the surfaces of grooves and the adjacent areas shall be
cleared at least 30mm.
5.3.2
Spiral case will be welded after adjacent segment is installed certifiably.
5.3.3 4 4

Butt circular welding sequence of each segment of spiral case is started from locating
segment show in fig 4. There shall be 4 welders taking block welding conversely in the inner and
outer surfaces of spiral case.
5.3.4
4
Welding sequence:weld the seams between spiral case segments,and then weld the vertical
seams,weld the seams between spiral case and transtition plate finally.Assembling and welding
sequence of each segment of spiral case refer to fig4.Welding sequence of the joint between spiral
case and transtition plate refer to fig4.
5.3.5 3
2/3 MT
With single pass, Multi layer block sequence and back-step welding, the welding sequence for
single ring welding seam is according to fig 3. After finishing 2/3 depth big groove, gouge and
grind the small groove and take MT. Then weld seams alternately and symmetrically if the MT is
performed and qualified.

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0637-351
6
5
1
2
3
6
5
4
7
4
3
2
1

3
Fig 3

4
Fig 4

notes
:assembling and welding sequence of
each segment of spiral case.
18
18welding sequence of the joint between
spiral case and transtition plate.

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0637-351
5.3.6 3.2mm 23 4.0mm
3.2mm

Use 3.2mm electrodes to backing welding4.0mm electrodes to filler welding after 23
layers finished and 3.2mm electrodes to cap welding. If the unfitness of butt joint is too big in the
process of cap welding, transition welding shall be needed. To avoid cracking under high stress,
perform hammering during welding process to reduce stress in seams to every layer except the first
one and the last one.
5.3.7

Assemble and weld compensation segment.Trim and cut compensation segment partly,
assemble compensation segment and take tack welding firmly. Weld seam between parts of
compensation segment, then weld seam between compensation segment and transtition plate.
5.3.8 48 4
5.3.6
100120250 2.5
3050

There shall be 48 welders to weld the seams between spiral case and upper and lower
transition plates. Symmetrically weld the seams separated to upper and lower layers in the
circumferential direction according to the sequence of fig 4 and the requirments of welding is as
same as item 5.3.6. The welding process of the seams shall be continuous and not allowed to be
interrupted and the preheating temperature could be improved to 100 120. If it is
necessary.Heat the circular seams of compensation segment to 250 after welding, keep the
temperature for 2.5 hours, and cool to room temperature slowly, the cooling velocity shall be less
than 3050/h. The welding of segment shall be relieved stress with hammering except the first
and the last layer to avoid cracking.
5.3.9
Assemble and weld measuring taps, U beam steels, bolts, nuts and other items needed to be
welded at site.
5.3.10
The spiral case is checked according to the drawing and related standard. After the results are

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0637-351
qualified, paint the water-swept surface.
5.4
Weld quality control of spiral case
5.4.1 ,
2ISO5817
Appearance inspection: after each welding seam is finished, welder shall self-check the seam
layer-by-layer, and the seam shall be repaired if there are defects or welding demensions which is
unaccepted. The special requirement is shown in table 2 and the items not mentioned in the table
refer to international standard ISO5817.
2
Table 2 weld appearance inspection standard

no.

defect type

permitting defect dimension or treatment
1

crack, slag inclusion,
lack of fusion and pore

not permitted (need clearing)
2

undercut
0.5mm,100mm,
10%
depth not more than 0.5mm, and continues length not more
than 100mm. and accumulative total length of two sides
not more than 10% length of seam.
3

underfill

not permitted
4

spatter, weld beading, arc
strikes

not permitted (need clearing)
5

the height of seam after
grind water passage surface
01.5mm
6

other
ISO5817 C
refer to drawing or related standard ISO5817 Class C
5.4.2

After the self-checking of welders finished, marking NO. of welders shall be recorded in

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proper position to be checked and detected expediently by inspector.
5.4.3 24 100%UT100%MT PT25%RT

Grind welding surface, and all welding seams shall be taken 100% UT, 100% MT or PT and
25% RT spot check at least 24 hours after welding, the inspection standard is shown as follow.

a RT
Radiographic inspection (RT)
ASME 4
ASME volume D.1 appendix 4
b MT
magnetic particle inspection(MT)
ASME 6

c PT
liquid penetrant inspection (PT)
ASME 8
d UT
ultrasonic inspection(UT)
ASME 12

5.4.4 PT MT

Remove the defects detected by NDT with carbon arc gouging machine. Grind the surfaces
and take PT or MT. Take welding after all defects have been removed, the technology requirement
is as same as the welding procedure mentioned above.
5.4.5
PT MT
All temporary bridging blocks between upper and lower transition plates of stay ring and
spiral case and between segments shall be grinded smoothly after be cut. Partial cupped areas need
to be taken repairing and welding, then do PT or MT inspection.
5.4.6

After welding visual inspection and nondestructive testing, fill in the related checking record
carefully and accurately. The checking report shall be sent to the supervisor and owner.

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6 Safety Notes Items

6.1
In operating field, water, wind, gas, oil pipelines, power source, oxygen, acetylene and so on
shall be located according to the requirement of relevant rules.
6.2
The electric connection and placement of temporary lighting equipments and instruments
shall be controlled according to relevant rules, and designate special person to manage them for
avoiding fire.
6.3 10

Storage oil and other inflammable and explosives material is forbidden in welding platform.
Fire-fighting apparatus and material is necessary. Ensure good light and aeration.
6.4

Workers shall tie life belt and other protective measures when working high above the ground,
and else there shall be special man for monitoring. Tools when used shall be passed by tool-pocket
and forbidden to throw from top to bottom or bottom to top.
6.5
Auxiliary operating persons have to know safety common sense of electrics and gas welding.
Handlers have to take care of the safety of auxiliary operating persons.
6.6
Dowser visor is necessary when there are many persons working on the same platform.
Awake persons around do not directly view arc.
6.7
Concurrent operation at upper and lower parts is forbidden. Use safety clapboard if necessary.
6.8

It is necessary to teach operators all assembly and welding technology, working demands,
fireproofing measure and notice items that shall be declared as lists and performed with monitor by
professional.

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1 Accessional table 1

Assembly Checking Record of Water
Turbine
QCR

Set No.

Drawing No.
checking tool

environment temperature
before checking
after checking:

conclusion qualified unqualified rework
declaration

HEC

supervisor

initial checking

rechecking

final checking

HEC

checking item

level point and center of spiral case to center of set

checking point

level point to center of set
mm

altitude of level point
mm
a /
length a/ altitude
mm
b /
length b / altitude
mm

design value and
deviation
Re0.004Re H15
a/H1
()
(reference)
b/H0
()
(reference)
1
2
3
4
5
6
7
8
9
10

remark

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2 Accessional table 2

Assembly Checking Record of Water
Turbine
QCR

Set No.

Drawing No.
checking tool

environment temperature
before checking:
after checking:

checking item

level point and center of spiral case to center of set

checking point

Spiral case extension to
center of set
mm

inlet diameter
mm
altitude of
center point
mm
a()
length a
(altitude)
mm
b()
length b
(altitude)
mm

design value
and deviation
3476.2mm 0.003D
(D
3500mm)
(D is inlet diameter)
Ds 0.003D
(D )
(D is inlet
diameter)
H5
H1
()
(reference)
H0
()
(reference)
A
B
C
D

conclusion qualified unqualified rework
declaration

HEC

supervisor

initial checking

rechecking

final checking

HEC

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Accessional fig

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