1、1BAYER TECHNOLOGY SERVICES COMPANY LTDBTSSP10 NH3 Evaporator 021-6146 5712; 13301656866 ; ZP.O. No. BISP No. 2008 EWMLC 018 TDI KWB 20081028 PO00Vendor PO: 30126792Works Location: Nanjing ChinaMr. Shen QingyongTel. 025-57765148; Fax. 025- JIANGQIAO,DACHANG,LUHE DISTRICT,NANJING China. 210048南京市六合区大厂
2、姜桥一号CAOTDIX-V510- WT31-WA001/ WA002/ WA003/ WA004 Job No. 拜-9227B;拜-9229B; 拜-9228B; 拜-9230BDate of Meeting: 2009-6-10Equipment / Material Description: Main Material CS 16MnR, Equipment is Pressure vessel category II, and contact fluid NH3 with stress corrosion tendency.设备/材料名称：主材 16MnR，设备容器类别为 II 类，
3、氨应力腐蚀设备ATTENDED BY 与会人员CLIENTBAYER SignatureVENDORNCMW SignatureZiqi Rong13301656866021-6146 5712Z Liu TYangjie Lin21-6146 5780Y Shen QGuoping Sun021-6146 5738G Wang Yunjun13815887669Mr. Bjoern Blondin021-6146 5772B Zhang Sheng13851534752Achilles Wu021 -6146 5660Achilles.W Ye Dongmei13512509155Yin H
4、ongmei13645182418Fang JinAGENDA 议程1.0. Purchase Order Review 采购订单审查2.0. Material delivery status材料交付状态3.0. Material traceability specified材料追踪号的规定4.0. Engineering Status工程状态5.0. Fabrication updated status and tour of workshop 制造最新状态和车间参观6.0. Assembling fit mark punched组对标记7.0. Inspection and Test Pl
5、an ; Fabrication processing checklist Review ITP 和制造工艺一览表的审查8.0. WPS/PQR review and qualified welder list WPS/PQR 的审查和合格焊工一览表9.0. Proper procedure for Tube / Tube-sheet joint welding and Make detail T/TS joint processing check list:管子管板接头焊接的正确工艺和制定管子管板接头工艺一览表10.0. Weld production coupon产品焊接试板 11.0.
6、Weld workmanship焊接工艺12.0NDE and RT test procedure plan review 无损检测及 RT 程序审查13.0. PWHT and welds local PWHT焊后热处理及局部热处理 14.0. Hydraulic Pressure test /Pneumatic leak test procedure doc. Review水压试验程序及氨渗透试验程序审查15.0. Manufacturing schedule制造进度计划16.0. Blasting, Painting plan review喷砂、油漆程序审查 17.0. Packing
7、and transportation plan包装及运输程序 18.0. Vendor Data Book Catalogue specified供货商资料文本目录的规定2Peng Kouqin/./2009BAYER TECHNOLOGY SERVICES COMPANY LTDBTSSP10 NH3 Evaporator Delivery date: Nov.-12-2009Item No. Description Job No. QTY1 CAOTDIX-V510- WT31-WA001 NH3 Evaporator 1 拜-9227B 12 CAOTDIX-V510- WT31-WA0
8、02 Ammonia Economizer Cooler 1 拜-9229B 13 CAOTDIX-V510- WT31-WA003 NH3 Evaporator 2 拜-9228B 14 CAOTDIX-V510- WT31-WA004 Ammonia Economizer Cooler 2 拜-9230B 14P.O. and technical condition attachments are confirmed and approval, acceptable by both side.At PIM, BTSS received and reviewed, confirmed the
9、 PIM agenda document submitted by NCMW. as follows:采购订单及技术条件附件经双方确认、批准和接受。预检会上 BTSS 对 NCMW 按如下提交的文件进行认可、审查及确认。1). WPS/PQR (submitted to Bayer)2). Qualified welder list and NDT personnel list (issued Parts No.; Inquiry No.; 16MnR; thk; punched on corner (size. 100*50 total) hard mark should be used.
10、Tube-sheet Mark: including Work No.; Parts No.; Inquiry No.; 16MnR; size*thk. With hard stamping on side face. 仓库里所有材料要有标记号，所有受压件在制造前都应进行标记号的移植，移植标记号的规定：板材标记号：16MnR 碳钢板在板材边角上（尺寸 100*50）用钢印清楚的打印上工作令号、零部件件号、本厂标记号、16MnR 及厚度标识。管板标记号：管板侧面上用钢印清楚的打印上工作令号、零部件件号、本厂标记号、16MnR、尺寸厚度标识。Flange/forging Mark: includ
11、ing Work No.; Parts No.; MTL-type; flange type: size and pressure rating. With hard stamping on flange side faceDn 250 and larger nozzle pipes are with mark as same as plates. Smaller than Dn 250 pipe is adhering mark label .法兰、锻件标记号：在法兰侧面上用钢印清楚的打印上工作令号、零部件件号、材料型号、法兰类型、尺寸和压力等级标识。DN250 的接管标记号的标识要求与板材
12、一样，DN250 的接管标记用记号标签粘贴。Engineering Status:工程状态45.0 Item No. Description QTY DWG No.1 CAOTDIX-V510- WT31-WA001 NH3 Evaporator 1(-19.9 50C) 1 WT31 WA001-CAO1233079-rev 1-0904152 CAOTDIX-V510- WT31-WA002Ammonia Economizer Cooler 1(-19.9 50C)1WT31 WA002 CAO1233080 rev1 -0904153 CAOTDIX-V510- WT31-WA003 N
13、H3 Evaporator 2(-19.9 50C) 1 WT31 WA003-CAO1233081-rev 0-0904154 CAOTDIX-V510- WT31-WA004Ammonia Economizer Cooler 2(-19.9 50C)1WT31 WA004 CAO1233082 rev0 -0904151) The design is in the scope of SCEI (Shanghai Chemical Engineering Incorporation). The fabrication drawings as rev. C provided to vendor
14、 NCMW. SCEI is responsible for the design drawing and calculation sheet, which is get approval by Bayer. 图纸设计是 SCEI 的工作范围。制造图 C 版已提供给南化机，SCEI 负责的图纸设计和计算书，已获得拜耳公司的批准。2) NCMW shall fabricate the vessels fully comply with SCEIs design and Purchasers specifications, vendor issue vessel plate layout and
15、weld seam map drawing as supplemental.南化机制造的容器应完全符合 SCEI 的设计要求和买方的技术规范，制造商编制容器板材的布置图和焊缝排版图作为补充。Fabrication updated status and tour of workshop :制造的最新状态和车间参观1). Vendor NCMW is ongoing for Head forming in sub-vendor, ellipsoid head ID 3200x30, 2 pcs. and ID 3200x24, 2 pcs., which is permitted one butt
16、 long welds for each head. And head ID 2400x24, 4 pcs. ID 1200x20, 4 pcs., which is one piece plate formed. The head long weld 56.0seam is full RT by NCMW, and four heads arrived. 南化机对规格 ID3200x30 和 D3200x24 的各两件椭圆封头进行外协，每件封头可以允许有一道对接缝。规格ID2400x24 和 D1200x20 的各四件椭圆封头应整板成型。南化机对封头板的拼缝进行完全 RT，封头已交付给南化机
17、。Assembling fit mark punched: 组对标记的标识To fit assembled each shell section and head, tube-sheet. 筒节、封头、管板的组对1) The head formed; acc. Actual middle diameter of head is developed shell cylinder circumferential cut length.根据实际成型的封头中径对筒体周长展开进行下料。2) the head is punched three hard mark (on line) for each or
18、ientation 0, 90, 180, 270 from apart head bevel edge 50mm.在离封头坡口边缘 50 mm 处 0, 90, 180, 270 方位上打印 3 个清楚的标记（在线上）3) Each shell cylinder both side is punched three hard mark (on line) for orientation 0, 90, 180, 270 from apart shell bevel edge 50mm. while head/shell, and shell /shell section assembled,
19、adjacent six punched marks are fit on line for alignment at orientation 0, 90, 180, 270.在离每件筒体坡口边缘处两边 50mm 处的 0, 90, 180, 270 方位上打印上 3 个清楚的标记（在线上）。4) The tube sheet side face is punched three hard mark (on line) for orientation 0, 90, 180, 270在管板侧面 0, 90, 180, 270 方位上打印上 3 个清楚的标记（在线上）。5) Circumferen
20、tial datum line punched and lineation: The tube side first down channel cylinder (connecting to head side) is punched circumferential hard mark apart from cylinder bevel edge 100mm and lineation, which is as connecting length measuring datum line. As well as for shell side first bottom cylinder is p
21、unched measuring datum line hard mark and lineation.环缝基准线的打印和标线：在离管程第 1 个管箱筒节（连接封头侧）坡口边缘 100mm 处清楚打印上环向的标记和标线，作为连接长度尺寸的基准线。同时在壳程第一节筒体末端清楚打印上基准线的标记和标线。6) alignment fit is measuring acc. All orientation 0, 90, 180, 270 mark is on line. 方位的校准根据线上的所有 0, 90, 180, 270 的标记来调整。7) Total length and each nozzl
22、e position is measuring acc. From datum line and drawing shown orientation. The each nozzle position lineation mark on shell prior nozzle opening is as “W” point for inspection and confirmed by both NCMW and BTSS. All nozzle flange holes shall be straddle on centre line.总长度和每个接管位置按照基准线和图上所标示的方位进行测量。
23、在接管开孔前，壳体上的每个接管方位划线标记作为检验的 W 点，需要 NCMW 和 BTSS 进行确认。所有接管法兰孔应跨中分布。8). Especially opening nozzle N12 (located on NH3 evaporator exchanger ) and nozzle N13 (located on NH3 evaporator vessel) shall be match NH3 liquid level meter spacing 3800 +/- 1mm, and mounted together while nozzle N12, N15 fillet wel
24、ding, and while welding 6 pcs. of 564x32 NH3 up-riser to NH3 up-vessel, and further PWHT.特别是 N12 的接管开孔（位于氨蒸发器交换器上）和接管 N13（位于氨蒸发器汽包上）应匹配 NH3 液位计的间67.08.0距 3800 +/- 1mm 的要求，当接管 N12、N15 角焊接和 6 根上升管与汽包焊接后热处理时，要一起安装上接管N12、N13。Inspection and Test Plan / Processing checklist Review: ITP 及工艺一览表的审查BTSS has r
25、eviewed NCMW submitted ITP /Processing checklist for four pieces of equipment, and in general acceptable. Both side will execute and sign on ITP inspection stage R; W H point during each equipment fabrication.BTSS 已审查南化机提交的四台设备的 ITP 及工艺一览表，总体上给予了认可。双方应在每台设备制造过程中执行ITP 标记的 R、W、H 点的要求。WPS/PQR review an
26、d qualified welder list: WPS/PQR 的审查和合格焊工一览表1). All CS 16MnR thk 30 and 32mm butt or fillet welding GTAW, SMAW, SAW should be preheating 100C min.所有 30mm 和 32mm 厚的 16MnR 板的对接焊缝或角焊缝在 GTAW,SMAW,SAW 前应进行预热，最小 100C 。2). NH3 evaporator tube side channel pass partition should be both side fillet welded an
27、d with full penetration.氨蒸发器管程管箱分程隔板应双面角焊接且全焊透。3). CS 16MnR-16MnR, GTAW; SAW; SMAW. 16MnR 之间的焊接，GTAW,SAW,SMAW,Weld for long and circular category A, B welds and nozzle / shell fillet welds C, D overall requirement: 纵、环焊缝的类别为 A,B 类，接管与壳体的角焊缝为 C,D 类。3-1). BTSS agree NCMW issued 16MnR-16MnR welding WPS
28、 (for SAW, SMAW, GTAW, FCAW) parameter, and welding material SMAW is using J507 RH, SAW and GTAW is using H10Mn2; and PWHT condition at620Cx2.5 hrs (for 32mm thick of WT31-WA001/WA003) and at620Cx1.5 hrs(for 14mm thick of WT31-WA002/WA004), but lack corresponding PQR supported, BTSS require,that pri
29、or formal welding NCMW shall submit qualified PQR under PWHT at620Cx2 hrs (for 32mm thick of WT31-WA001/WA003) and at620Cx1 hrs (for 14mm thick of WT31-WA002/WA004) with impact test Akv. at -19C for HAZ and welds deposit; In servicing practice status at -19C, Akv 48 J. which is acceptable. Submit to
30、 BTSS for review and approval, then could start formal welding work.BTSS 同意南化机提交的 16MnR 与 16MnR 焊接的 WPS（对 SAW、SMAW、GTAW、FCAW ）参数，焊材SMAW 使用 J507RH,SAW 和 GTAW 使用 H10Mn2，PWHT 状态为 620Cx2 hrs（对 WT31-WA001/WA003 设备32mm 厚的板材），PWHT 状态为 620Cx1 hrs（对 WT31-WA002/WA004 设备 14mm 厚的板材），但缺少相符合的 PQR 支持。 BTSS 要求南化机在正
31、式焊接前提供合格的在 620Cx2 .5hrs 下（对 WT31-WA001/WA003 设备32mm 厚的板材）和在 620Cx1.5 hrs 下（对 WT31-WA002/WA004 设备 14mm 厚的板材）在-19C 下热影响区和焊缝熔敷金属冲击试验冲击功的 PQR。在-19 C 的使用实际状态下，Akv 48 J 才是可接收的。提交此 PQR给 BTSS 审查和批准，然后可以进行正式的焊接工作。(14mm 和 32mm 的板，氩弧焊+手工焊做一个、自动焊做一个模拟试板，内容包括拉伸、侧弯、-19C 焊缝及热影响区冲击、1/4T 处，焊缝两边每 2mm 打一点 HV，最大硬度 200，
32、HV 偏差小于 30)3-2). Main shell long and circular A, B welds should be with SAW as possible, the SAW welds reinforcement h= 0 1.6mm high. If use SMAW, the all manual welds should be ground smoothly and without undercut or spatter. The single pass of SMAW welds weave is 20 mm limit, and SMAW reinforcemen
33、t h=0 2mm high. 壳体主要 A,B 类纵、环焊缝尽可能采取 SAW 焊接，焊缝余高 0 1.6mm。假如用 SMAW，所有手工焊缝应进行打磨光滑无咬边、毛刺。SMAW 焊接横摆不超过 20mm，SMAW 焊缝余高 0 2mm。3-3). Nozzle/shell fillet welds D should be with SMAW + final GTAW, GTAW for final forming reinforcement highness to 35 conical profile to nozzle side, all nozzle fillet welds prof
34、ile should be ground smoothly. Welds D inside should be ground to flat smoothly acc. shell inside face, the nozzle inside ID edge is with R round filed (R=3 for Dn80). The all instrument nozzle to flange butt welds B inside should be ground to flat smoothly. The all fillet welds D shall be full pene
35、tration.接管与壳体的 D 类角焊缝应 SMAW+最后 GTAW，GTAW 用来成形最后焊缝余高，余高的高度要使锥面与接管侧面达到 35，所有的接管角焊缝面都应打磨光滑。内部的 D 类焊缝根据壳体内表面打磨平滑，接管内径边缘倒圆角(R=3,DN80)。所有接管与法兰的 B 类对接焊缝内部应打磨平滑。所有 D 类角焊缝7应全焊透。3-4). All tube-sheet to shell cylinder fillet welds C shall be GTAW (for root) + SMAW with full penetration and reinforcement to for
36、ming 45 conical profile + full ground + full MT/PT + full UT. 所有管板与筒体的 C 类角焊缝的焊接应为 GTAW（根部）+SMAW，焊缝全焊透，余高高度要使成形锥面达到 45 ，焊缝完全打磨+完全 MT/PT+完全 UT 检测 。 3-5). For NH3 evaporator: shell side: two pieces of solid tube-sheet /300 mm wide shell cylinder joint welds C first to PWHT at 620C x 2 hr; other shell
37、cylinder (both end is shorter 300mm for total length) together with welded up-riser 6- 564x32 and up-vessel, mounted level gage to PWHT laid on horizontal status at 620C x 2 hr, the shell cylinder both end should be by cross or circular ring supported, and 6 pcs. of up-riser centre with inner ring s
38、upported, up-vessel horizontal laid supported. (But NH3 evaporator shell cylinder with up-vessel stand in vertical status to PWHT is not acceptable, which may be caused NH3 up-vessel down side roundness is flatten deformation in 6 up-riser areas). The 6 pcs. of up-riser are constituted by 12 pcs. of
39、 welded pipe 564x32x 300 with outer bevel and butt welding GTAW for two layer connection (the each weld pipe long welds shall be stagger, no cross welds). The level meter shall be mounted to nozzle flange N12.1/N12 and N15.1/N15 and attend PWHT. After PWHT, cut the 6 pcs. of up-riser central circula
40、r welds B, let shell middle cylinder could be butt welded to both end 300 mm long shell cylinder easily in rotation status, then after shell side closed, the each up-riser pipe shall be full butt welded and local PWHT. The nozzle N2 (Dn 500) seal face should be second machined after PWHT. Each tube
41、side channel PWHT at 620C x2 hr. respectively, and channel flange and two big nozzles N7, N8 seal faces are second machined after PWHT. Shell side final closed two butt circumferential welds B in both side and 6 pcs. of up-riser pipe circular butt connected welds B are local PWHT at 620C x 2 hr. by
42、electric heating and insulation. (during up-riser pipe butt welding and local PWHT, the level meter shall be mounted on flange N12.1/N12 and N15.1/N15).氨蒸发器的壳程： 300mm 长的两节筒体与两块管板进行 C 类接头焊接后，先进行 620C x 2 hr 下的 PWHT，壳体其他筒节（整个筒节短了两倍的 300mm 长度）与 6 根上升管和汽包一起焊接，安装好的液面计以水平状态的放置进行 620C x 2 hr 下 PWHT，热处理时筒节两
43、头用交叉的或圆形胎圈支撑、6 根上升管的中心用内部胎圈支撑、汽包水平放置在支撑上。（蒸发器筒节与汽包在垂直状态下放置参与 PWHT 是不可接受的，因为这样会引起汽包的 6 根上升管部位处的圆度的变形）。6 根上升管是由 12 根 564x32x 300 对接而成，564x32x 300 管子间的焊接为外坡口的对接焊, 焊接采用氩弧焊进行（每个管子的纵缝应相互错开，不能形成交叉焊缝）。液位计应安装在接管法兰 N12.1/N12 和 N15.1/N15 参与 PWHT。PWHT 后，割开 6 根上升管中心 B 类环缝，让蒸发器中间筒节与 2 件 300mm 长的筒节在可旋转状态下很顺利的对接，然后
44、壳程焊接闭合，每根上升管应对接焊接、局部热处理。N2 接管（DN500）密封面在热处理后应进行二次加工。管程的管箱进行 620C x 2 hr 下的 PWHT。管箱法兰和接管 N7、 N8 密封面在热处理后进行二次加工。壳程最后两道对接 B 类闭合环缝和 6 根上升管连接的对接 B 类焊缝进行 620C x 2 hr 下的局部热处理，热处理方式用电加热、包保温层。（在上升管对接焊接和局部热处理过程中，液位计应安装在法兰 N12.1/N12 和 N15.1/N15 上）。81 2 3 4 53-6). For NH3 economizer cooler: (ID 1200 )Tube-sheet
45、 to shell joint fillet welds C, only single side welding, shall be GTAW (for root) + SMAW to insure full penetration, and welds profile should be ground to smooth. The TS/shell cylinder fillet third pass and further multi-pass reinforced welds C should be welded after all T/TS welds completed and sy
46、mmetrical welding to avoid tube-sheet deformation to minimum. Both shell side welds C and tube side welds C completed, full UT + MT/PT, then welds C is final local PWHT at 620C x1hrs.氨节能器：ID1200 的管板与壳体接头 C 类角焊缝只进行单面焊接，采用 GTAW(根部)+SMAW 确保全焊透，焊缝面打磨光滑。管板与筒节的角焊缝先焊 1/3，在管子与管板焊接完成后再进一步进行多道 C 类焊缝的对称焊接使管板变形
47、最小。壳程 C 类焊缝和管程 C 类焊缝焊接完后，进行全 UT+MT/PT,最终 C 类焊缝进行 620C x1hrs 下的PWHT。3-7). For T/TS joint welding: Tube-sheet hole inner groove is 2x45,and tube is protrusion 2 mm on tube-sheet surface (for 25x2.0),or tube protrusion 1mm (for 16x1.8);two layers of round pass of Auto-GTAW; Auto-GTAW welding wire is 0.
48、8mm ASME / AWS A5.18 ER70S-G, like CHINESE Tian-tai TIG-50 spool wire. (Features: Good impact value at low temperatures as typical Akv. -29: 99.0180 J. at AW status.), it could be free of PWHT.管子与管板的焊接：管板管孔内部坡口为 2x45，管子伸出管板面 2mm（对 25x2.0 管子）或管子伸出管板面1mm（对 16x1.8 管子）,自动 GTAW 进行圆形孔型的两层焊接；自动 GTAW 焊丝为 ASME / AWS A5.18 ER70S-G 的 0.8mm 焊丝，例如国产天泰的 TIG-50 焊丝（特性：低温下良好的冲击值 ,如在 AW 状况下，AKv.-29 :180J）。3-8). FCAW / GMAW is not permitted for pressure parts welding, but FCAW / GMAW is recommended to
