QP-06焊接返修程序

General Welding Repair Procedure

焊 接 返 修 程 序

Prepared by Date _____________

编 制： 日期：

Approved by _________________ Date ____________

批 准： 日期：

Accepted by _________________ Date ____________

认 可： 日期：

ASME Procedures Shijiazhuang gongda Chemical Equipment Co., Ltd. General Welding Repair Procedure SJZGD/ASME-06 Rev. No.: 0 Page：2 of 4 1 Scope 范围

1.1 This procedure is prepared to establish repair procedure for defects on the material, welds and pressure parts of Code items which is frequently found on the material and welds. This procedure is supplementary requirement to the QC Manual.

本程序针对材料、焊缝和规范产品上的压力部件的焊接缺陷建立通用的返修程序，这些缺陷发现率很高。本程序是对质量控制手册的补充。 2

Repair of Defects in Materials 材料上的缺陷返修

2.1 When defects found on the pressure parts or material during the receiving inspection. Examiner shall report to QC Engineer ， If nonconformity exists, QC Engineer prepare NCR. 当在入厂检验过程中，在压力部件和材料上发现不能接受的缺陷时，检验员应向质控工程师报告。如果发现不符合项存在，质控工程师应准备NCR。

2.2 QC Engineer shall be responsible for proposing the disposition of NCR. QC Engineer shall put the number of NCR on the Process Check List (PCL). QC Engineer is responsible for proposed repair method.

质控工程师应负责在NCR上提出不符合项的处置建议。质控工程师应将NCR的编号记录在过程检查单上（PCL）。质控工程师负责提出返修方法。

2.3 If the defects shall be repaired by welding, the qualified WPS and welder or welding operator shall be used in repair, the repair method including removing the defects and Welding Procedure Specification (WPS) shall be prepared based on the material specification, mill certificate. 如果缺陷需要焊接来返修，应使用合格的WPS和有资格的焊工或焊接操作者来返修。返修方法应包括缺陷的去除方式，和根据材料规格及质量证明书所编制的WPS。

2.4 AI shall be informed the kind and extent of defect, methods of removing defects, repair methods and intended NDE or testing before repair. All inspection and examination reports and results shall be presented to the AI to assist him to make the decision on the acceptance of the material repair. 在返修前，应通知AI关于缺陷的长度和种类，去除缺陷的方法，返修的方法和无损探伤或检验试验等内容。所有的检验和检侧报告及结果应提交给AI，以便帮助他决定是否接受此材料返修。

2.5 Defective material that can not be satisfactorily repaired or repair is unacceptable to the AI, it

Shijiazhuang gongda Chemical Equipment Co., Ltd. ASME Procedures General Welding Repair Procedure SJZGD/ASME-06 Rev. No.: 0 Page：3 of 4 shall be rejected.

如对缺陷材料的返修不能令人满意，则对于AI来说，返修是不可接受的，它应被拒绝。 2.6 All welding repair on the material shall be conducted to fully comply with the ASME Code requirements. After repair and found acceptable by inspection and examination, material can be used for the Code items.

所有在材料上的焊接返修应按照ASME规范的要求来执行。在返修后经检查和检验合格之后，此材料可以使用在规范产品上。

3.0 Repair of Defects in Welds 焊缝缺陷的返修

3.1 Defects such as irregular surface profiles, overlap, too much high and low shall be repaired by grinding. Defects such as lack of penetration, lack of fusion, slag inclusion, porosity, undercut, under-fill etc. were randomly found in the welds by visual check shall be repaired by welding. Defects shall be thoroughly removed before repair. The visual check shall be conducted after removing defects. Repair welding shall be performed by qualified and experienced welders according to the original WPS. Welding consumables used for repair shall be controlled as the original. Repair weld shall also be identified by stamping or recording of welder identification number. After repairing, the visual check shall be performed and the results shall be made available to the AI during his next visit. If the defect was found during NDE, the NDE shall be done after repair. The repair result shall be available to AI.

当焊缝上发现例如不规则外观形状、焊缝搭接处、焊缝加强高太高或太低等缺陷均可采用打磨的方式来返修。由目视检测时在焊缝上经常发现例如未焊透、未熔合、夹渣、密集气孔、咬边、弧坑等缺陷时,此类缺陷应用焊接来返修。在返修之前，缺陷应彻底地被除去。返修焊接应由合格有经验的焊工根据WPS来进行。用来返修的焊材应按照焊接材料控制规程来管理。返修焊缝的焊工号也应用钢印或记录的方式进行标记。在返修后，应进行焊缝目视检查，检查结果应提交给AI。如缺陷是通过无损检测手段被发现的焊缝内部缺陷，缺陷返修后应再次进行无损检测，并重新评定，其结果应提交给AI。

3.2 When defects regularly found in the welding, QC Engineer shall carry out investigation on the possible causes. NCR shall be issued and proposed dispose shall be collected from relevant departments. If deemed necessary, new WPS or re-qualification of welder shall be carried out. All

Shijiazhuang gongda Chemical Equipment Co., Ltd. ASME Procedures General Welding Repair Procedure SJZGD/ASME-06 Rev. No.: 0 Page：4 of 4 repair related inspection and examination shall be indicated on the Process Check List. AI shall be

informed before, during and after welding. All repair related examination and inspection results or reports and NCR shall be made available to the AI for review and acceptance.

当在焊缝上经常发现有规律的缺陷，质控工程师应调查发生的原因。应提出NCR和建议的处置意见。如果认为有必要，WPS需重新评定或焊工的资格也应重新考试。所有与返修相关的检验和检查应在过程检查单上注明。所有与返修相关的检验和检查的结果或报告、NCR都应提交AI的审核。 4

Repair of Defects caused by Testing 检测引起的缺陷返修

4.1 When defects occurred during the pressure testing or other operation such as assembly and

pressure testing, the defects shall be repaired according to paragraph 3.0.

当缺陷在压力试验或其它操作之间发生，如装配和压力试验，应根据3.0进行返修。 4.2. After repair including welding repair, visual and/or dimensional check shall be carried out to

ensure that no defects existed in the welds, and possible deformation or deviation in dimensions of the repaired pressure vessel shall within tolerance of the ASME Code required. 在返修之后，包括焊接返修、要进行目视和/或尺寸的检验，以确保在焊缝上没有缺陷，

在被返修的压力容器上的可能的变形或误差都应在ASME规范的公差之内。

4.3 After welding repair, the pressure testing shall be carried out on Code items according to

drawing.

在焊接返修后，压力试验应根据图纸进行。